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TECHNICAL FIELD
[0001] The teachings herein relate generally to wireless signal acquisition in a cognitive radio environment, such as for example sensing spectrum that is available for use by a wireless user equipment.
BACKGROUND
[0002] The way wireless spectrum is used is changing in the future. The strict allocation of bandwidth to a certain standard will be changed, at least in some frequency bands, to be more flexible. The band, which has been primarily allocated to one wireless standard, might also have other secondary users operating there under certain rules, such as for example that secondary users are not allowed to cause any harmful interference to the primary user. This typically means that the secondary user must detect and avoid the primary users which use the allocated frequency bands. Since it is up to the secondary user to avoid interference and it is seen as impractical for a central node to routinely inform the secondary user which spectrum it might access, the secondary user must be cognizant of the spectrum and is therefore termed herein for brevity as a cognitive user or cognitive radio CR.
[0003] CR technology is supposed to implement negotiated or opportunistic spectrum sharing over a wide frequency range covering multiple mobile communication standards, and so the CR link should intelligently detect the usage of a frequency segment in the radio spectrum and jump into any temporarily unused spectrum rapidly without interfering the communication between other authorized (e.g., primary) users. CR technology is promising for the friendly coexistence of the heterogeneous wireless networks, i.e., cellular, wireless Personal Area Network (PAN), wireless Local Area Network (WAN), and wireless Metro Area Network (MAN), etc. In the US, the FCC has encouraged the development of the CR technology for unlicensed operation in the TV broadcasting bands, and CR technology has been adopted as a core feature in the emerging wireless access standards such as the IEEE 802.22-Wireless Regional Area Network (WRAN).
[0004] The operation under a primary user (or in a band where there can be several wireless standards with no fixed allocations) means that the CR has to find free (unoccupied) frequencies in three dimensional boundaries: time, frequency and space (for brevity, TFS). The CR has to be aware of the radio environment and change its operation if any of the primary users are occupying the current TFS. The control and maintenance of this kind of system is challenging, and operating on a very wide bandwidth can be a time and power consuming operation.
[0005] One consideration addressed herein is how a CR device, when first powered up for the first time in a new location, will find a CR system when the CR device does not have any prior information of the spectrum occupancy/usage in the TFS domains. This is generally termed the so called acquisition problem. Typically, the CR devices may potentially spend vast amounts of time in an acquisition mode, and thus minimizing the power consumption in this mode has substantial implications to the overall power consumption of the CR device. Therefore, in the cognitive radio field a great emphasis has been placed on the spectrum sensing area, i.e. how to find the unused frequency spaces.
[0006] One relevant reference for the acquisition problem is by J. Laskar, et al, and entitled “R ECONFIGURABLE RFICS AND M ODULES FOR C OGNITIVE R ADIO ” (IEEE, SiRF 2006 ). The Laskar paper asserts that the realization of CR requires two essential features: (i) wideband spectrum sensing, and (ii) frequency-agile operation. In order to find the vacant spectrum available, the CR system can recognize the existence of the signals with meaningful power levels throughout the wide frequency range from tens of MHz to several GHz. Additionally, it should have reliable detection performance with low power consumption for various types of interference signals. The proposal in the Laskar paper does spectrum sensing first by coarse sensing and then by fine sensing in the frequency domain. The coarse-sensing block detects the existence of any meaningful RF signals received by the wideband antenna. Since the impacts of the interferers depend on the signal types and the modulation schemes, Laskar asserts that the identification of the specific signal format is very important for reliable CR link performance. Hence, the fine-sensing block of Laskar further scrutinizes the detected spectrum segment to determine the type of the received interference signal. The resulting spectrum usage status is then reported to the MAC, which processes the reported usage data to allocate the available spectrum for safe CR link.
[0007] The Laskar teachings may well be an effective and efficient way to find the spectrum holes that an opportunistic CR can then use, but by the inventors' lights this alone misses an important aspect of the whole CR acquisition problem. Namely, how does a CR device first find the CR system? Once this is done then the CR device can begin its spectrum sensing that finds the free spectrum holes, but as Laskar admits this is a wideband problem. It therefore has the potential to consume excessive power, which is always a consideration in mobile devices. What is needed in the art is a way to find the CR system in the first place, in a manner more power-efficient than simple blind detection over a wideband potential spectrum. Once that is done in an efficient manner, then the terminal in the CR system can take advantage of the already detected spectrum usage and holes and continue to update this information in conjunction with other terminals in CR system.
SUMMARY
[0008] According to an embodiment of the invention is a method that includes detecting signal instances from within a long period of a received radiofrequency RF signal envelope, grouping the signal instances according to signal level and determining periodicities among the grouped signal instances. Periodicity of one of the groups is matched to a known periodicity, and a frequency domain is estimated at a time instance derived from the matched periodicity. If an expected frequency pattern is found that occupies the derived time instance in the estimated frequency domain, then a receiver is synchronized to a candidate signal that lies within the frequency pattern. The method then decodes content of the candidate signal and uses that content to access a cognitive radio system (e.g., register to the system, start the normal operation in the network such as spectrum detection and/or transmission in a traffic channel, etc.).
[0009] According to another embodiment of the invention is an apparatus that includes one or more signal detectors configured to detect signal instances within a long period of a received radiofrequency RF signal envelope; and a processor that is configured to group the signal instances according to signal level, to determine periodicities among the grouped signal instances, to match a periodicity of one of the groups to a known periodicity, to estimate a frequency domain spectrum at a time instance derived from the matched periodicity, and if an expected frequency pattern is found in the estimated frequency domain that occupies the derived time instance, the processor is configured to synchronize a receiver to a candidate signal that lies within the frequency pattern. The apparatus also includes a receiver that is configured with the processor to decode content of the candidate signal and thereafter based on the decoded content to access a cognitive radio system. In various embodiments, accessing may include registering to the CR system, and/or starting normal operation in the CR network such as by spectrum detection, transmitting in a traffic channel, etc.
[0010] According to another embodiment of the invention is a memory embodying a program of machine-readable instructions executable by a digital data processor to perform actions directed toward determining a traffic channel. In this embodiment the actions include detecting signal instances within a long period of a received radiofrequency RF signal envelope, grouping the signal instances according to signal level, determining periodicities among the grouped signal instances and matching one of the groups to a known periodicity. Then the actions include estimating a frequency domain spectrum at a time instance derived from the matched periodicity, and if an expected frequency pattern is found in the estimated frequency domain that occupies the derived time instance, the actions include synchronizing a receiver to a candidate signal that lies within the frequency pattern. Content of the candidate signal is decoded, after which the apparatus accesses a cognitive radio system (e.g., such as by registering to the system and/or starting normal operation in the network such as spectrum detection, transmission in a traffic channel, etc.) based on that decoded content.
[0011] According to another embodiment of the invention is an apparatus that includes detecting means, processing means and receiver means. The detecting means is for detecting signal instances within a long period of a received radiofrequency RF signal envelope. The processing means is for grouping the signal instances according to signal level, for determining periodicities among the grouped signal instances, and for matching a periodicity of one of the groups to a known periodicity. The processing means is further for estimating a frequency domain spectrum at a time instance derived from the matched periodicity, and if an expected frequency pattern is found in the estimated frequency domain that occupies the derived time instance, the processor is for synchronizing receiver means to a candidate signal that lies within the frequency pattern. The receiving means with the processing means is further for decoding content of the candidate signal, and based on that decoded content for accessing a cognitive radio system. In an embodiment, accessing the CR system could be embodied as registering to the CR system, engaging in spectrum detection for the CR system, determining a traffic channel for the CR system and transmitting on that traffic channel, and the like. In a particular embodiment, the detecting means includes one or more signal detectors, where if there are more than one they are in parallel with one another; the processing means includes a microprocessor; and the receiving means includes a receiver.
[0012] These and other aspects are detailed below with particularity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing and other aspects of these teachings are made more evident in the following Detailed Description, when read in conjunction with the attached Drawing Figures.
[0014] FIG. 1 shows a simplified block diagram of an electronic apparatus that is suitable for use in practicing the exemplary embodiments of this invention.
[0015] FIG. 2 is a block diagram showing detail of the RF front end module of FIG. 1 for envelope detection according to an embodiment of the invention.
[0016] FIG. 3 is a conceptual diagram showing a relationship between detectors, signal thresholds and envelope dynamic range according to one specific implementation of the invention.
[0017] FIG. 4 is a timing diagram showing in the time domain three different systems of the band under study according to an embodiment of the invention.
[0018] FIG. 5 is a process flow diagram illustrating an exemplary algorithm according to an embodiment of the invention.
[0019] FIG. 6 is a schematic diagram of a spectrum sensing receiver according to an embodiment of the invention.
DETAILED DESCRIPTION
[0020] As noted above, the pre-existing literature in this area has concentrated on spectrum sensing, but in the opinion of the inventors this assumes away an initial problem of how to first discover the CR spectrum that may then yield the frequency holes for use.
[0021] It is expected that the CR system to which the CR device seeks entry sends broadcasting information of various types, from which the CR devices can find relevant information for maintaining their connection, establishing/re-establishing themselves to the CR system, and registering to the CR system. Many existing cellular systems use a fixed channel to broadcast this synchronization and control information to their primary users. The most challenging case for CR system acquisition is seen to be where this broadcast information is over a frequency hopped channel. In many cases other devices nearby to the CR device seeking first access already have the spectrum usage information and can transmit this information instead of a dedicated base station or access point broadcasting it (as system information for example). Such transmission by users is also considered herein as a broadcasting channel, as it makes no difference to the CR device that seeks to find the spectrum from where the broadcasts originate. The repetition interval for the broadcasting channel can be quite long and the time during which the broadcasting channel is active within the frame can be very short (<1% of the frame) to minimize the on-time used to monitor that broadcast channel by the battery operated devices. The task for the newcomer CR is to find this channel, synchronize to it and decode the content after which it can start to communicate with other devices in the same network.
[0022] The solution to the problem of minimizing the power consumption when trying to find the (rarely) existing but repetitive “broadcasting” channel is to detect a longer period of the received envelope of the spectrum area under study and trying to find either suitable time symbol/frame lengths or other such periodicities of the “broadcasting” channel. This detection, which can take quite a long time, requires only a minimal amount of hardware (RF front end, detector(s), comparators, some digital logic and memory). After the analysis of the results the most promising time instants will be investigated by the main receiver to identify the frequency and time instances where the signal is present. This can require several detections if the receiver is not able to also decode the signal from the wide spectrum range under study and the broadcasting channel is hopping. In this case, if the content of the broadcasting channel has not been detected before the identification of the hopping sequence, the data receiver will receive the channel from the frequency of the next predicted frequency according to the hopping sequence or if not successful (that frequency changed because of primary signal occupancy) at the next frequency and time instant in the hopping sequence.
[0023] To find a broadcasting signal by frequency domain spectrum sensing function is a very power hungry operation because time-wise such a broadcasting signal is rare, in RF terms of time (e.g., 1% of the frame time as noted above, for example). This generally would require a full receiver with the whole analog chain and digital processing to be turned on for long periods of time. So there is an opportunity for substantial power savings if the CR device can study the available spectrum without the entire analog and digital receiver chains being fully powered the whole time. One practical consideration is that, if the band under study has several higher level signals at the CR device location as compared to the signals for the network the CR device seeks to access, they can mask the signals of the CR device's wanted network (e.g., at the CR device some signals from one or more primary networks obscure some signals from the wanted CR network).
[0024] Reference is now made to FIG. 1 for illustrating a simplified block diagram of an electronic CR device 10 that is suitable for use in practicing the exemplary embodiments of this invention. In FIG. 1 a wireless network (not shown) is adapted for communication with other devices, and the CR device 10 is initially unaware of the specifics of that network (e.g., a cellular network uses a user equipment and a Node B for example). The CR device 10 includes a data processor (DP) 10 A, a memory (MEM) 10 B that stores a program (PROG) 10 C, and a suitable radio frequency (RF) transceiver 10 E (transmitter and receiver) that is functionally distinct from a radiofrequency front-end circuit RF FE 10 D. The transceiver 10 E is coupled through the RF FE 10 D to one or more antennas 10 F (one shown) via a feed 10 G of the RF FE 10 D for wireless communications over one or more wireless links with one or more elements of the wireless network. During the acquisition stage this link may be considered downlink only (e.g., receiving the broadcast channel) and once acquired and holes are discovered the link may then become bi-directional.
[0025] The terms “connected,” “coupled,” or any variant thereof, mean any connection or coupling, either direct or indirect, between two or more elements, and may encompass the presence of one or more intermediate elements between two elements that are “connected” or “coupled” together. The coupling or connection between the elements can be physical, logical, or a combination thereof. As employed herein two elements may be considered to be “connected” or “coupled” together by the use of one or more wires, cables and printed electrical connections, as well as by the use of electromagnetic energy, such as electromagnetic energy having wavelengths in the radio frequency region, the microwave region and the optical (both visible and invisible) region, as non-limiting examples.
[0026] At least the PROG 10 C is assumed to include program instructions that, when executed by the associated DP, enable the electronic device to operate in accordance with the exemplary embodiments of this invention, as detailed above. Inherent in the DP 10 A is a clock to enable synchronism among the CR device 10 and the elements of the network(s) that it seeks to acquire, for transmissions and receptions within the appropriate time intervals and slots required as may be the case for the specific network in question. The PROG 10 C may be embodied in software, firmware and/or hardware, as is appropriate. In general, the exemplary embodiments of this invention may be implemented by computer software stored in the MEM 10 B and executable by the DP 10 A of the CR device 10 , or by hardware, or by a combination of software and/or firmware and hardware in the CR device 10 .
[0027] In general, the various embodiments of the CR device 10 can include, but are not limited to, mobile stations, cellular telephones, personal digital assistants (PDAs) having wireless communication capabilities, portable computers having wireless communication capabilities, image capture devices such as digital cameras having wireless communication capabilities, gaming devices having wireless communication capabilities, music storage and playback appliances having wireless communication capabilities, Internet appliances permitting wireless Internet access and browsing, as well as portable units or terminals that incorporate combinations of such functions. Handheld portable CR devices may be generically termed user equipment UE.
[0028] The MEM 10 B may be of any type suitable to the local technical environment and may be implemented using any suitable data storage technology, such as semiconductor-based memory devices, magnetic memory devices and systems, optical memory devices and systems, fixed memory and removable memory. The DP 10 A may be of any type suitable to the local technical environment, and may include one or more of general purpose computers, special purpose computers, microprocessors, digital signal processors (DSPs) and processors based on a multi-core processor architecture, as non-limiting examples. The RF FE 10 D may also incorporate a microprocessor separate and distinct from any main processor.
[0029] As noted above, the acquisition of the cognitive radio signal is challenging because of its nature; it can be located basically in a very wide frequency band, there are not allocated any clear frequencies e.g. to broadcasting type signals. In a worst case the acquisition process can take very long time or even be unsuccessful and this process can take a lot of power. Also as noted above, an important constraint is to minimize the power consumption within the CR device 10 . These teachings acquire the signal in what may be generally regarded as two phases. The first phase is to detect a longer period of the received envelope of the current spectrum area and possible periodicities. The longer period can be selected as a multiple of the frame length for the wanted CR system (or of any other system known to be in operation at the location of the CR device). This longer period enables the CR device to find periodicities despite some broadcasts from the wanted CR system being obscured by signals from other systems that are sent at a period different than the wanted system broadcasts. After the analysis of the first phase results the second phase makes feature detection or spectrum estimation to the most promising parts in frequency domain at time instants specified by the results of the first phase. The first phase can take e.g. 1 second (generally 1.0 sec.+/−0.5 sec) and the snaps shots in the second phase are of the order of 1 millisecond (1.0 msec+/−0.5 msec).
[0030] Substantial power savings arise because during the first phase only the RF front end 10 D (as opposed to the transceiver 10 E) needs to be powered, including detector(s), threshold(s) and relevant digital components. Reference in this regard may be seen at FIG. 2 . The signal received at the antenna 10 F passes through a passband filter 22 pass only the wideband signal of interest and a (first) low noise amplifier 24 A as is known in the art. The main receiver 34 is shown but is not processing the signal in this first phase; it is operating in a low power mode or even a fully depowered state and performs no signal processing. In this first phase the signal is analyzed only within the RF FE 10 D, in which there are one or more envelope detectors 26 A, 26 B in parallel operating at different portions (signal levels, see FIG. 3 ) of the passed wideband signal. In this manner the envelope detectors are covering the full dynamic range from noise floor up to the maximum expected reception level. The received signal instances are split into multiple signal level (amplitude) ranges, each range represented by one detector 26 A, 26 B that detects whether or not there is a signal within its signal level range. The number of signal detectors 26 A, 26 B (there can be as few as one) depends on the received dynamic range (e.g., the wider the bandwidth, the more probable that there are high level signals). As an example, if the noise floor is about −85 dBm and the maximum expected level about −5 dBm at the low noise amplifier (LNA) input and one detector can cover about 40 dB range, then two detectors are required to cover the 80 dB [−5-(−85) dynamic range]. One or more additional low noise amplifiers 24 B may also be imposed to further amplify the received signal and therefore shift it to next signal level range not been covered by the preceding detector. Consider the first detector 26 A. It covers the highest signal level range. The envelope of the received signal at the output of detector 26 A goes to the comparators 28 . The comparators 28 have different thresholds for signal envelope amplitudes, see FIG. 3 . All the comparators, which threshold is exceeded by the signal envelope, gives “1” as an output bit, otherwise it gives “0”. The whole output from the bank of comparators is a digital word, where there are a sequence of 1s until the signal level does not anymore exceed the threshold and the rest of the word is a sequence of 0s. This information is connected to the logic, which detects a change in the word and triggers the output in the memory command including the word and the relevant time stamp. The threshold detectors 28 , 30 (comparators) output to a memory 32 which also has decision logic as detailed below, which in the schematic diagram of FIG. 1 may be the DP 10 A and the MEM 10 B, components of which may or may not be physically disposed on the RF FE 10 D circuit chip. Similar hardware is shown in relation to the other envelope detector 28 B at FIG. 2 .
[0031] The memory needed for the first phase (at block 32 of FIG. 2 or 10 B of FIG. 1 ) is only for data related to transition moments across the signal level thresholds with low resolution and with the relevant time stamp. In the second phase, the signal is sampled for the whole sampling period with a high clock rate and high resolution (though a one-bit solution might be possible if not trying to decode the data also). The sampling period in the first phase has to be at least as long as the longest expected gap in between transmissions of the searched CR system at that band.
[0032] The CR device 10 collects information of time instants when the received waveform passes across the thresholds (comparators 28 , 30 ), and stores in memory either the word made from the output of the comparators or the highest threshold for that time instant that still lies within the waveform envelope. These alternatives are implementation details that are not limiting to the broader aspects of the invention. One particular solution for relationships between envelope detectors, thresholds of the comparators, and envelope dynamic range is shown at FIGS. 3-4 . At the right side of FIG. 3 is the wideband signal passed by the passband filter 22 within which the CR device 10 seeks to acquire a signal. This shows the signal envelope. As seen at the left side of FIG. 3 , the first envelope detector 26 A and the second envelope detector 28 B operate in respective higher and lower dynamic ranges. There are comparators associated with each of those two envelope detectors, each at a different dynamic range part: thresholds 1 and 2 of FIGS. 3-4 correspond to comparators 28 of FIG. 2 , and thresholds 3 and 4 of FIGS. 3-4 correspond to comparators 30 of FIG. 2 .
[0033] So the thresholds for the detected envelope and the time instants associated with those threshold changes are stored in the memory of the CR device 10 . From this stored information is determined the information shown in chart form at FIG. 4 , still within the first phase noted above with minimal power consumption. FIG. 4 shows signal from three different systems, where the x-axis is time and y-axis is the level of the total envelope detected from the band received. The figure does not give any bandwidth information of the signal. As an illustrative purposes each system's signal is shown by different shading. The real output is the sum of these signals digitized by the thresholds. Only the moments, when the sum of the signals passes through the threshold, are put to the memory with the corresponding time stamp.
[0034] There are different cases when trying to find the CR device's wanted network signal (the lightest shading in FIG. 4 ). This can be very dependent on the bandwidth; the wider the bandwidth the more probable that there are more transmissions on simultaneously. Three possible cases are outlined with reference to FIG. 4 . First, the wanted network signal length and repetition period are detected. There are two variations to this: the level of the wanted network signal is higher than other signals at the same time, such as signal W 4 is higher than Y 3 ; or there are not other signals on simultaneously in time domain such as signals W 2 and W 5 . So for signals W 4 and W 5 the correct repetition period is found and for signals W 2 and W 4 the repetition period is twice the searched one. There can be both broadcasting type and data transfer type signals. They can have different packet and repetition lengths. There can be also several broadcasting signals detected having the same repetition period but different time offset in transmission. All of these are within the first case.
[0035] In a second case, the length of the wanted network signal is detected (such as at W 2 , W 4 and W 5 ), and other ones or some of the wanted network signals are masked by other systems such as shown at signal W 3 which is partially obscured by signal X 2 . In a third case, signals from other systems might have masked the CR device's own network signal totally such as seen at FIG. 4 where signal X 1 fully masks signal W 1 . The CR device does not know if a signal from its wanted network exists there or if it is masked by another system's signal in that position and band (spatial/frequency/time domains). FIG. 4 also makes clear that the number of threshold detectors gives greater granularity to the available information; using only the four thresholds of FIG. 3 (plus a peak threshold detector) would place the system X signals at the peak threshold, those of system Y at threshold 3 , and those of the wanted system at threshold 2 . They are plotted in FIG. 4 to fall between thresholds to illustrate this granularity improvement.
[0036] From the above phase 1 aspect of the invention, then there are selected one or more candidate time periods. The receiver is powered up and those candidate time bounds are evaluated using signal processing of a received signal to detect features and see if in fact it is a channel on the wanted network. As can be seen, the majority of the work in reducing the scope of the receivers search for the wanted network lied within the first phase, and that is exactly where minimal power consumption takes place.
[0037] An exemplary algorithm for the time domain estimation can then be broken into two major components for phase 1 : sensing and collecting the transitions, and analyzing those collected transitions for periodicities of the wanted system. These are detailed with respect to FIG. 5 . In transition collection, the RF FE detects and stores at block 502 the transition moments as 1) a threshold number which is the highest above which the signal is, and 2) the time instant when this transition has happened.
[0038] In the analysis of the RF FE results by the DP or microprocessor, the transitions are scanned and periodicities are determined at block 504 , and periods of time which matches to the wanted or target wireless cognitive radio system are identified at block 506 . It might be that the data string is formed from the several symbols/bursts. Then very short transitions down and up can be ignored (but this information can be used to identify the burst lengths and their match to the CR system). For the suitable periods of time that are found, then look to see if their repetition period (or multiple of it) matches with the CR system, and also at block 508 see if there are different levels of suitable candidates (prioritizing for the power-hungry signal processing at the powered-up receiver). If there are not found any suitable time periods, but there is activity found in that band, then 1) locate the thresholds between which the envelope is most of the time, 2) zoom the receiver there as detailed below, and 3) repeat the transition collection and signal analysis. If there are still not found any suitable periods, then another option is detailed below. For phase 2 , choose for the first candidate of block 512 the one which has the highest level (next transmission time can be calculated from the time this was received and from the knowledge of the repetition of this frame in our CR system). If there is no (appreciable) difference in the levels but different candidates have different repetition times, then choose the candidate with best match to the CR system frame repetition rate (most candidates for that).
[0039] One can take another time domain reception if the results are promising, but more accuracy will likely be needed. This situation occurs when there are longer periods of envelope between thresholds of two comparators. The signal detector and comparator entities can be tuned so that the gain before the detectors (the other low noise amplifier 24 B of FIG. 2 ) is adjustable optimally to the area where the envelope has mainly been, and the thresholds of the comparators are adjusted to make a finer grid. After that the procedure follows the above example algorithm.
[0040] The next step in the first case is to find the position of the wanted signal in the frequency domain and to detect the features at block 512 and decode the signal at block 516 to obtain the content of the “broadcasting” signal to be able to read the frequency list and to be synchronized to the wanted system. The basic method for that is spectrum sensing by some kind of feature detection (block 514 ). There are methods which can locate the signal within the spectrum by detecting a certain feature of that signal. At this stage the whole spectrum sensing receiver is turned on at block 510 . Some confidence level in the feature detection may be imposed at block 514 before actual decoding of the signal. The end result is that the CR device 10 accesses the CR system successfully at block 518 on one of the channels decoded from the broadcast channel, assuming that the process of FIG. 5 was successful and the candidate for which the features were detected was in fact the broadcast channel.
[0041] But this leaves certain challenges. Even though the repetition period is detected, the signal might hop. The information of the last frequency does not help to know the frequency of the next frequency in the hopping sequence. Also, detecting the last transmission frequency might not make it possible to read the content of the signal (e.g., resolution of the wideband spectrum might not enable to detect the own signal content in narrow band even when optimizing the automatic gain control AGC from the first phase information).
[0042] However, broadcasting and data transmission signals might have different features used for spectrum sensing detection. If the broadcasting signal is hopping, the number of frequencies in hopping is quite limited. The hopping sequence can then be detected by measuring the frequencies at each transmission moment and when it starts to repeat itself the data receiver can predict the next position and adjust itself before the next transmission.
[0043] Now is described an exemplary approach to detect frequency hopped broadcast channels. If with a reasonable probability we can recognize the wanted system signal from the envelope analysis (see FIG. 4 ), then set the AGC and sampling time according to the next predicted time instant of the wanted signal and sample the received signal (this will be wideband sampling). Estimate the position in-band by feature detection or by standard spectrum analysis measurement (where only bandwidth information is available, so the expected wanted network signal SNR>10 dB for example). If the wanted network signal is found, then filter that wanted signal from others and decode the content. If decoding is not possible (and the signal of the wanted system is hopping), then estimate the positions in-band as long as the signals starts to repeat itself. Then use the data receiver at the correct time and frequency to decode the signal.
[0044] The resolution of the ADC of the spectrum sensing receiver can be from 1 bit (decoding not possible) to almost 10 bit depending on the bandwidth and the final target of this receiver.
[0045] Two options are explored for the case where no sign of the wanted signal is found from the envelope analysis. The first option is to use the information of periods when there is something else other than noise (if periodic) and predict the next time to make the feature detection with an optimized AGC setting as above. The second option is to use a threshold detector to detect the moment when the associated threshold is exceeded and then immediately start sampling for a predetermined period of time and use feature detection to that data to find if there is any sign of the wanted network's signal. If not found, repeat for a set number of iterations or a set amount of time. If found, then continue as detailed above (broadcasting period is known, feature detection at those times if data decoding is not possible, frequency hopping sequence discovered and data decoding by data receiver afterwards).
[0046] There are three possible outputs from the acquisition process: either the CR network is found (and terminal will join that network); or the CR network is not found and the spectrum has not been frequently occupied by high level signals (high probability that there is not any CR network); or the spectrum has been frequently occupied by high level signals (high uncertainty that there is not any CR network). If the CR device 10 does not find the wanted signal, there are two ways forward: try another frequency band, or stay at the current band and use spectrum sensing to find white (all noise or noiseless) spectrum and thereafter start CR transmissions to advertise the existence of the CR device according to the rules of the CR system.
[0047] FIG. 6 is a schematic diagram example of a spectrum sensing receiver 60 showing more detail than that of FIG. 2 . There are two sections which have different power on times. The first power-on block 10 D is similar to that shown in FIG. 2 and operates in the first phase, doing the time domain analysis. The second power on block 34 is the full receiver of FIG. 2 and operates in the second phase for frequency domain analysis of the received signal (with time base information) in the actual signal acquisition process. The antenna 10 F, passband filter 22 and low noise amplifier 24 A are as detailed with respect to FIG. 2 . The detector and threshold system 62 includes the hardware shown in FIG. 2 as the envelope detectors and comparators with threshold. The first power-on block 10 D may be powered at all times during phase one and phase two, but the second power-on block 34 is fully powered only during phase two. The two blocks are synchronized to a clock 78 , which serves as the time base from which the periodicities are determined.
[0048] The second power-on block 34 operates on the candidate time instants of the received signals and includes a mixer 64 that adjusts the received signals from the antenna 10 F that are identified by the decision logic 32 of the first power-on block as candidate instants. A variable amplifier 68 and filter 70 pass the candidate signal to an analog to digital converter 72 and the digital FE 74 moves the signal to a spectrum sensing block 76 that performs the feature extraction/recognition or other signal processing detailed above. A decision is made at processor block 80 whether or not the candidate signal is within the wanted network, and particularly in an embodiment whether or not the candidate signal represents a broadcast channel of the wanted network. If yes, then the candidate signal is output at 82 for decoding, after which the CR device is able to access the CR network. After accessing the network CR device 10 can start normal operation in the network also looking for new spectrum holes in which the CR network might operate. It is at that point that the teachings of the Laskar paper may then be employed in order to find those specific holes that the CR device 10 can opportunistically use.
[0049] Embodiments of this invention may be implemented by computer software executable by a data processor of a portable wireless device such as the processor 10 A shown for the CR device 10 , or by hardware, or by a combination of software and hardware. Further in this regard it should be noted that the various logical step descriptions above may represent program steps, or interconnected logic circuits, blocks and functions, or a combination of program steps and logic circuits, blocks and functions.
[0050] In general, the various embodiments may be implemented in hardware or special purpose circuits, software (computer readable instructions embodied on a computer readable medium), logic or any combination thereof. For example, some aspects may be implemented in hardware, while other aspects may be implemented in firmware or software which may be executed by a controller, microprocessor or other computing device, although the invention is not limited thereto. While various aspects of the invention may be illustrated and described as block diagrams, flow charts, or using some other pictorial representation, it is well understood that these blocks, apparatus, systems, techniques or methods described herein may be implemented in, as non-limiting examples, hardware, software, firmware, special purpose circuits or logic, general purpose hardware or controller or other computing devices, or some combination thereof.
[0051] Embodiments of the inventions may be practiced in various components such as integrated circuit modules. The design of integrated circuits is by and large a highly automated process. Complex and powerful software tools are available for converting a logic level design into a semiconductor circuit design ready to be etched and formed on a semiconductor substrate.
[0052] Programs, such as those provided by Synopsys, Inc. of Mountain View, Calif. and Cadence Design, of San Jose, Calif. automatically route conductors and locate components on a semiconductor chip using well established rules of design as well as libraries of pre-stored design modules. Once the design for a semiconductor circuit has been completed, the resultant design, in a standardized electronic format (e.g., Opus, GDSII, or the like) may be transmitted to a semiconductor fabrication facility or “fab” for fabrication.
[0053] Various modifications and adaptations may become apparent to those skilled in the relevant arts in view of the foregoing description, when read in conjunction with the accompanying drawings. However, any and all modifications of the teachings of this invention will still fall within the scope of the non-limiting embodiments of this invention.
[0054] Although described in the context of particular embodiments, it will be apparent to those skilled in the art that a number of modifications and various changes to these teachings may occur. Thus, while the invention has been particularly shown and described with respect to one or more embodiments thereof, it will be understood by those skilled in the art that certain modifications or changes may be made therein without departing from the scope of the invention as set forth above, or from the scope of the ensuing claims. | Signal instances are detected from within a long period of a received radiofrequency RF signal envelope, grouped according to signal level, and periodicities are determined among the grouped signal instances. Periodicity of one of the groups is matched to a known periodicity, and a frequency domain is estimated at a time instance derived from the matched periodicity. If an expected frequency pattern is found that occupies the derived time instance in the estimated frequency domain, then a receiver is synchronized to a candidate signal that lies within the frequency pattern. Then content of the candidate signal is decoded and that content is used to access a cognitive radio system (e.g., register to the system, start the normal operation in the network such as spectrum detection and/or transmission in a traffic channel, etc.). | 7 |
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Application No. 60/668,708, filed Apr. 5, 2005, which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention relates to shoot houses and ballistic training. More specifically, the present invention relates to a method for forming shoot houses with modular ballistic walls and/or a modular ballistic ceiling.
[0004] 2. State of the Art
[0005] In conducting training for individuals such as police officers, military personnel, etc., it is desirable to duplicate the conditions which the individual may encounter while working. Thus, training should simulate real life scenarios, with the goal of making the training as realistic as is practical.
[0006] Accordingly, it is common to form shoot houses for training purposes. A shoot house is a building which is formed with bullet proof walls such that police officers, military personnel, or the like may train in the building under line of fire conditions. The training may include breaking into a building, sweeping the area to make it secure, finding objects in the building, etc. and targets may be used in the building to represent the threats encountered in the course of duty.
[0007] It is desirable to make such shoot houses modular so that they may be constructed in a variety of configurations, and even partially or completely disassembled to move the shoot house or reconstruct it in a different configuration. A modular shoot house is thus more useful as it may be used to train for a variety of different situations.
[0008] For similar reasons, it is desirable to form a shoot house which has two or more levels so that the shoot house resembles a building with multiple floors, such as a two story building. It would also be desirable if the shoot house remains modular even with multiple floor levels.
[0009] In making shoot houses with multiple levels, individuals have formed a separately supported concrete ceiling over the first level which also forms the floor of the second level. This, however, is a permanent structure that can not be changed without significant difficulty. The concrete ceiling and floor is typically formed on top of permanent walls or pillars and thus may not be changed. The walls, pillars, stair openings, etc. often are not in the proper location for a desired shoot house arrangement. Additionally, if the shoot house is to be moved the concrete ceiling and support structure must either be left behind or demolished at a sizable expense.
[0010] Additionally, it has been known to form small catwalks above a shoot house to allow a supervisor to oversee the training occurring in the shoot house. They do not, however, prevent bullets from exiting the shoot house and would not support a second floor of a shoot house. As such they do not present a safe and effective way of forming a two story shoot house. It has also been known to suspend bullet proof ceiling baffles above a shoot house. The baffles may be suspended in an arc above the shoot house, forming a canopy above the shoot house to prevent stray bullets from exiting the training area. The baffles do not form a ceiling, however, being merely suspended from a structure above the shoot house.
[0011] There is thus a need for a modular ceiling which may be easily disassembled and which may be easily rearranged when changing the configuration of the shoot house.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide an improved method for forming shoot houses. It is a further object of the present invention to provide a method for forming a modular ceiling which is bullet proof. It is a further object to provide a method of forming a modular shoot house having multiple levels.
[0013] According to some aspects of the present invention, a modular ceiling may be formed as part of a modular shoot house. The ceiling may thus be formed from standard sized steel panels. The ceiling may thus be rearranged easily when changing the configuration of the shoot house and is less expensive to manufacture. Replacement plates may be obtained or constructed with less machining required.
[0014] According to other aspects of the invention, the ceiling may be formed from standard sized bullet proof plate. The steel plate is then easier to replace and requires less machining of the hardened steel, which is difficult and may weaken the steel.
[0015] According to other aspects of the invention, the ceiling may be relatively inexpensive. Using standard sized steel panels for the ceiling reduces the machining required to produce the ceiling parts and makes the parts easier to replace. Additionally, parts which require more machining may be formed of a milder steel.
[0016] According to other aspects of the invention, the ceiling may be easily constructed. The ceiling may be assembled with readily available tools and without great difficulty. A modular ceiling made of standard pieces is relatively easy to construct.
[0017] According to yet another aspect of the invention, the ceiling may be easily configured to operate with a variety of different shoot house configurations. Because standard sized steel panels may be used in combination with standard joining and support pieces, the ceiling may easily be arranged in a number of configurations without the hassle of purchasing or acquiring many specialized pieces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Various embodiments of the present invention are shown and described in reference to the numbered drawings wherein:
[0019] FIG. 1 shows a portion of a modular shoot house wall as is known in the prior art;
[0020] FIG. 2 shows a portion of a shoot house wall according to aspects of the present invention;
[0021] FIGS. 3 a - 3 e show ceiling brackets according to aspects of the present invention;
[0022] FIGS. 4 a and 4 b show end views of a ceiling according to aspects of the present invention;
[0023] FIGS. 4 c and 4 d show details of a bullet proof plate according to the present invention;
[0024] FIG. 5 shows a side view of a ceiling according to aspects of the present invention;
[0025] FIG. 6 a shows a side view of another ceiling according to the present invention;
[0026] FIG. 6 b shows a side view of another ceiling according to the present invention;
[0027] FIG. 7 shows a side view of yet another ceiling according to the present invention;
[0028] FIGS. 8 a - 8 f show end views of support members according to the present invention;
[0029] FIG. 9 a shows a side view of a portion of a shoot house according to the present invention;
[0030] FIG. 9 b shows a side view of a portion of a shoot house according to the present invention;
[0031] FIG. 10 shows a front view of first and second floor walls according to the present invention;
[0032] FIG. 11 a shows a front view of a bracket of the present invention;
[0033] FIG. 11 b shows a side view of the bracket of FIG. 11 a;
[0034] FIG. 12 a shows a front view of a bracket of the present invention;
[0035] FIG. 12 b shows a side view of the bracket of FIG. 12 a;
[0036] FIG. 13 shows a joint of a shoot house using the bracket of FIGS. 11 a and 11 b;
[0037] FIG. 14 shows a joint of a shoot house using the bracket of FIGS. 12 a and 12 b;
[0038] FIG. 15 a shows a top view of a bracket of the present invention;
[0039] FIG. 15 b shows a side view of the bracket of FIG. 15 a;
[0040] FIG. 15 c shows an end view of the bracket of FIG. 15 a;
[0041] FIG. 16 a shows a side view of a bracket of the present invention;
[0042] FIG. 16 b shows a top view of the bracket of FIG. 16 a;
[0043] FIG. 17 shows a joint of a shoot house using the bracket of FIGS. 16 a and 16 b ; and
[0044] FIG. 18 shows a joint of a shoot house using the bracket of FIGS. 15 a through 15 c.
[0045] It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The various embodiments shown accomplish various aspects and objects of the invention. It is further appreciated that it is not possible to show each structure and element of the invention in a single drawing, and as such multiple drawings are presented which each show aspects of the invention in greater detail. The invention thus encompasses all of the drawings.
DETAILED DESCRIPTION
[0046] The drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The drawings and descriptions are exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims.
[0047] Turning to FIG. 1 , a section of a modular shoot house wall as known in the prior art is shown. Modular shoot houses have been formed with bullet proof steel plate wall panels 10 , 14 , and 18 . The joints 22 between the plates 10 , 14 , 18 , may be covered with a backing strip of steel 26 and a facing strip of steel 30 which are bolted together to prevent bullets from passing through the joint.
[0048] Additionally, strips of wood 34 may be attached to the steel wall, with sheets of sheetrock or plywood 38 attached to the wood strips 34 , forming a space to contain bullets and also making the surface of the wall look more similar to a conventional wall. Typically, a simple roof, such as a layer of corrugated metal or a tent like canopy, is placed over the shoot house to protect the shoot house from rain or the like if the shoot house is used in a rainy environment.
[0049] As mentioned previously, two level shoot houses have been formed by constructing sufficient support pillars or load bearing walls to support a concrete ceiling and then forming a shoot house under the structure. The lower level of the shoot house is built underneath the concrete, and an upper level is built above the concrete. As previously discussed, the concrete ceiling and supports can not be moved, and often do not integrate well into the shoot house. For example, a support column may extend into a room or may partially obstruct a hall.
[0050] Turning to FIG. 2 , a wall of a shoot house according to the present invention is shown. The wall, indicated generally at 42 , is formed of panels of steel 46 and 50 . The panels are placed adjacent each other and a facing strip 54 is placed over the joint. A backing member, such as a strip, washers, or the like (not shown), is placed across the back of the joint and the facing strip and backing member are bolted against the plates by bolts 58 , clamping the facing strip and backing member against the plates and securely holding the wall together.
[0051] A bracket 62 is also attached to the wall 42 . The bracket 62 may be attached with bolts 66 , or it may be welded to the facing strip or otherwise attached to the facing strip, or formed integrally with the facing strip. The bracket 62 is designed to support the ceiling of the shoot house as will be discussed in the following figures. As the various ceiling pieces are assembled on top of the walls, the ceiling pieces brace the walls and strengthen the structure. It will be appreciated that using a number of bolts 66 not only strengthens the attachment between the wall 42 and the bracket 62 , but also provides some flexibility in mounting the bracket. In addition to bolts 66 , the bracket may simply be welded or otherwise attached to the facing strip 54 if so desired. For example, facing strips made for a multi-level shoot house may be constructed with brackets permanently attached, as nearly all facing strips can be used to support the ceiling structure. Likewise, the brackets can be formed integrally with the facing strips. It is appreciated that the wall shows in FIG. 2 may also include spacing strips such as wood strips disposed along and/or attached to the facing strips, and plywood sheet or other sheet attached to the spacing strip to form a bullet containment chamber similar to that of FIG. 1 .
[0052] The structures shown and discussed relative to FIG. 2 are also encompassed in the other figures, as FIG. 2 shows only a portion of the invention.
[0053] Turning to FIG. 3 a through FIG. 3 e , various brackets according to the present invention are shown. FIG. 3 a shows a bracket 70 which is simply an L shaped bracket formed form a piece of steel. It will be appreciated that the bracket must both attach to the wall and support the ceiling, and that an L bracket provides the necessary surfaces. The bracket may be welded or otherwise attached to the walls and ceiling. Additionally, the bracket may be bolted to the walls and ceiling. In one embodiment, the bracket is bolted to the wall facing strips and the ceiling support members so that the facing strips form support columns integral to the shoot house. This leaves maximum flexibility in constructing a modular shoot house. Accordingly, the bracket may be provided with holes formed in the bracket for receiving such bolts.
[0054] FIG. 3 b shows another bracket 74 which has been formed from a strip of steel which is twisted such that one end 78 may attach to the wall and the other end 82 may be attached to the side of a ceiling rail or support. Also, holes 86 have been formed in the bracket 74 so that the bracket may be easily attached to the wall and ceiling. As many holes as are necessary may be formed in the bracket. It will be appreciated that the bracket may be made sufficiently large to be strong enough to support the weight which will be placed on it. One of skill in the art will recognize that the bracket must be sufficiently large so as not to bend or otherwise deform under the weight of the ceiling. Additionally, the attachment means, such as the bolts, must be sufficiently strong to support the weight of the ceiling and any other shoot house structure on top of the ceiling. This may mean that a particular number of bolts must be used, depending on the shear strength of the bolts.
[0055] FIG. 3 c shows another bracket according to the present invention. The bracket 90 has been formed from steel, and has an upper portion 94 which is attached to the wall. The lower portion 98 attaches to the ceiling members, and has two side arms 102 and 106 which have been bent to form a cradle. The lower portion 98 has been shaped to support a beam or channel which supports the ceiling panels. With the part of the bracket which attaches to the wall 94 being bent up above the part of the bracket which supports the ceiling 98 , the upper portion 94 is protected from bullets by the ceiling. It will be appreciated that many different means may be used to attach the bracket to the wall and ceiling, with welding and bolting being the most common methods. In one embodiment, the bracket will be formed with holes similar to the brackets in FIGS. 3 b and 3 d , and that the various shoot house components such as the facing strips and ceiling support members will have corresponding holes formed therein to facilitate construction of the shoot house.
[0056] FIG. 3 d shows a bracket 110 which is similar to the bracket of FIG. 3 , except that the lower portion 114 is configured for attachment to a wall, and the upper portion 118 is shaped to support the ceiling. The upper portion has two tabs 122 , 126 which are bent upwardly to form a cradle to receive a ceiling support member. The bracket 110 is shown with holes 130 to attach the bracket to the wall and ceiling. As many holes 130 as are needed may be formed so long as the bracket 110 is not weakened by the holes. It will be appreciated that while the lower portion 114 is more exposed to bullets than the upper portion 94 of the bracket of FIG. 3 c , the bracket 110 of FIG. 3 d may be easier to install.
[0057] FIG. 3 e shows another bracket 134 according to the present invention. The bracket 134 may be formed from an L shaped piece of metal which has been bent twice into the shape shown. The bracket 134 is thus simple to form. A lower portion 138 is provided to attach the bracket to a wall, and an upper portion 142 is attached to the ceiling members. A tab 146 is bent as shown to further support the ceiling members. Holes 150 have been formed in the upper portion 142 of the bracket 134 to allow the ceiling members to be bolted to the bracket. Additionally, a number of holes 154 have been formed in the lower portion 138 of the bracket 134 for attachment to the walls of a shoot house. Having a number of holes 154 may allow the height of the bracket 134 relative to the wall to be adjusted if so desired, ensuring that the floor is level and in the correct position. Having a number of holes will also allow more bolts to be used to attach the bracket to the wall, providing a more secure attachment to the walls of the shoot house.
[0058] It is appreciated from FIGS. 3 a - 3 e that many different bracket shapes and configurations are available which are suitable for attaching a ceiling member (typically a support beam type member) to a modular ballistic wall. The brackets of FIGS. 3 a - 3 e are thus part of FIGS. 9 a and 9 b , and of the other figures. Many of the figures show only subassemblies or portions of the invention and are thus viewed in combination with the other figures to appreciate the entire invention.
[0059] Turning to FIG. 4 a , an end view of a ceiling of the present invention is shown. The ceiling may be formed of standard sized steel plates 158 . Typically, the edges 162 of the plates 158 are placed adjacent one another forming a joint. The joint is covered with a facing strip 166 and a backing means or backing member 170 , which may be a backing strip, a number of washers, or the like. The facing strip 166 and backing member 170 may be held together by an attachment means such as bolts 174 and nuts 178 which may extend between or through the plates. Alternative methods of fastening are available, such as threading the backing member, using rivets or screws or the like, but a nut and bolt are the most convenient.
[0060] The steel plate may be supported by various support members, such as channels 182 . The support members may be sized and spaced according to the strength needed in the ceiling. The support members may typically be attached to the brackets which are attached to the walls. They will then serve to both support and strengthen the ceiling and brace the walls. It will be appreciated that many different shapes of support members may be used, including members with cross sections such as channels, boxes, I beams, C beams, etc. Additionally, many methods of attaching the steel plate 158 to the support members 182 , such as welding, bolting, gluing, etc. The more preferred method of attaching the plate to the support members is bolting, as it leaves maximum flexibility in constructing and modifying the shoot house.
[0061] Turning now to FIG. 4 b , another side view of a ceiling of the present invention is shown. The ceiling shown is similar to the ceiling of FIG. 4 a , and is a functional equivalent of the ceiling of FIG. 4 a . The ceiling includes steel plates 158 which are placed adjacent each other and joined with a facing strip 166 and backing means 170 , which may be a backing strip, washers, etc. The edges 162 of the steel plates 158 have openings 164 formed therein to allow the bolts 174 to pass through the plates 158 to assemble the joint. It is appreciated that various methods of forming the joint are possible, including passing the bolts 174 between the plates or through the plates. What is important is forming a joint which is not easily penetrated by bullets, as is accomplished by securely fastening the facing strip 166 to the edges 162 of the plates 158 .
[0062] Turning now to FIG. 4 c , a perspective view of a part of a plate as may be used in forming walls or ceilings is shown. The plate 158 includes an opening 164 which a bolt may pass through. In the plate 158 shown, the opening 164 is a hole. FIG. 4 d shows a similar portion of a plate 158 where the opening 164 is formed as a keyhole slot. Such a keyhole slot may be more easily formed by a plasma cutter, or other methods. It is thus appreciated that it is not critical precisely how a hole may be formed. Any of the joints between plates shown in the present invention may be formed as shown in FIGS. 4 a - 4 d . For clarity, not every possible type of joint is shown with every possible wall or ceiling structure, or in combination with every possible shape of support beam.
[0063] Turning to FIG. 5 , another side view of a ceiling is shown. The ceiling is formed with steel plates 186 , 190 , and 194 . The edges of the plates are placed together forming joints, indicated generally at 198 and 202 . Here, support members 206 and 210 having C shaped cross sections have been used. An upper edge 214 and 218 of the members 206 , 210 has been used as a facing strip to cover the joints 198 , 202 . Accordingly, the backing member 222 and 226 may be bolted to the support 206 , 210 using bolts 230 and 234 and nuts 238 and 242 . Using the support members to cover the joint simplifies the joint and makes it easier to manufacture and assemble.
[0064] It will be appreciated that a ceiling such as that of FIG. 5 may be assembled by attaching the support members 206 , 210 to the brackets which have been attached to the tops of the walls, placing the steel panels 186 , 190 , 194 on top of the support members, placing backing members such as backing strips 222 , 226 over the joint, and bolting the assembly together. The resulting structure may easily be made strong enough to support the weight of another floor of the shoot house and the individuals and equipment placed in the shoot house.
[0065] If necessary, additional support members may be placed between the joints to stiffen the ceiling and prevent the steel plate from bending under the weight which may be placed upon it. Such support member may be similar to the supports 206 , 210 , and may run parallel to or transverse to the support members 206 , 210 . Additionally, one will realize that many variations may be made without departing from the present invention, such as using washers instead of backing strips, or using a fastener other than bolts. The present invention encompasses such variations.
[0066] In addition to ease of assembly, the ceiling may be assembled in a variety of configurations. If the ceiling is assembled with standard sized steel panels, each panel may be placed in any location in the ceiling whereas specially shaped panels must be placed in particular locations in a ceiling. Additionally, the steel panels used may be the same size as the walls of the shoot house. For example, if four foot by eight foot panels are used, the walls of the first level of the shoot house would form joints which are spaced apart every four feet and walls would be spaced apart in four foot increments. All of the joints would be evenly spaced in four foot increments.
[0067] Accordingly, ceiling plates which are also four foot by eight foot panels would align with the wall panels such that the ceiling joints and edges would align with the joints of the wall panels. Thus, it is easy to locate the support members and construct the ceiling. Accordingly, support members may be placed in a parallel arrangement between the joints of the wall panels, stretching across the shoot house, and the ceiling panels would line up properly on the support members. Additionally, the support members would only need be provided in four foot increments, and the maximum length of the members needed would be determined by the width of the rooms. Many configurations of shoot houses could be built by having four, eight, and twelve foot support members. If the members all stretch the same direction across the shoot house, rooms with a side longer than twelve feet such as hallways may be oriented perpendicular to the support members.
[0068] Turning to FIG. 6 a , a side view of another ceiling according to the present invention is shown. The ceiling has been formed from a number of steel plates 246 , 250 , 254 . The steel plates have bee joined at the edges using facing strips 258 , 262 which are used in combination with bolts 266 , 270 and nuts 274 , 278 to hold the plates 246 , 250 , 254 firmly between the facing strips 258 , 262 and the support members 282 , 286 . The ceiling has also been constructed with a floor surface for an upper level of the shoot house. The floor surface is made of panels 290 , 294 which are placed on top of the ceiling panels and joints. The floor panels 290 , 294 may be plywood, particle board, oriented strand board, ordinary construction floor sheeting, etc. so long as the material is sufficiently durable for use as a floor material. The floor sheeting 290 , 294 , while not strictly necessary, forms a smoother floor surface by covering the ridges made by the facing strips 258 , 262 and bolts 266 , 270 , making the floor surface somewhat safer.
[0069] Additionally, sheets of a second material have been attached to the ceiling. The sheets 298 , 302 , 306 may be attached to the support members 274 , 278 by bolts 310 and nuts 314 , or by screws or any other suitable attachment method. The sheets 298 , 302 , 306 may be formed of sheetrock, ceiling tile, plywood, etc. The sheets provide an enhanced appearance to the ceiling as viewed from the shoot house beneath. More importantly, the sheets may be designed so as to provide a bullet containment area 318 in the ceiling to prevent bullets from striking the ceiling and ricocheting back towards people in the shoot house. Thus, plywood may be an ideal sheeting material as it is not overly damaged by a bullet and is strong enough to prevent bullets from exiting the containment area. Additionally, the floor sheeting may make the floor less slippery when wet.
[0070] Turning now to FIG. 6 b , another side view of a ceiling according to the present invention is shown. The ceiling is similar to the ceiling of FIG. 6 a , but includes additional floor support structure. The structure of FIG. 6 b includes brackets 264 which may be formed as part of or simply attached to the facing strips 258 , 262 . The brackets 264 may be used to attach support rails 268 , such as 2×4 lumber, which are used to support the floor panels 290 , 294 . The support rails 268 may run parallel to or transverse to the support members 282 , 286 . It is appreciated that the use of such support members may help in isolating the floor from the bullet proof plates. Additionally, if the support rails 168 are placed transverse to the support members 282 , 286 , the support rails may be spaced at different intervals than the support rails.
[0071] Turning now to FIG. 7 , an end view of another ceiling according to the present invention. The ceiling, indicated generally at 322 , is formed with a plurality of steel panels 326 , 330 , 334 which have been placed adjacent each other. The joints 338 , 342 have been covered by the support members 346 , 350 . The support members 346 , 350 have been formed as elongate square members. The panels have been attached to the support members using backing strips 354 , 358 and a plurality of bolts 362 , 366 . The support member, facing strips, and plates are attached to form bullet proof joints. If a ceiling is formed as shown in FIG. 7 and a second floor is to be built above the ceiling, sheet material 370 , such as plywood, may be placed on top of the support members 346 , 350 such that a smooth surface is provided. If the ballistic ceiling is the uppermost surface on the complete structure, the sheet material 370 may be replaced by a roofing material of choice, or whatever material is necessary and suitable.
[0072] The strips and support members cover the joint between the panels and make it very unlikely that a bullet striking the joint would be able to pass through the joint. It will be appreciated from this figure that a large number of different ceiling configurations are possible with the present ceiling. As shown, the steel plates may be suspended from the support members. Additionally, the support members may have a variety of different shapes. In a preferred embodiment, the shapes may have a flat side for attachment to the steel panels.
[0073] Turning now to FIGS. 8 a - 8 f , a number of different shapes for support members are shown. The shapes shown are support member shapes according to a more preferred embodiment, and do not represent all of the shapes of support members which are suitable for use in the invention. The shapes include a box section 374 , a C section 378 , an L section 382 , an I beam 386 , and two channel shaped members 390 and 394 . Of note, all of the shapes shown have at least one flat surface 398 , 402 , 406 , 410 , 414 , 418 , 422 , 426 , 430 , 434 , 438 , 442 , 446 , which may be used to attach steel plates to form the ballistic ceiling, or to attach other materials, such as a bullet penetrable material as may be used to form a bullet containment chamber, and are thus a preferred embodiment, though other shapes may be used.
[0074] A shoot house which is formed according to the present invention should be sufficiently rigid and strong for most applications. While an open framework of facing strips and ceiling support members may be moved somewhat with relative ease, that same framework is quite stiff with the steel plate panels attached thereto. The steel plates prevent motion of the framework. As the shoot house is built by adding steel plates and either facing strips or ceiling support members in close succession, it is naturally rigid as it is being constructed. It is not, however, beyond the scope of the invention to use bracing members to further strengthen a shoot house where the size or particular configuration necessitates such bracing strips.
[0075] The bracing strips primarily prevent the shoot house from swaying side to side, front to back, or from twisting, as may be caused by wind, weather, moving objects within a shoot house, etc. Accordingly, the bracing strips may simply be strips of steel which attach to existing joints within the shoot house, such as facing strips, backing means, ceiling support members, etc. The bracing strips would typically be placed so as to connect two pieces, such as facing strips or ceiling support members, with the bracing strip being at an angle, preferably a 45 degree angle or close thereto, relative to the facing strips or support member. The bracing strip, when placed at an angle relative to the facing strip or support member, substantially inhibits movement of the facing strip or support member.
[0076] According to the present invention, multi-story shoot houses may be formed. A shoot house may be formed which has a modular ceiling attached at or near the top of the walls. As discussed, the ceiling members will substantially stiffen the shoot house and inhibit movement of the shoot house. A second story or shoot house level may be constructed on top of the ceiling. Accordingly, the ceiling members may form part of or support for a floor for the second level. The walls for the second level may be attached to the upper portion of the first level walls, or may be attached to ceiling joints. It will be appreciated that if a modular shoot house is formed with each wall panel being a consistent width, such as four feet, the ceiling panels are also in four foot increments and joints may be found every four feet. Thus, virtually any configuration is possible for the second floor of the shoot house as joints between wall and ceiling panels occur every four feet, in each possible location for joints between wall panels for the second floor.
[0077] Turning to FIG. 9 a , a side view of a multi story shoot house is shown. A lower level wall has been formed with bullet proof wall panels 450 , a backing strip 454 and facing strip 458 placed to cover the joint between adjacent wall panels, and bolts 462 placed to hold the facing strip, backing strip, and panels firmly together. A bracket 466 has been attached to the wall via facing strip 458 with bolts 470 . It will be appreciated, however, that the bracket 466 may simply be welded to the facing strip 458 , or may be formed integral to the facing strip. A support member 474 is attached to the bracket 466 and used to support ceiling panels 478 in a manner similar to that shown in FIG. 6 . A backing strip 482 may be used to cover joints between ceiling panels if necessary. The ceiling panels have been bolted 486 to the support member 474 . As shown, the ceiling forms a floor for a second level of a shoot house.
[0078] A bracket 490 has been attached to the ceiling with bolts 494 , and used to support a second floor wall. The wall has been formed with bullet proof panels 498 , a facing strip 502 , and a backing strip 506 held together with bolts 510 . The wall is attached to the bracket 490 via the facing strip 502 and is secured with bolts 514 . Additionally, a plate or strip 518 may be attached to the walls and used to support the upper level wall alone or in combination with a bracket 490 . A second bracket 522 has been attached to the ceiling via the backing strip 482 , and has been bolted 526 to the support member 474 . The bracket 522 has been used to attach a wall to the ceiling where there is not a lower level wall. The wall is formed with bullet proof panels 530 , a facing strip 534 , and a backing strip 538 , and the facing strip and backing strip are held to the panels with bolts 542 . The wall is bolted 546 to the bracket 522 via the facing strip 534 .
[0079] Turning to FIG. 9 b , a side view of a shoot house of the present invention is shown. The shoot house is similar to that of FIG. 9 a and is numbered accordingly. One difference is that a space 516 has been formed between the lower wall (including steel plate 450 , backing strip 454 , and facing strip 458 ) and the ceiling (including the panels 478 and backing strips 482 ). The space 516 may be used to route electrical cables, target control cables, etc. between adjacent rooms of the shoot house. Such a space may also be used for ventilation in the shoot house if desired.
[0080] A strip or plate 518 may be used to bridge between the lower wall (including steel plate 450 , backing strip 454 , and facing strip 458 ) and the ceiling (including the panels 478 and backing strips 482 ) or an upper wall (including steel plates 498 , facing strips 502 , and backing strips 506 ). A plate 518 may be used which partially, substantially, or completely closes the space 516 , or a strip may be used to provide a stronger joint. Thus, the shoot house may be formed with spaces 516 which are then closed if desired with plates 516 after installation of all necessary wires, control cables, etc. Substantially closing the space 516 would aid in containing bullets which might otherwise pass through the opening and exit the shoot house. It is appreciated that the areas adjacent the ceiling and floor of a shoot house often may pose increased risk of bullets passing around the ballistic walls, and often “no shoot zones” are designated for these areas.
[0081] While omitted for clarity, the walls and ceiling shown in FIGS. 9 a and 9 b may also be covered with a sheeting material similar to the wall of FIG. 1 and the ceiling of FIG. 6 . The sheeting material is preferably a material which is penetrable by bullets but sufficiently durable to not be rapidly be broken down by the bullets. The sheeting material also should be sufficiently durable to not allow a bullet which has passed through the sheeting and ricocheted off of the bullet proof panel to again pass through the sheeting and exit the wall. It is also preferable to space the sheeting apart from the bullet proof panels. The sheeting would thus form a bullet containment area and would make the shoot house significantly safer by substantially eliminating the risk of being hit by a ricocheting bullet. Plywood has been found to be an optimal material for covering the walls and ceiling. Sheeting material may also be placed on top of the ceiling to make a smoother floor for the second shoot house level. The sheeting may cover any backing strips, bolts, or the like which protrude from the ceiling.
[0082] It is appreciated that FIG. 9 a and FIG. 9 b show assembled portions of a shoot house according to the present invention. It is not possible to show each of the structures without making these drawings confusing. Accordingly, wall joints, brackets, bullet containment chambers, etc. have been omitted for clarity in showing the assembled structure. As such, it is appreciated that FIGS. 9 a and 9 b encompass and include the attachment details of FIG. 2 , the brackets of FIGS. 3 a through 3 e , the joint details shown in FIGS. 4 a , 4 b , 5 , 6 a , 6 b , and 7 , the plate details shown in FIGS. 4 c and 4 d , the bullet containment structures and floor structures of FIGS. 6 a , 6 b , and 7 , the beams of FIGS. 8 a - 8 f , and the joint details of FIG. 10 . These structures are all shown individually for clarity in discussing the various substructures of the invention, but are all part of the whole invention embodied in a modular shoot house, as detailed in FIGS. 9 a and 9 b.
[0083] FIGS. 9 a and 9 b show, in cross section, the general joint structure of a modular shoot house according to the present invention. It is appreciated that the specific shape and configuration of the brackets, joiner strips, pieces or plates, etc. may vary according to the use of the joint in the shoot house structure. Thus, different brackets and different resulting joint structures may be necessary where a ceiling support member is parallel to or perpendicular to a wall, or where the ceiling support member is placed above a wall or abutting into a wall. Thus, FIGS. 10 through 18 show details of the bracket shapes and resulting joint structures which accomplish various joints required in constructing a modular shoot house. As such, the joints and structures shown in FIGS. 10 through 18 are considered as part of FIGS. 9 a and 9 b , being variations of the joint structures based on particular location or application within the resulting shoot house.
[0084] Turning now to FIG. 10 , a front view of upper and lower bullet proof walls as used in a modular shoot house of to the present invention is shown. A lower wall has been formed with bullet proof panels 550 and facing strips 554 covering the joints between panels 550 . An upper wall has been similarly formed with bullet proof panels 558 and facing strips 562 . It will be appreciated that often a joint 566 will exist between upper wall panels 558 and lower wall panels 550 . To further strengthen the shoot house, the joint 566 may be covered with a facing strip 570 which is attached to the wall panels 550 , 558 by bolts 574 . A backing means such as a backing strip, washer, or the like, may be placed on the opposite side of the joint 566 and held to the joint with the bolts 574 . Alternatively, the joint 566 may be strengthened by smaller joint plates 578 which are attached to the wall panels 550 , 558 by bolts 582 . Additionally, the joint 566 may simply be strengthened by a plurality of bolts 586 and washers 590 , having washers and nuts placed on the opposite side of the joint 566 . As the joint 566 will typically be covered by the lower level ceiling/upper level floor or will be very near the floor in an area unlikely to be struck by a bullet, it may not be necessary to cover the entire joint 566 with a joint strip 570 . It may, however, be desirable to use a simple fastener such as bolts 586 and washers 590 to further attach the upper panels 558 to the lower panels 550 and thereby brace the panels.
[0085] It will be appreciated that in building a shoot house according to the present invention, it is desirable to cover the joints between wall and ceiling panels with a continuous strip of metal. Thus, facing strips have been shown covering the wall joints and ceiling joints. It is also possible to cover the ceiling joints with a flat surface of a support member, as has been shown. Once the joint has been covered by a metal strip, it is not necessary, though it is desirable, to cover the side of the joint opposite the facing strip or support member with a continuous metal strip. Washers or other similarly sized objects are sufficient to secure the bolts and facing strips to the joints, providing an increased support surface for attaching the bolts. Backing means may not be necessary in all situations. It will also be appreciated that whenever bolts are used in this application to fasten objects together, the bolts may be inserted into threaded holes in the appropriate location, or may simply be attached and tightened with nuts. Screws, rivets, welding, or other fastening methods are also equally applicable and within the scope of the invention.
[0086] Turning now to FIG. 11 a a front view of a bracket of the present invention is shown. The bracket 610 is configured to attach a horizontal support member as may be used in a ceiling to a shoot house wall. The bracket therefore has holes 614 formed therein for attachment to the wall, such as by bolting to the facing strip or to the joint between wall plates. The bracket 610 also includes a flange 618 which is disposed perpendicular to the body of the bracket and which is used to attach the ceiling support member to the bracket.
[0087] FIG. 11 b shows a side view of the bracket of FIG. 11 a . The side view of the bracket 610 more clearly shows the flange 618 and the holes 622 formed in the flange which are used to bolt or otherwise attach the bracket to the ceiling support member. It will be appreciated that the flange 618 may be formed integrally to the bracket, such as by bending a flat plate into a bracket with perpendicular flange. Alternatively, the flange may be a separate plate which is welded or otherwise attached to the bracket.
[0088] Turning now to FIG. 12 a , a front view of another bracket of the present invention is shown. The bracket 626 is configured to attach a ceiling support member to a wall where the support member is parallel to the wall. As such, the bracket has a first flange 630 which is attached to the wall and a second flange 634 which is attached to the support member.
[0089] FIG. 12 b more clearly shows the first flange 630 and second flange 634 . It is again appreciated that the first flange 630 and second flange 634 may be formed as part of the bracket 626 , such as being cut from flat sheet and bent into place, or may be welded or attached to the bracket. Holes 638 are formed in the first flange 630 and used to attach the flange to the wall, such as by attachment to a facing strip or to the joint. Similarly, holes may be formed in the second flange 634 and used to attach the bracket to the ceiling support member.
[0090] Turning now to FIG. 13 , a joint of a shoot house incorporating the bracket of FIGS. 11 a and 11 b is shown. The bracket 610 is attached, with fasteners 654 such as bolts, to a joint (indicated generally at 650 ) formed between two plates 652 , 656 . The joint 650 is typically formed with a facing strip 658 as has been discussed. For clarity, many of the structures such as facing or backing strips, bolts, bullet containment chambers, sheeting, flooring, etc. are removed from the joints shown in FIGS. 13, 14 , 17 , and 18 . The joints are shown without such structures to allow for greater clarity in viewing the brackets and methods of attaching wall panels and joints to ceiling support members and ceiling panels. The ceiling panels may not be shown, but are attached according to the methods shown.
[0091] The bracket 610 is typically bolted to a ceiling support member 662 via flange 618 . The ceiling support member 662 is used to support the ceiling structure, shown generally at 666 . The ceiling structure 666 is as has been discussed and may include ballistic panels and joints, as well as support rails and flooring sheets such as plywood or subflooring. Another wall section (indicated at 670 ) may be attached to the ceiling structure 666 as has been shown, such as in FIG. 9 a.
[0092] Turning now to FIG. 14 , a joint of a shoot house of the present invention is shown. The joint utilizes the bracket of FIGS. 12 a and 12 b . As has been discussed, the bracket 626 is configured for mounting a ceiling support member 678 parallel to a wall 682 . The wall 682 is formed with steel panels 686 joined with a facing strip 690 as has been discussed. The bracket 626 is attached to the wall 682 by bolting the first flange 630 to the joint, and to the ceiling support member 678 by bolting the second flange 634 to the ceiling support member. A ceiling/floor 694 may be attached to the ceiling support member 678 , and may possibly include bullet proof panels, bullet containment chambers, floor beams and sheeting, etc. as has been discussed. An upper wall 698 may be attached to the ceiling support member 678 or to the floor/ceiling 694 as has been previously shown and discussed, such as in FIG. 9 a or 9 b.
[0093] Turning now to FIG. 15 a , a top view of another bracket of the present invention is shown. The bracket 706 is configured for attaching a support member such as the ceiling support members discussed to a wall where the support member is perpendicular to the wall and extends from a wall rather than being disposed above the wall. The bracket 706 includes a first flange 710 having holes 714 which is configured for attachment to a wall, such as by bolting to a joint between wall panels. The bracket 706 also includes a second flange 718 having holes 722 which is configured for attachment to a support member.
[0094] FIG. 15 b shows a side view of the bracket of FIG. 15 a , better illustrating the second flange 718 and holes 722 . FIG. 15 c shows an end view of the bracket of FIG. 15 a , and better illustrates the first flange 710 and holes 714 . In discussing this and all other brackets, it is appreciated that the number and location of holes as well as the configuration of the bracket may be adjusted according to the mounting location of the bracket, weight carried by the bracket, etc.
[0095] Turning now to FIG. 16 a , a side view of a bracket of the present invention is shown. Then bracket 730 is configured for attaching a support member to a wall where the support member is generally parallel to the wall and extends from the wall instead of being above the wall. The bracket 730 has a first flange 734 having holes 738 which attaches to a wall, such as to a joint or facing strip. The bracket also has a second flange 742 with holes 746 which may be attached to a support member. As can more clearly be seen in FIG. 16 b , the bracket 730 may have a center section 750 which connects the first flange 734 and second flange 742 in a zigzag shape. Such a center flange 750 offsets the first flange 734 and second flange 742 from each other, allowing for easier attachment of the bracket to both a wall and support member.
[0096] Turning now to FIG. 17 , a joint of a shoot house incorporating the bracket of FIGS. 16 a and 16 b is shown. The bracket 730 is shown attaching a support member 758 to a wall joint, indicated at 762 . The wall structure and joint 762 are formed as has been shown and discussed previously. It will be appreciated that a space 766 may formed between the plates 770 adjacent the bracket 730 and support member 758 , or no space may be present. Attaching a support member parallel to a wall as shown may allow for the installation of stairs, etc. in the shoot house.
[0097] Turning now to FIG. 18 , a joint of a shoot house using the bracket of FIGS. 15 a through 15 c is shown. The bracket 706 has been used to attach a support member 778 to a wall. The support member 778 extends perpendicularly from the wall. The wall includes steel panels 782 joined by a facing strip 786 as has been previously discussed. The bracket 706 has been bolted to the joint, but may be welded or otherwise attached.
[0098] It is appreciated that the various structures and assemblies of the shoot house which have been discussed are each small parts of the invention, which may require a combination of these structures to form a completed shoot house. Various structures of the shoot house, such as ceilings, floors, stairs, etc. will each require different types of brackets, or combinations of the brackets and joints shown.
[0099] There is thus disclosed an improved method for forming shoot houses. It will be appreciated that numerous modifications may be made to the present invention without departing from the scope of the invention. The preceding examples are illustrative of the invention, and do not define the scope of the invention. | A modular ballistic ceiling allows increased flexibility in building and reassembling shoot houses. Shoot houses may be built with multiple levels which are completely modular. | 5 |
TECHNICAL FIELD OF THE INVENTION
This invention relates in general to downhole tools and, in particular to, a downhole tool for generating electromagnetic waves to determine the resistivity of the earth surrounding a wellbore.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with transmitting downhole data to the surface during well logging and during the placement of downhole tools such as packers, perforating guns, valves and similar devices, however, it should be noted that the principles of the present invention are applicable throughout the life of a wellbore.
During the drilling, completion and operation of a typical hydrocarbon well, various tools are placed downhole for operations such as packing, perforating and well control. The tools may be packers, perforating guns, flow control devices and the like. Placing the tools in the correct location is a key consideration in successful well operation. Misplacement of a tool can result in multiple trips down the well to retrieve and/or reposition the tool in the correct location as well as repairing any damage to the wellbore or casing resulting from, for example, the discharge of a perforating gun outside of the desired zone. The placement of downhole tools consequently represents an important step in the completion and operation of an oil or gas well. Therefore, from an economic standpoint, it is critical that the tools used to complete and produce a well are correctly placed.
While a number of techniques have been utilized to transmit downhole data such as temperatures, pressures and the like to the surface, these methods have not been exploited in connection with downhole logging and tool placement. In particular, one technique utilized to telemeter downhole data to an operator on the surface is based upon the generation and propagation of electromagnetic waves. Electromagnetic waves may be produced by inducing an axial current into, for example, the production casing or drill string. The axially induced current produces electromagnetic waves including an electric field and a magnetic field, formed at right angles to each other. The axial current impressed on the casing or drill string is modulated with data causing the electric and magnetic fields to expand and collapse, creating a means by which data may be propagated and intercepted by a receiving system. The receiving system is typically positioned at ground level or, in the case of offshore operations, at the sea floor, where the electromagnetic signal is picked up and recorded.
The intensity of the electromagnetic signal at a given distance from the telemetry tool is directly related to the distance of transmission, the characteristics of the media through which the signal is propagated and other factors. The intensity of electromagnetic waves transmitted through the earth strata is dependent upon the skin depth (δ) of the media through which the electromagnetic waves travel. Skin depth is defined as the distance at which the power from a downhole signal will attenuate by a factor of 8.69 db. (approximately seven times decrease from the initial power input), and is primarily dependent upon the frequency (f) of the transmission and the conductivity (σ) of the media through which the electromagnetic waves are propagating. For example, at a frequency of 10 Hz, and a conductance of 1 mho/meter (1 ohmmeter), the skin depth would be 159 meters (522 feet) Therefore, for each 522 feet in a consistent 1 mho/meter media, an 8.69 db loss occurs. Skin depth may be calculated using the following equation.
Skin Depth=δ=1/√ (πfμσ) where:
n=3.1417;
f=frequency (Hz);
μ=permeability (4π×10 6 ); and
σ=conductance (mhos/meter).
As should be apparent, the higher the conductance of the media through which the electromagnetic waves are propagated, the lower the frequency must be to achieve the same transmission distance. Likewise, the lower the frequency, the greater the distance of transmission with the same amount of power. In any case, the current flow or current drain during the transmission is proportional to the conductivity of the media surrounding the telemetry tool. Thus, the use of electromagnetic telemetry provides an opportunity to meet an existing need for an accurate, reliable and economical means of determining the location of a tool in a wellbore.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises a downhole telemetry tool including an electromagnetic transmitter for determining the location of the downhole tool utilizing Ultra Low Frequency ("ULF") to Very Low Frequency ("VLF") electromagnetic waves. The method and apparatus of the present invention also provide for the generation of a resistivity log that may be obtained as the result of the natural transmission characteristics of an electromagnetic data transmission system. The resistivity log may be generated when tripping into or out of the wellbore.
Electromagnetic waves in the ULF range, 0.0001 Hz to 20 Hz, will penetrate the earth media at a very great depth, resulting in a broad band resistance. Due to the transmission characteristics of ULF electromagnetic waves, the load presented by the surrounding media and measured by the telemetry tool is not greatly affected by the presence of casing which provides a constant load. Thus, as the apparatus and method of the present invention contemplate the use of ULF electromagnetic transmissions in both open and cased boreholes.
Increasing the frequency of the electromagnetic waves to the VLF range, 3 Khz to 30 KHz, narrows the bandwidth and provides a more definitive signal as the waves propagate through the surrounding media. In either case, the transmission of both ULF and VLF electromagnetic waves results in an electrical current draw upon the transmitting electronics that is inversely proportional to the resistivity of the surrounding media, thus enabling the creation of a resistivity log or the identification of the surrounding media based upon prior resistivity logging of the strata through which the wellbore extends. Thus, the operator, by comparing real time readings against a previously obtained resistivity log, may set tools such as packers, perforating guns, sensors, flow control devices and the like in the desired zone. The operator may take ULF readings first to obtain a general location and then use VLF readings to more accurately position the particular tool.
In one embodiment of the present invention, each time the electromagnetic telemetry system is used to transmit a data stream to the surface, the load (current draw) on the telemetry tool is measured using a current sensing circuit device incorporated in the downhole electronics unit. The measurement is stored and transmitted to the surface with the next data transmission.
In the method of the present invention, the location of a downhole tool is determined via the electromagnetic field load placed across an electrically isolated portion of a work string. The isolated portion of the drill string is separated from the remainder of the string by a dielectric material such as an oxide resin or thermoset resin, selected for its dielectric properties and capability of withstanding extrusion.
The downhole telemetry tool of the present invention comprises a housing having first and second subassemblies that are electrically isolated from one another. In one embodiment, an isolation subassembly is disposed between the first and second subassemblies using a dielectric layer positioned between the isolation subassembly and both the first subassembly and the second subassembly. The transmitter also includes a mandrel that is coaxially disposed within the housing. The mandrel is electrically isolated from the first subassembly with one or more dielectric layers and is electrically coupled to the second subassembly. In one embodiment, the mandrel includes a first section and a second section which are electrically isolated from one another by a dielectric material.
An important factor in measuring the electrical load across the gap is the length and radius of the collar, drill string or pipe below the gap, referred to as the electrode. The length and radius of the electrode, in combination with the skin depth and conductivity of the surrounding media is characterized by an impedance Z across the gap that is proportional to the resistivity of the media through which the electromagnetic wave travels. The impedance may be approximated through the use of the following equation:
Z=-ln(R/δ)/(2πσL) where:
π=3.1417;
δ=skin depth;
σ=conductivity (mhos/meter);
R=radius of the electrode; and
L=length of the electrode.
Thus, the conductance, or inversely, the resistivity of the media surrounding the electromagnetic telemetry tool may be determined. Also, by comparing the resistivity of the media with prior resistivity log records, the location of the telemetry tool can be determined on a real time basis. The apparatus and method of the present invention, by comparing real time readings against previously obtained resistivity logs, enable the operator to set and place packers, perforating guns and other devices in the desired downhole location or zone. In addition, the apparatus and method of the present invention provide for real time communication between downhole equipment and the surface using electromagnetic waves to carry the information. Alternatively, the information may be telemetered to surface using electromagnetic or acoustical waves or via a hardwired connection to a surface location. The apparatus of the present invention may be conveyed downhole on a wire line or may be configured as a tubing retrievable device. In either case, the apparatus and method of the present invention provide an economical and reliable means of locating downhole tools in the desired location, thereby minimizing the need for multiple trips to place tools in a wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic illustration of an offshore oil or gas drilling platform utilizing the apparatus and method of the present invention to locate a desired zone for placement of a downhole tool;
FIG. 2 is a schematic illustration of an offshore oil or gas drilling platform utilizing the apparatus and method of the present invention to adjust the location of a downhole tool after the location of the desired zone has been determined;
FIGS. 3A and 3B are quarter sectional views of one embodiment of the telemetry tool of the present invention;
FIG. 4 is a schematic illustration of a toroid with primary and secondary windings for utilization with one embodiment of the present invention;
FIG. 5 is an exploded view of a toroid with primary and secondary windings for utilization as a transmitter or receiver in connection with one embodiment of the present invention;
FIG. 6 is a perspective view of an annular carrier for a telemetry tool of the present invention;
FIG. 7 is a perspective view of an electronics package or member including a plurality of electronic devices incorporated therein for use in connection with the invention;
FIG. 8 is a perspective view of a battery pack for powering the telemetry tool of the present invention; and
FIG. 9 is a block diagram schematically illustrating signal processing in accordance with one embodiment of the method and apparatus of the invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring to FIG. 1, an offshore oil and gas drilling apparatus is schematically illustrated and generally designated 10. A semi-submergible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16. A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 including blowout preventers 24. Platform 12 has hoisting apparatus 26 and a derrick 28 for raising and lowering drill string 30 in wellbore 32.
Wellbore 32 penetrates and passes through a plurality of different strata or zones 38. During the completion or operation of the well, a variety of downhole tools such as packer 34 and perforation gun 36 are placed downhole to perform various operations such as isolating portions of wellbore 32 or perforating the casing 50 in order to produce from a selected zone. As will be appreciated by those skilled in the art, accurate placement of these tools is important to avoid multiple tool resets and/or multiple trips down the wellbore 32.
Electromagnetic telemetry tool 40 of the present invention is positioned adjacent to a tool, such as a perforating gun 36, in a first downhole location 15. Although the electromagnetic telemetry tool 40 is shown adjacent to the perforating gun 36, it will be appreciated by those skilled in the art that telemetry tool 40 may be positioned a known distance above or below perforating gun 36 along drill string 30. Telemetry tool 40 is capable of transmitting multiple frequencies ranging between, for example 1 Hz (ULF) and 20 KHz (VLF). Telemetry tool 40 may be equipped to receive transmissions from a surface transmitter 29 for two way communications between platform 12 and downhole locations as required.
Generation of electromagnetic waves 42 is enhanced by positioning telemetry tool 40 in an electrically isolated portion of the drill string 30 separated by a nonconductive gap 44 from the uphole portion of drill string 30. Telemetry tool 40 is powered by a battery pack which may include a plurality of batteries, such as nickel cadmium or lithium batteries, which are configured to provide proper operating voltage and current.
ULF electromagnetic waves 42 generated by the telemetry tool 40 travel through the earth and are received by electromagnetic pickup device 60 located on sea floor 16. Electromagnetic pickup device 60 may sense either the electric field or the magnetic field of electromagnetic wave fronts 42 using an electric field sensor 62 or a magnetic field sensor 64 or both. The electromagnetic pickup device 60 serves as a transducer transforming electromagnetic wave fronts 42 into an electrical signal using a plurality of electronic devices. The electrical signal may be sent to the surface on wire 70 that is attached to buoy 72 and onto platform 12 for processing. Upon reaching platform 12, the transmitted information, including the current draw from the prior transmission, is processed making any necessary adjustments, calculations and error corrections such that the information may be displayed in a usable format to determine the downhole location of, for example, perforating gun 36. Additionally, parameters such as pressure and temperature as well as a variety of other environmental information may be obtained by sensors (not shown) and transmitted via electromagnetic wave fronts 42 generated by telemetry tool 40.
In some instances it may be desirable to place a tool at a depth such that signal strength of the electromagnetic wave fronts 42 generated by telemetry tool 40 is not sufficient for detection at the sea floor 16. In these instances, one or more repeaters 35 may be interposed along the drill string 30 and sea floor 16 to receive, amplify and retransmit the signals. Repeaters 35 may utilized electromagnetic waves, acoustical waves or both depending upon the depth of the wellbore 32 and the desired location and the particular strata through which wellbore 32 extends.
Even though FIG. 1 depicts a single repeater 35, it should be noted by one skilled in the art that the number of repeaters will be determined by the depth of wellbore 32, the noise level in wellbore 32 and the characteristics of the earth's strata adjacent to wellbore 32 in that electromagnetic waves suffer from attenuation with increasing distance from their source at a rate that is dependent upon the composition characteristics of the transmission medium and the frequency of transmission. For example, repeaters 35 may be positioned between 3,000 and 5,000 feet apart. Thus, if wellbore 32 is 15,000 feet deep, between two and four repeaters 35 would be desirable. Additionally, as will be appreciated by those skilled in the art, telemetry tool 40 of the present invention may be incorporated as part of one or more of repeaters 35 if desired.
The current draw by telemetry tool 40 during the generation of electromagnetic wave fronts 42 may be stored and transmitted to the surface immediately or with the next data transmission. The current draw is used to determine the resistivity of the medium at 15. The current draw information to is transmitted to the surface for comparison with prior resistivity log records to determine the location of the tool 36. Based upon the results of the comparison, perforating gun 36 may be repositioned in the desired location.
Referring now to FIG. 2, perforating gun 36 has been repositioned in zone 15 is based upon the previously obtained resistivity readings. To increase the precision of the positioning of telemetry tool 40 and thereby perforating gun 36, telemetry tool 40 may generate VLF waves 46 at a frequency of, for example, 20 KHz. The resistivity information obtained using VLF waves 46 will be stored and may be transmitted to electromagnetic pickup device 60 using ULF electromagnetic wave fronts 42 as described with reference to FIG. 1. As previously noted, electromagnetic pickup device 60 may sense either the electric field or the magnetic field of electromagnetic wave fronts 42 utilizing an electric field sensor 62 or a magnetic field sensor 64 or both. The electromagnetic pickup device 60 converts electromagnetic wave fronts 42 into electrical signals using a plurality of electronic devices. The electrical signal may be sent to the surface on wire 70 that is attached to buoy 72 and onto platform 12 for processing. Upon reaching platform 12, the transmitted information, including the current draw during the transmission of VLF waves 46, is processed making any necessary adjustments, calculations and error corrections such that the information may be displayed in a usable format to determine the location of perforating gun 36.
Even though FIGS. 1 and 2 have been described with reference to transmitting electromagnetic waves in the ULF range and the VLF range, it should be understood by one skilled in the art that telemetry tool 40 of the present invention is equally well-suited for transmitting electromagnetic waves in other frequency ranges including, but not limited to, the low frequency range, 30 KHz to 300 KHz, the medium frequency range, 300 KHz to 3 MHz and the high frequency range, 3 MHz to 30 MHz. Additionally, it should be noted that transmitting electromagnetic waves in such higher frequency ranges will yield greater precision for downhole positioning and greater sensitivity for a downhole resistivity log.
Representatively illustrated in FIGS. 3A and 3B is one embodiment of an electromagnetic telemetry tool 40 of the present invention. For convenience of illustration, FIGS. 3A and 3B depict telemetry tool 40 in a quarter sectional view. Telemetry tool 40 has a box end 78 and a pin end 80 such that telemetry tool 40 is threadably adaptable to drill string 30. In one embodiment, telemetry tool 40 has an external housing 82 and a mandrel 84 having a full bore enabling the circulation of fluids therethrough. Housing 82 and mandrel 84 protect the components of telemetry tool 40 from fluids disposed within wellbore 22 and within drill string 30.
Housing 82 of telemetry tool 40 includes an axially extending and generally tubular upper connecter 86 including box end 78. Upper connecter 86 is normally sealed and connected to drill string 30 for conveyance into wellbore 32 by means of a threaded connection.
An axially extending generally tubular intermediate housing member 88 is threadably and sealably connected to upper connecter 86. An axially extending generally tubular lower housing member 90 is threadably and sealably connected to intermediate housing member 88. Upper connecter 86, intermediate housing member 88 and lower housing member 90 form upper subassembly 92. Upper subassembly 92, including upper connecter 86, intermediate housing member 88 and lower housing member 90, is electrically connected to the section of drill string 30 above telemetry tool 40.
An axially extending generally tubular isolation subassembly 94 is secured and coupled in sealing relationship to lower housing member 90. Interposed between isolation subassembly 94 and lower housing member 90 is a dielectric layer 96 that provides electric isolation between lower housing member 90 and isolation subassembly 94. Dielectric layer 96 is composed of a dielectric material, such as teflon, chosen for its dielectric properties and capably of withstanding compression loads without extruding.
An axially extending generally tubular lower connecter 98 is securably and sealably coupled to isolation subassembly 94. Disposed between lower connecter 98 and isolation subassembly 94 is a dielectric layer 100 that electrically isolates lower connecter 98 from isolation subassembly 94. Lower connecter 98 is adapted to threadably and sealably connect to drill string 30 and is electrically connected to the portion of drill string 30 below telemetry tool 40.
Isolation subassembly 94 provides a discontinuity in the electrical connection between lower connecter 98 and upper subassembly 92 of telemetry tool 40, thereby providing a discontinuity in the electrical connection between the portion of drill string 30 below telemetry tool 40 and the portion of drill string 30 above telemetry tool 40.
It should be apparent to those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward, etc. are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. It is to be understood that telemetry tool 40 may be operated in vertical, horizontal, inverted or inclined orientations without deviating from the principles of the present invention.
Mandrel 84 includes axially extending generally tubular upper mandrel section 102 and axially extending generally tubular lower mandrel section 104. Upper mandrel section 102 is partially disposed and sealing configured within upper connecter 86. A dielectric member 106 electrically isolates upper mandrel section 102 from upper connecter 86. The external surface of upper mandrel section 102 has a dielectric layer disposed thereon. Dielectric layer 108 may be, for example, a teflon layer. Together, dielectric layer 108 and dielectric member 106 serve to electrically isolate upper connecter 86 from upper mandrel section 102.
Between upper mandrel section 102 and lower mandrel section 104 is a dielectric member 110 that, along with dielectric layer 108 serves to electrically isolate upper mandrel section 102 from lower mandrel section 104. Between lower mandrel section 104 and lower housing member 90 is a dielectric member 112. On the external surface of lower mandrel section 104 is a dielectric layer 114 which, along with dielectric member 112 provide for electric isolation of lower mandrel section 104 from lower housing member 90. Dielectric layer 114 also provides for electric isolation between lower mandrel section 104 and isolation subassembly 94 as well as between lower mandrel section 104 and lower connecter 98. Lower end 116 of lower mandrel section 104 is disposed within lower connecter 98 and is in electrical communication with lower connecter 98.
Intermediate housing member 88 of external housing 82 and upper mandrel section 102 of mandrel 84 define annular area 118. An electronics package 122 and a transmitter 124 are disposed within annular area 118. In operation, a telemetry tool 40 will generate ULF electromagnetic wave fronts 42 as a course means for determining the location of telemetry tool 40 in wellbore 30 as described with reference to FIG. 1. Information relating to the current draw of ULF electromagnetic wave fronts 42 is sent to electronics package 122 via electrical conductor 128. ULF electromagnetic wave fronts 42 may also be used to generate an electromagnetic output signal that carries the resistivity information as well as other information through the earth that may be picked up by electromagnetic pickup device 60. Once telemetry tool 40 is generally positioned in the correct downhole location, telemetry tool 40 may generate VLF electromagnetic waves 46 to more precisely determine downhole position. Information relating to the current draw within telemetry tool 40 is then sent to electronics package 122 via electrical conductor 128. This information may be forwarded to the surface using ULF electromagnetic wave fronts 42 for transmission. Thus, telemetry tool 40 of the present invention may use ULF electromagnetic wave fronts 42 to determine course downhole position and to transmit information to the surface using a relatively small amount of power. Additionally, telemetry tool 40 of the present invention may determine precise downhole position using VLF waves 46.
In addition to using telemetry tool 40 of the present invention to identify a specific downhole location in comparison to a resistivity log, downhole telemetry tool 40 of the present invention may be used to generate a resistivity log. In such a case, telemetry tool 40 will operate as drill string 30 is tripped into or out of wellbore 32. The current draw information from transmitter 124 is fed to electronics package 122 via electrical conductor 128. For logging, telemetry tool 40 may be operated at any suitable frequency, however, the use of a higher frequency in the VLF range, for example, will yield a resistivity log with greater sensitivity.
Referring now to FIG. 4, a schematic illustration of a toroid suitable for use in one embodiment of the invention is depicted and generally designated 180. Toroid 180 includes magnetically permeable annular core 182, a plurality of electrical conductor windings 184 and a plurality of electrical conductor windings 186. Windings 184 and windings 186 are each wrapped around annular core 182. Collectively, annular core 182, windings 184 and windings 186 serve to approximate an electrical transformer wherein either windings 184 or windings 186 may serve as the primary or the secondary of the transformer.
In one embodiment, the ratio of primary windings to secondary windings is 2:1. For example, the primary windings may include 100 turns around annular core 182 while the secondary windings may include 50 turns around annular core 182. In another embodiment, the ratio of secondary windings to primary windings is 4:1. For example, primary windings may include 10 turns around annular core 182 while secondary windings may include 40 turns around annular core 182. It will be apparent to those skilled in the art that the ratio of primary windings to secondary windings as well as the specific number of turns around annular core 182 will vary based upon factors such as the diameter and height of annular core 182, the desired voltage, current and frequency characteristics associated with the primary windings and secondary windings and the desired magnetic flux density generated by the primary windings and secondary windings.
Toroid 180 of the present invention may serve as transmitter 124 of the telemetry tool 40 as described with reference to FIG. 3A. Windings 184 have a first end 188 and a second end 190. First end 188 of windings 184 is electrically connected to electronics package 122. Windings 184 serve as the primary wherein first end 188 of windings 184, receives an electrical signal from electronics package 122 via electrical conductor 128. Second end 190 of windings 184 is electrically connected to upper subassembly 92 of external housing 82 which serves as a ground.
Windings 186 of toroid 180 have a first end 192 and a second end 194. First end 192 of windings 186 is electrically connected to upper subassembly 92 of external housing 82.
Second end 194 of windings 186 is electrically connected to lower connecter 98 of external housing 82. First end 192 of windings 186 is thereby separated from second end 192 of windings 186 by isolations subassembly 94 which prevents a short between first end 192 and second end 194 of windings 186. The current supplied from electronics package 122 feeds windings 184, the primary, such that a current is induced in windings 186, the secondary. The current in windings 186 induces an axial current on drill string 30, thereby producing electromagnetic waves such as ULF waves 42 and VLF waves 46.
Referring now to FIG. 5, an exploded view of a toroid assembly 226 is depicted. Toroid assembly 226 may to serve as transmitter 124 of telemetry tool 40 of FIG. 3A. Toroid assembly 226 includes a magnetically permeable core 228, an upper winding cap 230, a lower winding cap 232, an upper protective plate 234 and a lower protective plate 236. Winding caps 230, 232 and protective plates 234, 236 are formed from a dielectric material such as fiberglass or phenolic. Windings 238 are wrapped around core 228 and winding caps 230, 232 by inserting windings 238 into a plurality of slots 240 which, along with the dielectric material, prevent electrical shorts between the turns of winding 238. For illustrative purposes, only one set of winding, windings 238, have been depicted. It will be apparent to those skilled in the art that, in operation, a primary and a secondary set of windings will be utilized by toroid assembly 226.
As should be apparent from FIG. 5, the number of magnetically permeable cores such as core 228 may be varied, dependent upon the required length for the toroid. In addition, as will be known by those skilled in the art, the number of cores 228 will be dependent upon the diameter of the cores as well as the desired voltage, current and frequency carried by primary windings 238 and secondary windings 240.
Referring now to FIGS. 6, 7 and 8, the components of electronics package 122 of the present invention are illustrated. Electronics package 122 includes an annular carrier 196, an electronics member 198 and one or more battery packs 200. Annular carrier 196 is disposed between external housing 82 and mandrel 84. Annular carrier 196 includes a plurality of axial openings 202 for receiving either electronics member 198 or battery packs 200.
Even though FIG. 6 depicts four axial openings 202, it should be understood by one skilled in the art that the number of axial openings in annular carrier 196 may be varied. Specifically, the number of axial openings 202 will be dependent upon the number of battery packs 200 which will be required for a specific implementation of the telemetry tool 40 of the present invention.
Electronics member 198 is configured for insertion into an axial opening 202 of annular carrier 196. Electronics member 198 receives current draw information from first end 188 of windings 184. Electronics member 198 includes a plurality of electronic devices such as a current sensor 204, a preamplifier 206, a filter 208, a sample and hold circuit 210, an analog to digital converter 212, a memory device 214 and an amplifier 216.
Battery packs 200 are sized for insertion into axial openings 202 of axial carrier 196. Battery packs 200, which includes batteries such as nickel cadmium batteries or lithium batteries, are configured to provide the proper operating voltage and current to the electronic devices of electronics member 198 and to for example toroid 180 of FIG. 4.
Even though FIGS. 6-8 have described electronics package 122 with reference to annular carrier 196, it will be appreciated that a variety of configurations may be used for the construction of electronics package 122. For example, electronics package 122 may be positioned concentrically within mandrel 84 using several stabilizers and having a narrow, elongated shape such that a minimum resistance will be created by electronics package 122 to the flow of fluids within drill string 30.
FIG. 9 is a block diagram schematically illustrating one embodiment of the method utilized in the practice of the present invention and is generally designated 300. Electromagnetic transmitter 302 is used to generate electromagnetic waves such as ULF electromagnetic waves 42 and VLF electromagnetic waves 46. The current drawn by electromagnetic transmitter 302 is fed back to a current sensor 304. An electrical signal from current sensor 304 is then amplified in amplifier 306 and filtered in filter 308 prior to entering sample and hold circuit 310. Sample and hold circuit 310 monitors the current draw at predetermined intervals determined by precision clock 312. The information obtained in sample and hold circuit 310 is passed to analog to digital converter 314 and into memory device 316 for storage. The current draw information may then be forwarded to amplifier 318 prior to transmission to the surface by electromagnetic transmitter 302. Method 300 may operate on a continuous basis which would be suitable for a logging operation. Alternatively, method 300 may be used as needed to determine the position of electromagnetic transmitter 302 within wellbore 30.
While the invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. For example while the apparatus of the present invention is illustrated and described in connection with offshore oil production, it should be understood by one skilled in the art that the invention is equally well-suited for operation in an onshore environment. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | An apparatus for obtaining resistivity readings of the earth surrounding a wellbore (32) to determine the downhole location of the apparatus or to generate a log is disclosed. The apparatus comprises an electromagnetic transmitter (40) for transmitting electromagnetic waves (42, 46) into the earth and an electronics package (122). The electronics package includes a power source (200) providing a current to the electromagnetic transmitter (40), a current sensing device (204) for detecting the current drawn by the electromagnetic transmitter (40), a sample and hold circuit (210) for sampling the current drawn by the electromagnetic transmitter (40) and a memory device (214) for storing the current draw information. | 4 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to a vertical power component capable of withstanding a high voltage (greater than 500 V) and more specifically to the peripheral structure of such a component.
[0003] 2. Discussion of the Related Art
[0004] FIGS. 1 , 2 , 3 , and 4 are cross-section views showing various ways of forming the periphery of such a high-voltage vertical power component to enable it to withstand high voltages.
[0005] These drawings show a triac comprising a lightly-doped N-type silicon substrate 1 (N − ), currently with a doping ranging from 10 14 to 10 15 atoms/cm 3 , having its upper and lower surfaces comprising P-type doped layers or regions 3 and 5 . Upper layer 3 contains a heavily-doped N-type region 4 and lower layer 5 contains a heavily-doped N-type region 6 in an area substantially complementary to that taken up by region 4 . An electrode A 1 coats the lower surface of the component and is in contact with regions 5 and 6 . An electrode A 2 coats the upper surface of the component and is in contact with region 4 and a portion of region 3 . In region 3 is also formed a heavily-doped N-type region 8 of small extension, and a gate electrode G covers region 8 and a portion of region 3 . Thus, whatever the biasing between electrodes A 1 and A 2 , if a gate control is provided, the component turns on. The conduction is performed from electrode A 1 to electrode A 2 through a vertical thyristor comprising regions 5 , 1 , 3 , and 4 , or from electrode A 2 to electrode A 1 through a vertical thyristor comprising regions 3 , 1 , 5 , and 6 . The thickness and the doping level of substrate 1 are calculated so that the triac, in the off state, can withstand high voltages, for example, voltages ranging between 600 and 800 volts. It should then be avoided that breakdowns occur at the component edges.
[0006] FIG. 1 shows a so-called double-mesa peripheral structure for avoiding such Breakdowns. A ring-shaped lateral trench deeper than P regions 3 and 5 is formed at the periphery of each of the two surfaces of the substrate. These trenches are filled with a passivation glass 9 . In practice, trenches are initially formed on a silicon trench between two components before dicing of the chip into individual components. If a breakdown occurs, it occurs in areas 11 where the PN − junctions cut insulating trenches 9 .
[0007] A disadvantage of double-mesa structures is that, given that the passivation glass never has the same thermal expansion coefficient as silicon, the interface between glass and silicon ages poorly and, in case of an incidental breakdown, if the voltage across the component exceeds the authorized limit, the component is no longer operative.
[0008] Another disadvantage of double-mesa is due to the fact that the lateral surfaces of substrate 1 are not insulated. Thus, when the component electrodes are welded to contact areas of another electronic device or of a package, it should be provided that lateral wickings do not electrically connect one of the electrodes to substrate 1 , which would short-circuit the corresponding PN − junction.
[0009] FIG. 2 shows another conventional peripheral structure of the power component. A groove filled with a passivation glass is present on the upper surface side. The component is surrounded with a heavily-doped P-type diffused wall 12 formed from the upper and lower surfaces and the groove extends between wall 12 and P-type layer 3 , substantially as shown. Thus, all voltage hold areas are gathered on the upper surface side of the component. Breakdowns are likely to occur at the periphery of the junction between wall 12 and substrate 1 , on the groove side, in the area designated with reference numeral 14 , when lower electrode A 1 is negative with respect to upper electrode A 2 (so-called reverse breakdown); and breakdowns are likely to occur at the periphery of the junction between substrate 1 and layer 3 , on the groove side, in the area designated with reference numeral 16 , when lower electrode A 1 is positive with respect to upper electrode A 2 (so-called forward breakdown).
[0010] This structure provides good results, and simplifies the forming of lower electrode A 1 and the steps of welding to an external device. In particular, the presence of wall 12 thus prevents any risk of short-circuit due to possible lateral wickings.
[0011] However, a disadvantage is that distance e 2 between the component edge and the glassivation limit (beginning of electrode A 2 or G, respectively) is greater than distance e 1 between the component edge and the glassivation limit in the former case. As an example, in the best conditions, that is, when the angle according to which the trenches filled with glass cut the junctions between the substrate and layers 3 and 5 is properly chosen, and when the amount of glass is optimized, in order to obtain a breakdown voltage greater than 800 volts, a distance e 1 on the order of 300 μm should be provided in the case of FIG. 1 , and a distance e 2 on the order of 350 μm should be provided in the case of FIG. 2 . This decreases, by this distance, the surface area available for the electrodes of the power component of FIG. 2 ; otherwise, for given values of the electrode surface areas, this increases the surface area of the component, and thus its cost.
[0012] Further, as in the previous case, the interface between the silicon and the passivation glass remains a problem.
[0013] Further, the presence of grooves only extending on the front surface side of the semiconductor substrate may raise mechanical stress issues.
[0014] Further, region 3 being relatively close to diffused wall 12 , there is a risk of breakdown of the component by punchthrough of the bipolar transistors formed by P-type region 3 , N-type substrate 1 , and P-type wall 12 , which limits the voltage behavior of the component.
[0015] FIG. 3 shows a passivation structure in so-called “planar” technology. As in the case of FIG. 2 , the structure is surrounded with a heavily-doped P-type ring-shaped wall at its periphery. To withstand the voltage, a distance is provided between the limit of P-type layer 3 and peripheral wall 20 . A breakdown, if any, would occur in regions 23 of curvature of P well 3 or in region 24 of junction between P layer 5 and substrate 1 .
[0016] An advantage of this structure is that a breakdown is not necessarily destructive for the component. However, this structure has the disadvantage of requiring a channel stop ring 22 at the periphery of the upper surface in the region of N substrate 1 between the limit of P region 3 and the limit of insulating wall 20 . This entails the disadvantage of requiring a relatively large guard distance e 3 between the component edge and the limit of electrode A 2 , for example, on the order of 370 μm to withstand a voltage greater than 800 volts.
[0017] Further, the method for forming this structure requires a larger number of masks than for previous structures.
[0018] FIG. 4 shows another peripheral structure for avoiding breakdowns, which is described in patent application US 2011/0210372. At the component periphery, on the lower surface side, is a heavily-doped P-type diffused wall region 30 crossing P-type layer 5 and penetrating down to a depth into substrate 1 of substantially half the substrate thickness. On the upper surface side, at the component periphery, a deep straight groove 32 joins diffused region 30 . Groove 32 is insulated at its periphery by an oxide layer 33 and is filled with undoped silicon 34 in its central portion. To withstand a high voltage, a distance e 4 is provided between the limit of P-type layer 3 and the groove 32 . In such a structure, forward breakdowns may occur in bending region 36 of P-type layer 3 and reverse breakdowns may occur in region 38 at any point along the lower junction formed by layer 5 and substrate 1 . In order to control the extension of the space charge area (especially for the reliability of the forward junction) and avoid any surface inversion phenomenon, a more heavily-doped N area 40 need to be provided in the vicinity of the end of the groove on the upper surface side.
[0019] A disadvantage of the structure of FIG. 4 is that, as in the case of FIG. 3 , the P-type region 3 is localized in the central portion of the component. Thus, forming the component requires a larger number of masks than for the structures of FIGS. 1 and 2 .
SUMMARY
[0020] An embodiment provides a peripheral power component structure overcoming at least some of the disadvantages of known peripheral structures.
[0021] Thus, an embodiment provides a high-voltage vertical power component comprising a silicon substrate of a first conductivity type, and a first semiconductor layer of the second conductivity type extending into the silicon substrate from an upper surface of the silicon substrate, wherein the component periphery comprises: a porous silicon ring extending into the silicon substrate from said upper surface to a depth deeper than said first layer; and a doped ring of the second conductivity type, extending from a lower surface of the silicon surface to said porous silicon ring.
[0022] According to an embodiment, said first layer extends laterally to the porous silicon ring.
[0023] According to an embodiment, said porous silicon ring has a porosity ranging between 30 and 70 percent.
[0024] According to an embodiment, said porous silicon ring is partially oxidized.
[0025] According to an embodiment, said porous silicon ring extends in depth by between one third to two thirds of the thickness of the silicon substrate.
[0026] According to an embodiment, the above-mentioned component forms a triac, wherein:
[0027] a first region of the first conductivity type extends in a portion of said first layer, said first region and a portion of said first layer being in contact with a first electrode; a second semiconductor layer of the second conductivity type extends into the silicon substrate from the lower surface of the silicon substrate; and a second region of the first conductivity type, extends in a portion of said second layer, substantially complementary to the first region in projection.
[0028] Another embodiment provides a method for forming the high-voltage vertical power component of claim 1 , comprising the successive steps of: forming a heavily-doped vertical ring-shaped wall, extending from the upper surface to the lower surface of the silicon substrate; making an upper portion of said wall porous; and forming diffused regions of the component.
[0029] According to an embodiment, the substrate is of type N, and said wall is formed by diffusion of boron atoms from the lower and upper surfaces of the substrate.
[0030] According to an embodiment, the substrate is of type N, and said wall is formed by temperature gradient zone melting.
[0031] According to an embodiment, the substrate is of type P, and said wall is formed by diffusion of phosphorus atoms from the lower and upper surfaces of the substrate.
[0032] The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIGS. 1 to 4 , previously described, are cross-section views showing various known vertical power component structures;
[0034] FIG. 5 is a cross-section view showing an embodiment of a vertical power component structure; and
[0035] FIGS. 6A to 6C are cross-section views showing steps of an example of a method for manufacturing the structure of FIG. 5 .
DETAILED DESCRIPTION
[0036] For clarity, the same elements have been designated with the same reference numerals in the different drawings and, further, as usual in the representation of integrated circuits, the various drawings are not to scale.
[0037] FIG. 5 shows a triac having its different elements designated with the same reference numerals as the corresponding elements of FIGS. 1 , 2 , 3 , and 4 .
[0038] At the component periphery, one can find, on the lower surface side, a heavily-doped P-type portion of diffused wall 40 , crossing lower P-type layer 5 and penetrating down to a certain depth into substrate 1 (substantially across half the substrate thickness in the shown example). One can further find on the upper surface side, substantially in front of diffused wall portion 40 , a deep ring-shaped region 42 , made of porous silicon, joining diffused region 40 .
[0039] On the upper surface side, P-type doped layer 3 extends all the way to porous silicon ring-shaped region 42 . In the shown example, heavily-doped N-type regions 4 and 8 extend all the way to the neighborhood of ring-shaped region 42 . A small guard distance, for example, approximately ranging from 1 to 10 micrometers, may be provided between the inner edge of ring-shaped region 42 and regions 4 and 8 .
[0040] Electrodes A 1 , A 2 , and G are for example made of aluminum. An upper insulating passivation layer 44 , for example made of silicon oxide or of glass, coats the upper surface of ring-shaped region 42 , as well as all the component surfaces which are not taken up by a metallization (except for the lateral surfaces). On the upper surface side, a distance e 5 separates the component edge from the limit of passivation layer 44 (beginning of electrode A 2 or G, respectively).
[0041] One will note that porous silicon has an electrical behavior of semi-resistive type. The electrical behavior of porous silicon has been described in more detail in the article “Non-oxidized porous silicon-based power AC switch peripheries”, that describes a study made by the inventors on the use of porous silicon in high-voltage component peripheries. The porous silicon of the ring-shaped region 42 is chosen to be sufficiently resistive to withstand high voltage (for example greater than 500 V) at the termination of the PN junctions between layer 3 and substrate 1 and between layer 5 and region 40 and substrate 1 . However, the porous silicon of the ring-shaped region 42 still has semi-conductive properties, allowing an accumulation of mobile charges at the interface between the ring 42 and the substrate to be avoided, and thus increasing the reliability and the voltage hold performances of the component. This constitutes a difference in comparison with the structure of FIG. 4 , in which the peripheral groove 32 is insulated by an oxide layer 33 . In the structure of FIG. 4 , mobile charges are susceptible to accumulate at the interface between the substrate and the oxide layer 33 , which may decrease the reliability and the voltage hold performances of the component. For this reason, in the structure of FIG. 4 , a non-zero distance e 4 is provided between the limit of P-type layer 3 and the groove 32 . An advantage of the structure of FIG. 5 is that the P-type layer 3 may extend laterally up to the ring-shaped region 42 of porous silicon, which reduces the number of masks necessary to realize the component, and the cost of the component.
[0042] In the structure of FIG. 5 , forward breakdowns may occur in region 46 where the upper PN − junction formed by layer 3 and substrate 1 cuts ring-shaped region 42 of porous silicon, and reverse breakdowns may occur in region 48 almost all along the P − junction between substrate 1 and layer 5 or wall portion 40 .
[0043] An advantage of such a structure is that width e 5 of the peripheral ring of the component is relatively small. In particular, distance e 5 is shorter than the corresponding distances e 2 and e 3 in the structures of FIGS. 2 and 3 . As an example, distance e 5 is of the same order as distance e 1 in the case of FIG. 1 , that is, on the order of 300 μm to obtain a breakdown voltage greater than 800 volts.
[0044] Further, an advantage of the provided structure over the structure of FIG. 1 is the ease of manufacturing of lower electrode A 1 and of assembly of the component.
[0045] Another advantage is that the porous silicon region 42 keeps the crystal structure of silicon, and thus has a thermal expansion coefficient close to that of non-porous silicon. An advantage is that no problem of premature aging at the interface between regions 1 and 3 and region 42 is posed. Further, in case of an incidental breakdown caused by a very high overvoltage, the component is not necessarily destroyed.
[0046] Another advantage of such a structure is that it has an increased mechanical resistance with respect to a groove structure of the type described in relation with FIG. 2 .
[0047] Further, in the provided structure, region 3 is relatively distant from diffused wall portion 40 . The risk of component breakdown by punchthrough effect is thus considerably decreased with respect to a structure of the type described in relation with FIG. 2 .
[0048] Another advantage is that the number of masks necessary to form such a structure is not higher than the number of masks necessary to form the structure of FIG. 2 .
[0049] FIGS. 6A to 6C are cross-section views illustrating steps of a method for manufacturing the structure of FIG. 5 .
[0050] FIG. 6A shows a portion of a lightly-doped N-type semiconductor trench 1 . FIG. 6A more specifically illustrates the forming of a heavily-doped P-type vertical ring-shaped diffused wall 40 , from the upper and lower surfaces of substrate 1 . Wall 40 delimits a substrate portion in which the power component will be formed. In practice, the diffused walls are formed on the silicon trench between two components before dicing of the chip into individual components. When, later on, the trench is diced into individual components, the dicing lines follow, in top view, longitudinal axes substantially crossing the middle of the diffused walls.
[0051] As an example, substrate 1 has a thickness ranging between 200 and 300 μm, for example, being on the order of 250 μm, and wall 40 is formed by diffusion of boron atoms or other P-type doping elements such as aluminum or gallium atoms, with a surface concentration approximately ranging from 5*10 17 to 5*10 18 atoms/cm 3 , for example, being on the order of 10 18 atoms/cm 3 . The diffusion depth is selected to be greater than or equal to half the substrate thickness, so that the upper and lower diffused regions join in the middle of the substrate thickness to form wall 40 .
[0052] FIG. 6B illustrates a step of forming of layers 3 and 5 and of regions 4 , 6 , and 8 of the component. As an example, layers 3 and 5 are formed by diffusion of boron atoms down to a depth approximately ranging from 20 to 50 μm, for example, on the order of 35 μm, with a surface concentration approximately ranging from 10 18 to 10 19 atoms/cm 3 , for example, on the order of 5*10 18 atoms/cm 3 . Regions 4 , 6 , and 8 may be formed by diffusion of phosphorus atoms down to a depth approximately ranging from 5 to 15 μm, for example, on the order of 10 μm, with a surface concentration approximately ranging from 5*10 19 to 3*10 20 atoms/cm 3 , for example, on the order of 10 20 atoms/cm 3 .
[0053] FIG. 6C illustrates a step of forming of ring-shaped region 42 , made of porous silicon, in front of the lower portion of wall 40 . Region 42 actually corresponds to an upper portion of wall 40 of FIG. 6B , which is made porous, for example, by an electrochemical dissolution method.
[0054] In this example, an upper insulating protection layer 51 is formed on the upper surface of the semiconductor trench, and has openings in front of the upper surface of wall 40 . A lower insulating protection layer 53 may optionally be formed on the lower surface of the trench, and has openings in front of the lower surface of wall 40 . Layers 51 and 53 are, for example, made of silicon nitride (Si 3 N 4 ).
[0055] The trench is then plunged into an electrolytic solution based on hydrofluoric acid, between two respectively positive and negative electrodes, so that a current flows between the two electrodes, through the electrolytic solution and through wall 40 . In this example, the negative electrode is arranged on the upper surface side of the trench, and the positive electrode is arranged on the lower surface side of the trench. On the negative electrode side (upper surface), a reaction resulting in progressively transforming the heavily-doped P-type silicon into porous silicon wall 40 occurs. This reaction essentially occurs in front of the openings formed in protection layer 51 and in the heavily-doped P-type portion corresponding to the upper portion of the wall.
[0056] The duration of the electrochemical etching and the intensity of the current flowing between the electrodes determine the degree of porosity (pore percentage) and the depth of ring-shaped region 42 . In the shown example, ring-shaped region 42 approximately extends across half the substrate thickness. More generally, it may be provided for region 42 to extend down to a thickness ranging between approximately one third and approximately two thirds of the substrate thickness. The electrical properties of region 42 depend on the degree of porosity of silicon, which may be selected by adjusting the electrolysis parameters. The desired voltage hold performance can thus be obtained. As an example, a region 42 having a degree of porosity approximately ranging from 30 to 70% may be formed. To achieve this, a solution based on hydrofluoric acid and ethanol may be used, through which an electrolysis current approximately ranging from 10 to 80 mA/cm 2 for a duration approximately ranging from 15 to 60 minutes is made to flow. It is further possible to adjust the current densities during the electrolysis, to form a region 42 having a degree of porosity varying according to depth. Further, after the electrochemical etching, a step of partial oxidation of the porous silicon 42 may be provided, which enables its resistivity to be increased. However, the porous silicon region 42 should not be entirely oxidized, so that the region 42 preserves semi-conductive properties that differentiates it from silicon oxide, and allows evacuation of mobile charges at the interface between region 42 and the silicon substrate.
[0057] Subsequent steps of removal of protection layers 51 and 53 and of forming of the electrodes and of the passivation layer are then provided.
[0058] It should be noted that it is preferable to provide forming porous silicon region 42 after the forming of the various diffused regions of the component (regions 3 , 5 , 4 , 6 , and 8 in this example), and not before. Indeed, if region 42 was formed before the diffused regions of the component, the various anneals of the trench, associated with the forming of the diffused regions, would damage porous silicon 42 .
[0059] Specific embodiments have been described. Various alterations, modifications and improvements will readily occur to those skilled in the art.
[0060] In particular, embodiments have been described in the case where the power component is a triac. It should be understood that the like structure may apply to any other known type of vertical power component.
[0061] Further, in the described example, heavily-doped P-type wall 40 ( FIG. 6A ) is formed by diffusion of boron atoms. Any other adapted method may be used to form a vertical heavily-doped P-type wall. For example, a temperature gradient zone melting or TGZM may be used. Such a method especially has the advantage of being much faster than a method by diffusion of boron atoms.
[0062] Further, in the above-described examples, the component is formed from an N-type substrate. The provided embodiments also apply to the case where the initial substrate is a P-type substrate. In this case, the vertical walls delimiting the components ( FIG. 6A ) are heavily-doped N-type walls. In this case, it may be necessary, in the electrochemical etching resulting in forming ring-shaped region 42 , to provide a lighting of the interface between the upper surface of wall 40 and the electrolytic solution, in order to enable the electrochemical reaction resulting in the forming of porous silicon.
[0063] Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | A high-voltage vertical power component including a silicon substrate of a first conductivity type, and a first semiconductor layer of the second conductivity type extending into the silicon substrate from an upper surface of the silicon substrate, wherein the component periphery includes: a porous silicon ring extending into the silicon substrate from the upper surface to a depth deeper than the first layer; and a doped ring of the second conductivity type, extending from a lower surface of the silicon surface to the porous silicon ring. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This disclosure relates generally to photocatalysts and, more particularly, to a method and system for decreasing deactivation in photocatalysts.
[0003] 2. Description of the Related Art
[0004] Ultraviolet (UV) Photocatalytic Oxidation may be used for fluid purification, in particular, indoor air purification. Generally, the irradiation from UV lamps is projected onto a photocatalyst coated substrate in order to purify air by UV Photocatalytic Oxidation. The substrate may be any surface, such as, a flat plate, mesh, or honeycomb. The photocatalyst may be, for example, titanium dioxide (TiO 2 ), which is a common white pigment used in paint that is readily available and economical. UV light is projected on the catalyst promoting the formation of reactive species on the catalyst surface. The reactive species interact with volatile organic compounds in air passing over and absorbing onto the surface of the catalyst to transform the volatile organic compounds into byproducts such as carbon dioxide (CO 2 ) and water.
[0005] Volatile organic compounds (VOCs) are known to be any organic compounds that participate in atmospheric photochemical reactions. The aggregate amount of VOCs in air is typically on the order of 1 part per million by volume. Volatile silicon-containing compound (VSCCs) concentrations are also typically present in air, but are typically two or more orders of magnitude lower. VOCs can originate from many sources, such as industrial emissions, building materials, transportation exhaust, paints, cleaning chemicals and building materials. VSCCs arise primarily from the use of certain personal care products, such as deodorants, shampoos and the like, or dry cleaning fluids, and from the use of RTV silicone caulks, adhesives, lubricants and the like. Where VOCs are constructed of carbon-based molecules such as aldehydes, ketones, or hydrocarbon functionalities, VSCCs are typically comprised of silicon oxygen backbone chains that incorporate hydrocarbon pendant groups along the silicon oxygen backbone.
[0006] Over the last decade, levels of VSCCs, including siloxanes, in the air have been increasing. Siloxanes are included in health, beauty and personal care products, such as, deodorant, skin cream, hair spray, etc. UV Photocatalytic Oxidation is effective in transforming siloxanes into harmless by-products. Unfortunately, the prior art photocatalysts may become ineffective in a short amount of time, due to conversion of silicon containing compounds to various forms of silica at the surface of the photocatalyst, which block the catalyst active sites.
SUMMARY OF THE INVENTION
[0007] The present disclosure provides a method and apparatus for decreasing deactivation and increasing the lifetime of a catalyst in a photocatalyst system.
[0008] A photocatalyst system for decomposing contaminants in a fluid is described. Specifically, a two-part photocatalyst system for decomposing VOCs and VSCCs contained in a fluid. The fluid has a first, minor portion of VSCCs, and a second, major portion of VOCs.
[0009] The photocatalyst is constructed of two parts, where a first part is a photocatalyst layer primarily constructed to decompose VOCs and a second part is an overlayer primarily constructed to decompose VSCCs. The photocatalyst system includes a photocatalyst layer on a substrate. The photocatalyst layer is reactive with the VOCs when UV light is projected thereon. An overlayer is on the photocatalyst layer. The overlayer is UV transparent, and has an interconnected pore network that allows a large portion of the fluid mixture to pass through but retards a small VSCC laden portion of the fluid from passing through.
[0010] A method of making a photocatalyst system for VOCs having a first part and a second part is also provided. The method includes applying a layer of a photocatalyst to a substrate where the photocatalyst is configured to create reactive products to the volatile organic compounds and applying the above-described overlayer on the photocatalyst.
[0011] The overlayer may have a high surface area that is formed by a plurality of nanoparticulate agglomerates. The plurality of nanoparticulate agglomerates may form a plurality of protrusions on a outer surface of the overlayer presented to the fluid, that is opposite the inner surface of the overlayer that is adjacent the photocatalyst layer. The interconnected pore network may be formed by a plurality of nanoparticulate agglomerates, and the plurality of nanoparticulate agglomerates may connect to one another, forming spaces in between the agglomerates.
[0012] The interconnected pore network represents a fractal structure where the arrangement of local particles creates small pores in a local environment. Larger pores result from the long scale arrangement of the local network. A plurality of different sized pores that range between about 3 nanometers and about 200 nanometers results. More specifically, the interconnected pore network may have a first plurality of pores, greater than about 3 nanometers, that connect with a second plurality of pores, greater than about 6 nanometers, that connect with a third plurality of pores, greater than about 12 nanometers, that connect with a fourth plurality of pores, greater than about 100 nanometers, that connect with a fifth plurality of pores less than about 200 nanometers.
[0013] The overlayer may absorb or backscatter less than about 25% of incident light. The overlayer may include amorphous, crystalline, or partially crystalline forms of silica (SiO 2 ). The silica may exist as discrete particles, agglomerates, or mixtures thereof. The interconnected pore network of the overlayer may have pores that are sized smaller than VSCCs. At least a portion of the photocatalyst layer may retain a portion of VSCCs contained in a fluid mixture, while the remaining fluid volume may pass through.
[0014] The application of the overlayer may include spraying an aqueous suspension of a particulate compound onto a photocatalyst supported on suitable substrate. The overlayer may be prepared by mixing or dispersing solid silica in water, aqueous or an organic liquid. The application of the overlayer may include applying a plurality of nanoparticulate agglomerates, and the plurality of nanoparticulate agglomerates may connect to one another, forming spaces between the agglomerates to form the interconnected pore network. The photocatalyst may be titanium dioxide (TiO 2 ). The substrate may be in an ultraviolet photocatalytic oxidation filter.
[0015] The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a schematic of an exemplary embodiment of a photocatalyst system according to the present disclosure;
[0017] FIG. 2 is a graphical depiction of catalyst deactivation after exposure to hexamethyldisiloxane at 50% relative humidity and ultraviolet A light comparing the system of FIG. 1 to prior art systems; and
[0018] FIG. 3 is a graph of UV-visible reflectance traces for selected silicas that can be used in the photocatalyst system of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] It has been determined by the present disclosure that the longevity of a photocatalyst can be increased against VSCCs by a protective overlayer. Without wishing to be bound by any particular theory, it is believed that by incorporating an overlayer with a high surface area, a suitably low mass transfer resistance pore structure prevents VSCCs from contacting a surface of the photocatalyst as easily as without the overlayer. Advantageously, it has been determined that pores in the overlayer form a tortuous path, such that smaller VOCs (such as, for example, formaldehyde, acetaldehyde, heptanal, ethanol, isopropanol, toluene, and xylenes) are allowed to reach the catalytic surface more rapidly than larger compounds such as VSCCs, that are relatively much larger and heavier.
[0020] Further, VSCCs and other volatile silicon compound deactivating agents may land on the surface of the overlayer and reside there for a period of time before adhering to the outer surface of the overlayer or migrating onto another surface. This allows active oxygen species, such as hydroxyl radicals or hydrogen peroxide, which originate at the catalyst surface to oxidize the VSCCs before they adsorb on the catalyst, where oxidation would result in deactivation. If oxidized while in contact with the overlayer, the deactivating layer would form on the overlayer, and not the catalyst. VSCCs are unable to traverse the overlayer, or take a longer time to travel through the overlayer than smaller molecules, thereby protecting the photocatalyst. As a result, the lifetime of the photocatalyst is increased.
[0021] A first exemplary embodiment of a photocatalyst system 10 is shown in FIG. 1 . A photocatalyst layer 12 is on a substrate 14 . The substrate 14 may be any surface a photocatalyst may bond to, such as, for example, a flat surface, mesh or honeycomb. The substrate may be aluminum, other metals or alloys, ceramic, glass, fiberglass, quartz, clear polymers such as polymethylmethacrylate (PMMA) or polycarbonate (PC), carbon or activated carbon, zeolites, or any other material that supports the catalyst in an open, low pressure drop arrangement. Polymer based substrates would be selected based on their inherent resistance to UV degradation.
[0022] The photocatalyst layer 12 may be a semiconductor, in which a photon (light) of the proper energy (wavelength) can promote an electron into the conduction band of the photocatalyst. This creates electron/hole pairs, which can react with adsorbed molecular oxygen and water to create active oxygen species, such as the hydroxyl radical. These species in turn react with adsorbed VOCs and SVOCs, oxidizing them. For example, the photocatalyst layer can be titanium oxide (TiO 2 ), tin oxide (SnO 2 ), indium oxide (In 2 O 3 ), zinc oxide, (ZnO), tungsten oxide (WO 3 ), and any combinations thereof. The photocatalyst layer 12 may be formed of an optically dense (6 to 10 microns for titanium dioxide) coating of the photocatalytic material. The photocatalytic material may be a single compound or a mixture of compounds.
[0023] System 10 also includes an overlayer 16 on an outer surface of photocatalyst layer 12 that is opposite the substrate 14 . The overlayer 16 has a high surface area, which is a non-flat surface. A surface that is non-flat has a greater surface area than a flat surface, due to depressions or protrusions thereon. The overlayer 16 has a high surface area that is greater than an overlayer having an upper surface 17 that is flat opposite the photocatalyst layer 12 . For example, the upper surface of overlayer 16 may be formed by a plurality of nanoparticulate agglomerates, having protrusions extending outward therefrom. The protrusions increase the surface area of the overlayer 16 in comparison to a flat surface, giving overlayer 16 a high surface area. The plurality of nanoparticulate agglomerates may be micron-sized. The high surface area may be formed of any non-flat geometry.
[0024] The overlayer 16 has a low mass transfer resistance pore structure. The pore structure with low mass transfer resistance can be defined as an interconnected pore network. The interconnected pore network may be in a random or fractal distribution having both small and large pores. The interconnected pore network may be formed by depositing a plurality of nanoparticulate agglomerates (that may be micron sized), on top of one another. The plurality of nanoparticulate agglomerates may connect to one another, forming spaces or pores therebetween.
[0025] The interconnected pore network may be in a fractal distribution, and have pores ranging in size from about 3 nanometers to about 200 nanometers. In one embodiment, the interconnected pore network may include a first plurality of pores that are greater than about 3 nanometers, that connect to a second plurality of pores that are greater than about 6 nanometers, that connect with a third plurality of pores that are greater than about 12 nanometers, that connect to a fourth plurality of pores greater than about 100 nanometers, that connect to a fifth plurality of pores having a size up to about 200 nanometers. The pore structure with low mass transfer resistance absorbs or backscatters, such as, for example, less than about 25% of the incident light directed to the photocatalyst surface.
[0026] The overlayer 16 is UV transparent or transparent to the wavelength of light activating the photocatalyst. This wavelength may be characterized as UVC, UVB, UVA or visible light. The overlayer 16 may be fumed silica to allow UV light therethrough. One example of a suitable fumed silica for the overlayer is silicon dioxide, SiO 2 , such as Alfa Aesar silicon dioxide, (amorphous fumed silica) having a surface area of approximately 350 to 420 meters squared per gram (m 2 /g). The overlayer may be any UV transparent, spherical or ruggedized spherical structure that creates a porous structure, where the majority of particles or agglomerates are less than 40 nm in diameter. The photocatalyst system 10 may be exposed to UV light, such as, for example, UVA, UVB, and/or UVC light, as shown by arrows 30 .
[0027] In use, ambient air 18 is passed over overlayer 16 . The ambient air 18 includes oxygen (O 2 ), nitrogen (N 2 ), and a mixture of VOCs. The VOC mixture includes a first portion that includes VSCCs, in particular, siloxanes. As previously described, the first portion would normally deactivate the photocatalyst layer 12 . The VOC mixture includes a second fraction that includes non-silicon containing VOCS. The second portion does not typically deactivate the photocatalyst layer 12 . UV light causes photocatalyst layer 12 to create volatile organic compound reactive species 32 (VOC+) in photocatalyst layer 12 . Thus, the VOC+ 32 are covered by overlayer 16 .
[0028] Ambient air 18 having the first portion and the second portion of the VOCs continues to pass over system 10 . Both the first portion and the second portion of the volatile organic compounds are attracted to the VOC+ 32 , as shown by arrow 20 . The first portion, which contains VSCCs, is prevented from passing through overlayer 16 , or slowed in passing the overlayer, relative to smaller molecules such as VOCs. Overlayer 16 traps VSCCs, at least temporarily, and may allow these molecules to be oxidized remotely by active species created on the photocatalytic surface. These species are created by the interaction of light with the catalyst producing electron hole pairs, which in turn interact with oxygen and water adsorbed on the catalyst surface. These active species may include hydroxyl radicals (OH.), hydrogen peroxide (HOOH), hydrogen peroxide radicals (HOO.), superoxide ion (O 2 − ) or other active oxygen species. These active oxygen species may oxidize the VSCCs, as shown by arrow 28 .
[0029] The second portion is allowed to pass through overlayer 16 , as shown by arrow 22 . The VOCs are oxidized by photocatalyst layer 12 into by-products, which are carbon dioxide and water if the VOC is completely mineralized. These by-products diffuse through overlayer 16 , back into the ambient layer, as shown by arrow 24 . The first portion of VSCCs are heavier and diffuse slower, for example 150 to 400 grams per mole. The second portion of VOCs are lighter, faster diffusing molecules, for example 38 to 200 grams per mole.
[0030] The overlayer 16 may be applied by spraying an aqueous suspension of a protective compound, or any other common coating technique that allows a porous structure to be achieved. One example of a photocatalyst system included preparing a photocatalyst test slide by dispersing 3 or 0.8 wt % of the composition of SiO 2 , such as Alfa Aesar® amorphous fumed silica, having a surface area of approximately 350 to 420 meters squared per gram (m 2 /g), in water, mixing for approximately 30 seconds in a centrifugal mixer at approximately 2500 rotations per minute (rpm), and then spraying a portion onto a photocatalyst, such as, for example, a P25-coated aluminum slide. P25 is a designation of titanium dioxide (TiO 2 ) from the manufacturer Degussa®.
[0031] An experimental demonstration of catalyst lifetime extension was conducted. Six identical 1 inch by 3 inch slides were prepared by the method described above for the example of the photocatalyst system. Each slide was coated with a reference photocatalytic material, titanium oxide (Degussa P25.) Three slides, P25 (C2), P25 (C1), and P25 (C7) were set aside as controls. Three additional slides were coated with an overlayer of SiO 2 . These slides were either coated with 60 milligrams of silica (High (B23) and High (C4)), or 17 milligrams of silica (low (B22)). UVA light was projected on the six slides at 50% relative humidity. The six slides were exposed to ambient air including a siloxane hexamethyldisiloxane (HMDS) and their deactivation was observed as a function of exposure time.
[0032] As shown in FIG. 2 , the comparison of the first slide to the fourth slide, the second slide to the fifth slide, and the third slide to the sixth slide, shows that photocatalyst systems including an overlayer of SiO 2 have a decrease in a rate of deactivation by 90 parts per billion (ppb) HMDS by a factor of approximately 2.5 that is indicated by normalized propanal activity, shown in percent, over time of exposure to HMDS, shown in hours. Propanal reactivity was used as a measure of the photocatalytic activity. As the photocatalyst deactivates, less propanal is removed by the photocatalytic reaction. Light intensity, humidity and propanal concentration were kept constant. As shown by the curves for the first, second, and third slides, the deactivation is generally an exponential trend. UVC radiation, a known germicidal source, may multiply this deactivation effect. The overlayer 16 may cause a change of the rate of deactivation in a range of about 2.5 to about 3.0, resulting in longer activity over time. Thus, it is apparent that the use of an overlayer extended the lifetime of the photocatalyst over an unprotected photocatalyst.
[0033] Referring to FIG. 3 , UV and visible light reflectance traces are shown for Aerosil 380 silica and Alfa-Aesar silica. Approximately 30 mg of each material was spray coated independently onto quartz slides. While both silica powders have surface areas of approximately 350-400 m 2 /g, the agglomerate size present in each determines whether UV light will be reflected or absorbed. The preferred mode of light is for light to be absorbed through the silica overlayer to the photocatalyst layer. Aerosil 380® silica powder has a large number of agglomerates greater than 40 nm, which contribute to reflecting the light and hence not all of the light would reach the photocatalyst. In contrast, the typical agglomerate size in the Alfa-Aesar silica is 30 nm, and light permeates through the silica layer to the quartz substrate, which could contain photocatalyst. The Aerosil 380® silica coating on a quartz slide has a higher reflectance value (˜greater than 65% R) than the Alfa Aesar fumed silica® coated slide prepared in an identical manner (˜less than 60% R). The higher reflectance value correlates to less light reaching the photocatalyst layer (Aerosil 380® silica powder), whereas the lower reflectance value correlates to more light reaching the photocatalyst layer (Alfa-Aesar fumed silica®). Due to the greater the percentage of light penetrating through the Alfa-Aesar fumed silica®, a photocatalyst under a comparable thickness of Alfa-Aesar fumed silica® will afford a higher photocatalytic activity than a silica layer constructed of Aerosil 380® silica.
[0034] Other materials transparent to the photocatalyst activating light wavelength may also be incorporated into the overlayer, such as, for example, titanium dioxide if a visible light activated photocatalyst is used. The key concept is that material sufficiently transparent to the wavelengths of the light which activates the photocatalyst must be employed. This allows transmittance and forward scattering of the photons to occur, so that a high percentage of the light reaches the photocatalyst and initiates the photocatalytic chemistry described above.
[0035] The overlayer 16 may be continuous or non-continuous. For example, the overlayer 16 may cover one or more portions of the photocatalyst and one or more portions of the photocatalyst may not be covered by the overlayer 16 .
[0036] The photocatalyst layer 12 may have a second interconnected pore network that is continuous with the interconnected pore network of overlayer 16 . This layer may be engineered to be resistant to deactivation. In other words, the photocatalyst may be specifically tailored, with respect to pore structure, crystallite size, crystallinity or other material characteristics to be resistant to deactivation.
[0037] The overlayer 16 may be added to a photocatalyst of a UV photocatalytic oxidation air purifier to extend a lifetime thereof. The overlayer 16 allows the air purifier to effectively purify air for a longer time period than without the overlayer before it deactivates.
[0038] While the instant disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope thereof. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A photocatalyst system for volatile organic compounds with two parts that include a photocatalyst layer on a substrate and a porous overlayer. The photocatalyst layer is reactive with volatile organic compounds when UV light is projected on it. The overlayer is situated on the photocatalyst layer. The overlayer is UV transparent and has an interconnected pore network that allows contaminated air to pass through the overlayer. The size and the shape of the interconnected pores acts to selectively exclude certain contaminants that can deactivate the photocatalyst. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for positioning a head on the basis of a premeasured amount of displacement.
2. Description of the Related Art
Disks used in magnetic disk apparatuses include a floppy disk and a hard disk. The hard disk has a thermal offtrack problem. The floppy disk has a humidity offtrack problem and a problem of eccentricity at the time of disk change, as well as the thermal offtrack problem. Therefore, it is technically very important to position a head to a destination track at high speed with high precision. For this purpose, servo data is written in the disk. The servo data are classified into dedicated servo data, sector servo data, and index servo data in accordance with schemes for writing the servo data.
In a conventional servo disk apparatus, servo data is read out from a disk and tracking control is performed in accordance with an amount of displacement upon detection of displacement derived from the servo data. That is, closed loop positioning control is performed. For example, in a case where an intermittent servo scheme such as a sector or index servo scheme is employed, the head position is adjusted in accordance with an amount of displacement derived from servo data of the current head position while the head is moved from the current head position to a position at which the next servo data is written. In a continuous servo scheme such as the dedicated servo scheme, servo data can be continuously obtained. This scheme has higher precision than the intermittent servo scheme, but is in fact the closed loop positioning control. The above problem will be described by exemplifying the sector servo scheme with reference to FIG. 1. When a displacement d1 is detected at a given sector, the head position is controlled to compensate for the displacement d1. However, when a disk-dependent displacement d2 is present, this displacement cannot be eliminated.
In the conventional control scheme, tracking control is performed in accordance with the detected amount of displacement. Therefore, if anisotropic variations such as eccentricity are present, the tracking operation is markedly delayed for a medium such as a floppy disk, or accurate tracking cannot be performed, resulting in inconvenience.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above problems, and has as its object to provide a method and apparatus for positioning a head based on a premeasured amount of displacement so as to perform open loop control coping with accurate, high-speed tracking even if displacements dependent on the disk itself, i.e., anisotropic variations are present.
In order to achieve the object, the magnetic disk apparatus having improved tracking performance, includes a head for accessing a magnetic disk which is rotated, a displacement detector, a head position controller, a table and a controller. The displacement detector detects an amount of displacement of the head from a designated track of the magnetic disk, based on a signal through the head from servo data associated with the designated track and generating displacement data from the displacement amount. The head position controller controls a position of the head in a radial direction of the magnetic disk in response to an input position control instruction. The table stores a plurality of disk-dependent displacement data. The controller reads out disk-dependent displacement data from the table in accordance with the designated track and outputting the position control instruction to the head position controller in accordance with the displacement data from the displacement detector and the disk-dependent displacement data.
In order to achieve the object, in a magnetic disk apparatus, a method of improving tracking performance, includes the steps of:
detecting an amount of displacement of a head from a designated track of the magnetic disk, based on a signal through said head from servo data associated with the designated track to generate resultant displacement data from the displacement amount, the magnetic disk being rotated;
detecting a position of said head in a rotation direction of the magnetic disk;
reading out track-dependent displacement data from a table in accordance with the designated track and the detected position of said head, said table storing a plurality of track-dependent displacement data with respect to positions of the head; and
controlling a position of said head in a radial direction of the magnetic disk in accordance with the track-dependent displacement data and the resultant displacement data.
As described above, according to the present invention, displacements dependent on the disk, e.g., anisotropic variations are present, accurate, high-speed tracking can be performed. That is, positioning control of the head is performed on the basis of a premeasured amount of displacement. Therefore, the present invention is especially effective to high-density recording disks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view for explaining tracking control of a head in a conventional disk apparatus;
FIG. 2 is a block diagram showing an arrangement of a disk apparatus according to an embodiment of the present invention;
FIG. 3 is a view showing layout of servo areas on a disk used in the disk apparatus of the present invention;
FIG. 4 is a view showing a state of servo and data areas shown in FIG. 3;
FIG. 5 is a flow chart for explaining an operation of the embodiment;
FIGS. 6A and 6B are waveform charts of signals obtained from a servo pattern on the basis of a head position; and
FIG. 7 is a view for explaining adjustment of a head position in the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A disk apparatus according to the present invention will be described in detail with reference to the accompanying drawings.
A disk apparatus according to an embodiment of the present invention will be described with reference to FIG. 2. A controller 4 controls the overalloperation of the disk apparatus. The controller 4 is connected to a host 2,a timer 32, and a table 6. The host 2 outputs various commands and various data to the controller 4. In particular, when a power switch is turned on,an update command is supplied from the host 2 to the controller 4. The controller 4 outputs various instruction signals to the respective parts (to be described below) in response to commands from the host 2. In addition, the controller 4 outputs a busy signal to the host 2 during measurement of a disk-dependent displacement in response to the update command.
The timer 32 measures a predetermined period of time. When the predetermined period of time has elapsed, the timer 32 outputs an update command to the controller 4. The table 6 stores disk-dependent displacement data used for positioning control of the head by the controller 4. This data is displacement data depending on the disk in association with track and sector positions.
The controller 4 outputs a rotation instruction signal ROT to a motor 12 inaccordance with a command from the host 2, and the motor 12 drives to rotate a disk 30 set in the disk apparatus. The disk 30 may be a floppy orhard disk. In this embodiment, the disk 30 is assumed to be a 16 MB type floppy disk. The disk 30 is a sector servo floppy disk, as shown in FIG. 3. The present invention can also be applied to the index servo scheme, which will be apparent from the following description. A given servo sector and a given data sector of the disk 30 are shown in FIG. 4. Patterns A and B are alternately written in the servo sectors in units of tracks.
A displacement detector 8 digitizes peak values DPA and DPB of the patternsA and B read out from the given servo sector of the disk 30 by a head 16-1 or 16-2 of a pair of heads 16 and outputs the digital peak values to the controller 4 as a data signal DP. The controller 4 generates displacement data from the values DPA and DPB. The controller 4 comprises a register 22for storing a track number representing the current state of the head 16, and a register 24 for storing a sector number. When the head 16 is moved relative to the disk 30, the contents of the registers 22 and 24 are updated. In a position control loop, the controller 4 refers to the table 6 in accordance with the contents of the registers 22 and 24 and reads outdisk-dependent displacement data of a servo sector next to the one designated by the content of the register 24 representing the track on which the head 16 is currently located. The controller 4 generates a position control instruction signal PC in accordance with the readout disk-dependent displacement data and the detected displacement data and outputs the signal PC to an actuator 10. The actuator 10 moves the heads 16-1 and 16-2 along the disk 3 to accurately position them onto the destination track in response to the instruction signal PC. When an operation is performed in response to the update command, the controller 4outputs a seek instruction signal SK to the actuator 10.
The actuator 10 includes a voice coil motor (not shown) and controls the position of the heads 16 in accordance with the position control instruction signal PC, i.e., a control current. A gage 14 is mounted on the actuator 10. The gage 14 is moved and interlocked with the heads 16-1 and 16-2. The position detector 20 receives a signal from the head 16-1 or16-2 and a light beam emitted from an LED 18 onto the gage 14 and outputs adetection signal P to the controller 4. During an operation in response to the update command, the LED 18 and the gage 14 are used in the position detection, and the controller 4 detects on the basis of the signal P from the detector 20 that the head 16 has sought the innermost or outermost track.
An operation of the disk apparatus according to the present invention will be described with reference to FIG. 5.
In step S2, when a power switch of the apparatus is turned on, the rotationinstruction signal ROT of the disk 30 is output to the motor 12 in responseto a command from the host 2, and then the disk 30 is rotated. Thereafter, the host 2 outputs an update command to the controller 4. The controller 4determines in step S4 whether a command is input. Since the input command is the update command, the flow advances to step S8 via step S6.
In step S8, the controller 4 generates the seek instruction signal SK for moving the heads to a first predetermined position, e.g., the innermost track. A seek control current as the seek instruction signal SK is supplied to the actuator 10. The heads 16-1 and 16-2 (these heads are referred to as heads 16 hereinafter) are moved toward the innermost track.At this time, during the movement of the heads 16, the content of the register 22 is updated on the basis of the signal P to a value representing a position at which the heads 16 are present. When the position detector 20 detects from light from the LED 18 through the gage 14 that the heads 16 have reached the first predetermined position of the floppy disk, the seek instruction SK is disabled, and a current for the positioning control without use of disk-dependent displacement data flows through a coil of the voice coil motor. Therefore, the heads 16 are almoststopped at the predetermined radial position. A track width is about 38 μm in the 16 MB type floppy disk and positional fluctuation at the first predetermined position is negligibly about 2 μm.
Since the disk 30 is being rotated, a signal corresponding to servo data written in each servo sector is supplied to the displacement detector 8 through, for example, the head 16-1. At this time, during rotation of the disk 30, the content of the register 24 is updated to represent a servo sector position at which the heads 16 are currently located. For example, when the head 16-1 is located at a position Pl, as shown in FIG. 4, the corresponding signal supplied to the detector 8 is shown in FIG. 6A. At this time, the head 16-1 is displaced to the pattern A side, a peak value of a signal corresponding to the pattern A is larger than that corresponding to the pattern B. The detector 8 sequentially digitizes peakvalues and outputs the result and digital data DPA and DPB to the controller 4. The controller 4 generates displacement data in accordance with the peak data DPA corresponding to the pattern A and the peak data DPB corresponding to the pattern B. That is, a calculation (DPA-DPB) is performed. In this manner, the disk-dependent displacement data has a sign. The controller 4 generates the disk-dependent displacement data for each servo sector as described above. Thereafter, step S10 is executed.
In step S10, the controller 4 generates the seek instruction signal SK for moving the heads to a second predetermined position, e.g., the outermost track. This instruction is output to the actuator 10, and the heads 16 aremoved toward the second predetermined position. The subsequent operations are the same as in head movement toward the innermost track, thereby generating disk-dependent displacement data corresponding to each servo sector. Step S12 is then executed.
In step S12, a difference between the displacement data at the outermost track and the displacement data at the innermost track is calculated for all the servo sectors. In order to calculate a displacement per track, thedifference is divided by the number of tracks present between the outermostand innermost tracks. The disk-dependent displacement data of the nth intermediate track is obtained by adding a value obtained by multiplying the displacement per track by n, to the displacement data at the innermosttrack. In this manner, when the disk-dependent displacement data of all tracks in all servo sectors are calculated, these data are written in the table 6. Thereafter, steps S14 and S16 are executed.
When the seek command is output from the host 2 to the controller 4, step S18 is executed after steps S4 and S6. The controller 4 determines in stepS18 whether an input command is a seek command. If YES in step S18, step S20 is executed. Otherwise, another processing is executed. In step S20, the seek instruction signal SK is output from the controller 4 to the actuator 10 so that the heads 16 seek a destination track. When the heads reach the destination track, position control in steps S14 and S16 is performed.
In step S14, as shown in FIG. 7, control resultant displacement data dl at a given servo sector is calculated in the same manner as described above. In step S16, the table 6 is referred to in accordance with the contents ofthe registers 22 and 24, and disk-dependent displacement data d2 corresponding to a next servo sector of the destination track is read out.The disk-dependent displacement data d2 is added to the control resultant displacement data d1, and the sum d is output as the position control instruction signal PC from the controller 4 to the actuator 10. Therefore,when the heads 16 reach the next servo sector, the head center is located at the track center, as indicated by a position P2 in FIG. 4. At this time, the control resultant displacement data is "0", as shown in FIG. 6B.Thereafter, position control is performed in steps S14 and S16, as shown inFIG. 6B.
When an update command is input from the timer 32 during position control, the controller 4 outputs a busy signal to the host 2, and the controller 4updates the contents of the table 6 in processing of steps S8 to S12.
In this manner, even if a disk-dependent displacement is present in the disk, the heads can trace the destination track with high precision.
In the above description, the disk is exemplified as a floppy disk. However, the disk may be a hard disk. Since the dedicated servo scheme is generally employed in the hard disk, servo data are sampled to obtain an appropriate number of samples in the controller 4.
In the above embodiment, the tracks used for the update command are the innermost and outermost tracks, but are not limited to these.
In the above embodiment, the displacement data is obtained by the first pair of data of the patterns A and B. However, the displacement data may be obtained by using an average value of the peak data corresponding to the pattern written in each servo sector. This arrangement can further improve precision.
In the above embodiment, the actuator 10 includes a voice coil motor. However, a stepping motor and the like may be used to arrangement the actuator 10. In this case, the LED 18, the gage 14, and a light-receiving section of the position detector 20 can be omitted, since the stepping motor can be stopped at any track position. | The magnetic disk apparatus having improved tracking performance, includes a head for accessing a magnetic disk which is rotated, a displacement detector, a head position controller, a table and a controller. The displacement detector detects an amount of displacement of the head from a designated track of the magnetic disk, based on a signal through the head from servo data associated with the designated track and generating displacement data from the displacement amount. The head position controller controls a position of the head in a radial direction of the magnetic disk in response to an input position control instruction. The table stores a plurality of disk-dependent displacement data. The controller reads out disk-dependent displacement data from the table in accordance with the designated track and outputting the position control instruction to the head position controller in accordance with the displacement data from the displacement detector and the disk-dependent displacement data. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a battery pack for a portable computer wherein the battery pack has a minimum number of hard wire connections.
2. Description of Related Art
There is currently a trend in personal computers today toward portables such as notebook-size portables and even smaller computers. These small portable computers need a battery operated power supply utilizing rechargeable batteries. In order to monitor such rechargeable batteries and recharge in a timely and proper manner, it is known to hard wire into the battery pack a number of electronic components such as for example a temperature sensor and a microcomputer or memory to monitor various battery operations and maintain battery information. Examples of the electronics for monitoring and recharging a battery pack for a computer system are found in U.S. Pat. No. 5,313,228 issued May 24, 1994, and entitled "Battery Charge Monitor and Fuel Gauge" and 08/033,821 filed Mar. 19, 1993 and entitled "Battery Pack Including Static Memory and a Timer For Charged Management" owned by Compaq Computer Corporation, the Applicant herein.
Hard wiring various circuits within the battery pack is expensive and time-consuming since all of the hard wiring must be done by hand. The combination of hand soldering and hand installation adds significant additional manpower to manufacture of such battery packs. Further, the necessity of hard wiring within a battery pack adds additional space to the overall battery pack housing in order to mount such hard wiring within the battery pack housing.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a battery pack for portable computer systems wherein the battery pack is interfaced with the main computer housing with a minimum amount of hard wiring, which reduces manufacturing costs and allows the overall battery pack housing to be smaller in size. The battery pack of this invention includes a generally rectangular housing which includes a bottom having an opening therein. The housing is sized to receive a plurality of batteries for providing power to the portable computer. A support chassis is mounted with the housing and includes a plurality of mounting slots, which mounting slots receive individual, electrical contacts. The support chassis is mounted over the opening in the bottom of the housing such that the electrical contacts are aligned with the housing bottom opening and are thus exposed for making electrical contact with circuitry of the main computer housing. A printed circuit board is attached to the support chassis. The printed circuit board includes a plurality of openings. The electrical contacts mounted in the support chassis mounting slots include tabbed end portions which extend through the openings in the printed circuit board in order to be electrically connected to the electronic components located on the printed circuit board. Hard wiring is necessary only to electrically connect the positive and negative terminal ends of the battery set within the battery pack housing. In this manner, a battery pack is provided which substantially minimizes the amount of hard wiring and instead provides electrical contacts mounted within a modular chassis for making electrical contact to the main computer housing.
This summary of the invention is intended as a summary only and is not intended to define the actual scope of the invention, which is set forth in the claims to follow the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom view in perspective of the battery pack of the preferred embodiment of this invention;
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1 showing one of the batteries partially removed to expose the inside of the printed circuit board support chassis;
FIG. 3 is a partly sectional view taken along line 3--3 of FIG. 2 illustrating the printed circuit board and its hard wire connection to the array of DC batteries; and
FIG. 4 is a sectional view taken along 4--4 of FIG. 3 illustrating the mounting of the support chassis in the opening in the bottom of the battery pack housing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the letter P generally designates the battery pack of the preferred embodiment of this invention. The battery pack P is specifically designed for use in a portable or notebook computer but has application in equivalent power systems. The battery pack P includes a generally rectangular, box-like housing 10 which includes a bottom 10a having formed therewith four sidewalls including side walls 10b and 10c which intersect to form a corner 10d. The housing 10 further includes a third sidewall which opposes sidewall 10b and a fourth sidewall which opposes sidewall 10c, neither of which is illustrated in the drawings but is easily understood as within the ordinary skill of the art. The upstanding sidewalls including sidewalls 10b and 10c are integrally formed with the bottom and cooperate to provide a generally rectangular box-like interior space to receive a plurality of batteries generally designated as B (FIG. 2). The housing 10 further includes a top or lid 10e which is generally rectangular in configuration and is sized to fit onto the four sidewalls such as 10b and 10c of the housing 10. A rectangular opening O is located in the bottom 10a of the housing 10. The opening O is formed by side edges 10g, 10h, 10i and 10j. Referring to FIG. 4, side opening edge 10h is slightly indented.
The batteries B are actually an array which are serially connected to provide the necessary voltage. Although not all batteries are shown, the batteries preferably utilized in this invention are 1.2-volt nickel metal hydride batteries connected in series to provide a total voltage of 12 volts. Referring to FIG. 2, batteries 12a, 12b, 12c, 12d, 12e and 12f are illustrated. The serial connection between batteries is provided by a series of conducting contact strips such as illustrated at 14 as is well-known in the art. Battery 12a includes a first terminal contact strip 14a and battery 12f includes a terminal contact strip 14b to the series connection of the batteries together. In addition and not shown, one or more fuses may be hard wired between various terminals of the batteries to act as circuit breakers or permanent disconnects in the event of power surges, shorts and the like.
A support chassis generally designated as 20 is provided for mounting within the battery housing 10 in the opening O in order to provide a wireless electrical interface between the batteries B, a printed circuit board generally designated as 30 and the main computer housing (not shown). The support chassis 20 includes a generally rectangular plate member designated as 20a. The plate member 20a includes a plurality of aligned openings 20b which cooperate with a second set of aligned openings 20c to provide mounting shoulders for a plurality of metal conducting strips or contacts 21. The outer face of the rectangular mounting plate 20a includes a plurality of ridges such as 20c and 20d which cooperate to receive the individually mounted electrical contacts or strips 21. As shown in FIG. 4, each electrical contact or strip 21 includes internally directed shoulders which are inserted into the openings 20b and 20c in order to snap the contacts into place in slots formed by the external ridges such as 20c and 20d.
Each electrical contact or conductive strip 21 further includes an inverted, T-shaped tab portion 21a. Each of the inverted T-shaped tab portions 21a extend through openings at 31a and 31b in the base 30a of the printed circuit board 30. The tabs 21a for each of the five electrical contacts illustrated in the drawings extend through the openings at 31a and 31b in the base 30 for the printed circuit board and are soldered into place as illustrated in FIG. 3 (the actual openings in the base being filled by the solder as illustrated in FIG. 3).
Referring again to the inside surface or face of the chassis plate 20a a generally U-shaped opening 22 cooperates with a node 22a to mount a thermister element 23. The thermistor element 23 includes two terminal end portions, one of which being identified as 23a, which extend through openings in the base 30a of the printed circuit board 30 and are soldered in place. The soldered joints such as 31a and 31b and the terminated end portions such as 23a of the thermistor 23 are electronically connected to the various electronic components generally designated as 40 mounted on the printed circuit board base 30a. The thermistor is a temperature sensor which generates temperature dependent signals which are utilized in the various circuits of the electrical components to, among other things, timely re-charge the batteries. The location of the thermistor element 23 is such that it is in close proximity to the batteries B when the batteries B are installed in the housing 10, allowing the thermistor element 23 to accurately sense the temperature of the batteries B.
The chassis plate 20a further includes two laterally extending pedastals or ledges such as 24 which mount the printed circuit board base 30a thereon such that the printed circuit board base 30a is at a right angle with respect to the internal flat surface of the chassis support plate 20a. Each of the pedestals 24 include an outwardly extending node such as 26 which has an enlarged end and extends through an opening in the printed circuit board face so that upon snapping the opening over the enlarged end of the node 26, the printed circuit board 30 is attached to the pedestals or ledges 24 of the overall chassis 20.
The chassis plate 20a further includes a stepped mounting ledge generally designated as 25 for mounting the chassis in the opening O in the battery pack housing bottom. The chassis 20 is actually mounted in place from inside of the housing by first inserting the mounting ledge or lip 25 over the indented bottom opening edge 10h and then rotating the chassis into a frictional fit in the remainder of the opening O.
The printed circuit board 30 is provided to electronically interface between the batteries B and the main computer housing through the electrical contacts 21 which are exposed through the opening O in the bottom of the battery pack. The utilization of the five electrical contact surfaces of points 21 to interface with the main computer housing eliminates the necessity of hard wiring those contact points thereby reducing expense and labor in the manufacture of the battery pack P. The printed circuit board 30 includes the electronics generally designated as 40 to perform whatever necessary electronic functions are needed to properly maintain and recharge the array of batteries B. One version of such electronics is found in U.S. Pat. No. 5,313,228, issued May 24, 1994 entitled "Battery Charge Monitor and Fuel Gauge" and U.S. patent application Ser. No. 08/033,821 filed Mar. 19, 1993 and entitled "Battery Pack Including Static Memory and a Timer For Charged Management." Since the electronic components mounted on the printed circuit board do not form part of this invention, there is no need for further description of the components themselves.
In addition to the soldered connections of the electrical contacts 21 into the printed circuit board base 30a, and the electrical connection of the termination ends such as 23a of the thermistor 23 into the base 20a of the printed circuit board, it is necessary to hard wire the actual series connection of the battery array B to the printed circuit board. This is accomplished through soldering hard wire 41 to battery terminal contact 14a and soldering hard wire 42 to battery contact 14b. These two hard wire connections to the plus and minus side of the battery array B are the only hard wire connections necessary in electronically connecting the battery to the main computer housing through the other, wireless connections available at the contacts 21.
The combination of the chassis 20 and printed circuit board 30 in cooperation of the array of batteries B provide for a substantially wireless connection between the host computer and the battery pack. Further, the positioning of the chassis 20 in the opening O in the bottom of the battery pack places the chassis in an unobtrusive relationship with the actual bottom 10a of the housing such that the chassis takes up minimal space within the confines of the housing. Further, the utilization of the pedestals such as 24 to mount the printed circuit board 30 at a right angle to the chassis base plate 20a allows the printed circuit board to be positioned adjacent the upright side wall 10c once again mounting the components in a highly efficient manner within the confines of the battery pack housing. This efficient mounting of the chassis 20 and printed circuit board 30a in cooperation with the utilization of the series of electrical contacts 21 provide a wireless, compact battery power and electronic transfer unit for portable and notebook computers.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape, materials, components, circuit elements, wiring connections and contacts, as well as in the details of the illustrated circuitry and construction and method of operation may be made without departing from the spirit of the invention. For example, while the housing 20 is described in terms of a bottom, sides and top, it is understood that actual mounting orientation may vary the position of the housing. | A battery pack for a portable or notebook computer which substantially eliminates hard wiring components including a generally rectangular housing having an opening in the bottom. The opening in the bottom receives a support chassis which mounts a series of electrical contact points for interfacing with the main computer housing. The support chassis mounts a printed circuit board which receives the electrical contact points for electrical connection to the various components of the printed circuit board such that electrical connection is made between the array of batteries and the main computer housing utilizing a series of electrical surface contact points rather than hard wiring, which preserves space and reduces manufacturing costs. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for drying semiconductor wafers or similar substrates and in particular relates to a process which maintains the substrates or wafers in a motionless or static situation during the drying procedure. This invention also relates to an apparatus for drying wafers or substrates, which maintains the wafers or substrates in a motionless or static situation during the drying process. Maintaining the wafers or substrates in a static situation during the drying procedure avoids the undesirable generation of particulate which is deleterious to the wafers or substrates.
2. Description of the Prior Art
At present, the majority of the processes available for wafer and substrate drying are based on a spin drying technique. The equipment used is commonly referred to as a spin rinser dryer (SRD). In SRD equipment, the wafers are contained in a carrier which is positioned either at the center or at the periphery of a basket, and the basket is rotated or spun about its axis at high speed. The centrifugal forces generated by high speed rotation strips the droplets of water from the surface of the wafer. During the high speed spin operation, nitrogen or other inert gas may be introduced to generate turbulence in the basket holding chamber assisting the complete removal of droplets from the wafer surface. Heating of the chamber and its contents above ambient temperatures may be used to enhance the drying operation. For example, heat may be introduced in the form of a flow of heated nitrogen or other suitable inert gas or the chamber itself may be equipped with heating elements.
In the SRD process, the high speed spinning of the basket has been found to be a source of generation of particulate which can deposit on and contaminate the wafers or substrates. Generally, the basket and the speed of rotation are designed to minimize relative movement of the wafers in relation to their position within the basket, but some movement of the wafer within the carrier is always possible. Any movement of the wafer substrate with respect to its position within the carrier is likely to generate deleterious particulate. In addition, the turbulence engendered by the introduction of inert gas into the system is further likely to be a source of particulate.
Another type of equipment used for drying of wafers and substrates, referred to as an IPA dryer, involves immersing the wafers in a liquid/gaseous bath of IPA (isopropyl alcohol). The IPA dryer is based on the principle that, since water is miscible with alcohol, the alcohol will mix with and carry away the water present on the surface of the wafer, eventually leaving only a film of alcohol on the wafer. Since the alcohol has a high vapor pressure, it quickly evaporates leaving the surface of the wafer dry. A negative aspect of the IPA drying process is that the alcohol may leave organic residue remaining on the surface of the wafer as it evaporates. Considering the high level of cleanliness required for the surface of the wafers, this is an unacceptable drawback to the IPA drying technique.
In co-pending commonly assigned U.S. patent application No. 06/832,506, filed Feb. 21, 1986, now U.S. Pat. No. 4,736,760, patented Apr. 12, 1988, there is disclosed a method and apparatus for cleaning substrates with megasonic energy and then for separately rinsing and drying the substrates. The rinsing and drying procedure involves immersing the substrates in a rinse solution at ambient or elevated temperature, and then lifting the substrates from the solution at a slow controlled rate of removal. Although this procedure has certain advantageous features over the SRD and IPA processes, there is still need for improvement in providing both equipment and method for rinsing and drying substrates in a static or motionless process, presenting them clean, dry and free of unwanted particulate.
In U.S. Pat. No. 4,577,650, issued Mar. 25, 1986, there is disclosed an apparatus for treating wafers and substrates which comprises a plurality of vessel segments serially nested together and engaged with a fluid inlet and a fluid outlet connected in a wafer treatment fluid flow line. This process has not so far met with commercial acceptance or success, and there is still need for improvement in the drying of such substrates.
SUMMARY OF THE INVENTION
This invention provides a process for drying wafers or substrates which allows the wafers or substrates to remain in an essentially motionless or static condition throughout the entire procedure. This invention also provides an apparatus for carrying out the process of drying wafers or substrates in an essentially motionless or static condition throughout the entire procedure. Maintaining the wafers or substrates in a static condition throughout the drying process prevents the undesirable generation of particulate.
The apparatus used in carrying out the process of this invention comprises a chamber for enclosing the wafers, provided with a means for opening the chamber to permit insertion and removal of the wafers and means for closing the chamber to maintain the chamber in a fluid-tight seal. The chamber is equipped with valves for controlling the introduction and draining or evacuation of process fluids.
Inside the chamber, the wafers are maintained in standard wafer carriers, which support the wafers primarily by their edges in spaced apart relationship generally parallel to each other. The wafers are further supported within the chamber so that the planar surfaces of the wafers are inclined from the vertical at an angle up to about 30°, preferably at an angle of about 5°-15° to the vertical. The wafers may suitably be maintained at the desired angle of inclination by inclining the chamber itself or the wafer carriers. The angled alignment of the chamber and the wafers facilitates the complete drainage of water from the surface of the wafers during the draining cycle.
The operation of the process comprises the following steps:
1. The wafers are loaded into the chamber, for example, in standard carriers in which they are supported primarily by their edges in spaced apart alignment generally parallel to each other. The carrier or carriers are positioned within the chamber such that the planar surface of the wafers are inclined from the vertical at an angle of up to about 30°, preferably at an angle of between 5° to 15° with the vertical. The chamber is closed in a fluid tight seal. The chamber may desirably be heated to a temperature of 50°-100° C. or slightly above throughout the process.
2. The chamber is completely filled with hot (approximately 50°-100° C.) conventional rinsing solutions, such as halocarbons, alcohols, polyhydric alcohols, or preferably deionized water, while maintaining vacuum aspiration of the interior of the chamber. D.I. water is introduced at a slow enough rate so as not to disturb the position of the wafers and is continued until the water overflows through the vacuum valve to assure complete filling of the chamber.
3. While maintaining the chamber completely filled with D.I. water, vacuum aspiration is continued for a few minutes to reduce the pressure in the chamber to between about 300 to 400 mm Hg. Since a small amount of water may be aspirated from the chamber during the vacuum aspiration procedure, additional hot D.I. water is introduced as necessary to maintain the chamber completely filled during the vacuum aspiration procedure.
4. While continuing vacuum aspiration of the chamber, the drain valve is opened allowing the water to drain from the chamber, while clean dry inert gas is introduced above the water. The drain valve may also preferably be vacuum assisted. Continued vacuum aspiration during and after completion of draining further serves to insure complete removal of water vapor from the interior of the chamber.
5. After the chamber interior has drained completely, the flow of inert gas is discontinued and vacuum aspiration is continued for a few minutes until the pressure in the chamber has been reduced to sub-atmospheric, approximately 650 mm Hg.
6. The chamber is then repressurized by introducing clean dry inert gas to a pressure at or slightly above normal atmospheric pressure, the fluid tight seal is released and the chamber is opened to remove the dry wafers.
The chamber used in the process according to this invention is of a suitable configuration that maintains the wafers throughout the process in the manner described and that provides a plurality of valves for controlling the introduction and drainage or evacuation of processing fluids as described.
Prior to drying the wafers according to the drying process of this invention, it may be desired to rinse the wafers in the chamber once or several times with hot or cold water or other conventional rinsing solutions as previously mentioned. Prior to rinsing the wafers, it may be desired to clean the wafers in teh chamber with hor or cold conventional cleaning solutions generally according to the sequence described hereinabove for the drying procedure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional schematic side elevation diagram.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The chamber 10 of the static dryer 12 used in carrying out the process of this invention encloses the wafers 20, maintaining them in a motionless or static position. The wafers 20 are preferably placed in the chamber 10 in standard carriers 40, wherein they are held in a spaced apart relationship generally parallel to each other supported primarily by their edges 42 so that the planar surfaces of the wafers are included at an angle from their vertical of up to 30°, preferably 5°-15°. The wafers are supported in a spaced apart relationship primarily by their edges 42 so that the planar surfaces of the wafers are exposed to the operation of the rinsing and drying procedures. Maintaining the wafers at an angle included from the vertical is designed to insure complete and efficient drainage of water from the surfaces of the wafers. Suitably, the chamber 10 may have lateral walls 30, 31 which may be rectangular or cylindrical, with a closed end 32 and an openable end 34 for insertion and removal of the wafers 20. The wafers may be maintained at the desired angle of inclination by suitably inclining the chamber 10. The angle of inclination A of the chamber 10 can be such that the normally horizontal axis C of the chamber forms an angle A with the horizontal H of between 0° to 89°, preferably between 5° to 15° from the horizontal, with the openable end 34 maintained relatively higher than the closed end 32.
The chamber 10 is further provided with a plurality of valves to allow introduction and drainage or evacuation of processing fluids, and is openable for insertion and removal of the wafers and closeable to maintain the chamber in a fluid tight seal. Desirably, the chamber is equipped with means for heating the chamber and its contents throughout the drying process, preferably to a temperature of 50°-100° C. or slightly higher, to prevent the development of a temperature differential between the processing fluids and the chamber and enclosed wafers. The interior of the chamber has a preferably hydrophobic finish 36 to efficiently facilitate the drainage of water. A chamber formed of or interiorly lined with a fluoropolymer material such as Teflon is preferred.
The wafers 20 may be contained inside the chamber 10 in standard wafer carriers 40 which may be of any standard material, such as a fluoropolymer or quartz.
A drain 50 is provided in the chamber 10 to allow controlled drainage of water from the chamber. To facilitate the complete drainage of the chamber, the drainage means is located in the lowest portion of the chamber. It is an important feature of the operation of the apparatus of the present invention that the drainage means be designed to control drainage of the water from the chamber during the drying cycle at a slow predetermined rate so that the surface tension of the water allows the water droplets to remain with the bulk of the draining water, rather than adhering to the surface of the wafers or the chamber.
The openable end 34 of the chamber 10 can be a door 52 which allows access to the interior of the chamber 10 for inserting and removing wafers 20. When closed, the chamber is maintained in a fluid tight seal. Preferably, pneumatic pressure is supplied by a plurality of pneumatic cylinders with a sealing gasket 54 interposed between the mating edges of the door 52 of the openable end 34 and the lateral walls 30, 31 of the chamber 10.
To begin the process, the chamber 10 is loaded with wafers 20 and closed in a fluid tight seal. If it is desired to rinse the wafers prior to the drying process, hot or cold deionized water is introduced into the chamber through the appropriate fluid inlet valve 60. After completion of the optional rinsing cycle, the drain 50 is opened to allow the chamber 10 to empty completely. If desired, several rinsing cycles may be used prior to beginning the drying process of this invention. If it is desired to clean the wafers prior to he rinsing process and the drying process of this invention, hot or cold conventional cleaning solution is introduced into the chamber from an appropriate reservoir 64 through the appropriate fluid inlet valve 60. The optional cleaning cycle then proceeds generally according to the sequence described hereinabove for the drying procedure. After completion of the optional cleaning cycle, the drain 50 is opened to allow the chamber to empty completely before proceeding with a subsequent rinsing cycle and then the drying procedure according to this invention.
To begin the drying cycle according to this invention, the chamber 10 is filled with hot water through the fluid inlet valve 60, while maintaining vacuum aspiration to remove air and any water vapor through valve 76. The hot water temperature may desirably be in the range of from about 50° to about 100° C. If high pressure operations are employed, temperatures higher than 100° C. may be used. The heated deionized water may be supplied to the chamber by a water heater which may be an integral part of the static dryer apparatus 12, or it may be supplied to the chamber from an external source of heated deionized water. It is important to avoid stagnant sites which might initiate bacterial growth or the accumulation of particulate or debris. Thus, the static dryer apparatus may be equipped with a deionized water by-pass 66.
It is an important feature of the present invention to avoid the development of a temperature differential between the heated water and the interior surfaces 36 of the chamber during the drying cycle. Thus, the chamber is equipped with means for maintaining the water and the interior surfaces of the chamber at a constant temperature throughout the drying cycle, particularly during filling and draining of the water. Heating elements 68 may desirably be provided on any or all of the exterior surfaces of the chamber to provide compensation for heat loss and to maintain the entire system at a constant temperature throughout the drying cycle.
During the drying procedure of this invention, filling with heated deionized water is continued until the water overflows through the vacuum aspirator valve 76. While maintaining the chamber completely filled with D.I. water, vacuum aspiration of the chamber is continued for a few minutes, for example 1.5 minutes, to completely degas the water. This step of degassing the water insures the removal of entrapped gas, particulate and other debris from the surface of the wafers and is extremely important to the efficient operation of this novel process. Since a small amount of water may be aspirated from the chamber through the vacuum aspirator valve 76, additional heated D.I. water is introduced as necessary to maintain the chamber completely filled throughout the degassing procedure.
At the completion of the degassing procedure, vacuum aspiration of the chamber is continued, and the drain valve 50 is opened allowing the water to drain from the chamber at a controlled rate, while clean dry inert gas is introduced through valve 82 over the draining water. According to the presently preferred embodiment, the chamber has a drain 50 which is connected to a vacuum aspirator 69 through a series of pneumatic valves 70, which may be both regulated and unregulated. During the rinsing operation prior to the drying process of this invention, the drain valves 70 allow the water to drain from the chamber completely. During the drying process, the regulated pneumatic valve 72 controls the drainage rate at between about one liter per minute up to about one gallon per second. The faster drainage rates may be made possible by providing multiple or larger drains 74, high vacuum aspiration, or by the use of a chamber with a collapsible wall 30 or 32.
The chamber is equipped with a vacuum valve 76 to provide aspiration and/or suction to the interior of the chamber 10 during both the filling and the draining procedures. The static dryer 12 of this invention is designed so that aspiration can be provided for both the vacuum valve 76 and the drain valve 50 of the chamber. During the filling procedure, the vacuum valve 76 is connected to the aspirator 69, allowing uniform filling of the chamber and exhausting any water vapor in the chamber generated by the water, particularly when heated water is being introduced. This prevents any undesirable build-up of pressure in the chamber. The vacuum in the chamber may range from about 100 mm to about 1000 mm Hg.
The vacuum and drainage valves 76 and 50, respectively, are connected in fluid flow communication with an aspirator tank 80 by means of fluid lines 78. Since water and condensable water vapor drain into the aspirator tank, the aspirator tank 80 is desirably provided with an overflow drain 92.
The chamber is also provided with a valve 82 to admit inert gas, such as clean air, argon or, preferably, nitrogen, into the evacuated chamber over the water during the draining, to insure that water droplets remain with the bulk of the draining water rather than allowing any water droplets to adhere to the surfaces of the wafers or the chamber. After the water has completely drained, the flow of inert gas is discontinued and vacuum aspiration of the chamber is continued for a few minutes to insure complete removal of water vapor from the chamber. Then, vacuum aspiration is discontinued. The flow of inert gas into the chamber is resumed, thereby re-pressurizing the chamber to normal atmospheric pressure or slightly above prior to releasing the fluid tight seal 54 and opening the chamber 10 to remove the dry wafers 20.
The entire operation of the static dryer 12 of this invention may suitably be programmed by a microprocessor based controller, capable of carrying out the necessary sequencing steps, including activating the various valves and equipment ancillary to the processing chamber.
Various sensors 90 are provided within the system responsive to its proper operation. Thus, sensors 90 are appropriately equipped to be responsive to the various levels of deionized water in the chamber 10 at different times in the rinsing and drying cycles, the proper operation of the chamber fluid tight seal 54, the proper operation of the drainage valve, vacuum valve, inert gas inlet valve, the aspirator tank and the inert gas supply. Should any of these sensors detect a malfunction, the operation of the system would immediately abort.
In operation of the static dryer 12 of this invention, the chamber is loaded with wafers and locked in a fluid tight seal. The cycle of rinsing the wafers is an optional procedure prior to the drying cycle. If rinsing of the wafers is preferred, the wafers may be rinsed using either cold or hot deionized water. To initiate the rinsing cycle, the vacuum valve 76 is opened in fluid flow communication with the aspirator 69 and the fluid inlet valve 60 is opened allowing the chamber to fill with deionized water. After the chamber has filled, the fluid inlet valve 60 is closed and the chamber drain valve 72 opens. This may be a slower regulated drain, a faster unregulated drain, or opening of the collapsible wall.
After completion of the rinse cycle, the chamber drain valve 72 is closed. The chamber heaters 68 maintain the temperature of the interior of the chamber at the same temperature as or slightly higher than the hot water which will be introduced for the drying cycle. Alternatively, the chamber may be heated by the introduction of heated inert gas of the same temperature as or slightly higher than the hot water which will be introduced. The fluid inlet valve 60 is then opened allowing the chamber 10 to fill with hot deionized water, while the vacuum valve 76 remains opened in fluid flow communication with the aspirator 69. The temperature of the water may generally be in the range of from 50° C. to about 100° C., preferably between about 60° and about 80° C., with the chamber heaters 68 maintained at the same temperature as or slightly higher than the hot water. Once the chamber has filled, vacuum aspiration of the filled chamber is continued for a few minutes, for example 1.5 minutes, to degas the water, removing entrapped gas, particulate and other debris to ensure that the surfaces of the wafers are completely wetted. Since a certain amount of water may be aspirated from the chamber through the vacuum valve 76, additional hot D.I. water may continue to be introduced to maintain the chamber completely filled. Once the degassing procedure has been completed, the fluid inlet valve 60 is closed, vacuum aspiration of the chamber is continued, inert gas is introduced over the water and the drain 50 is opened provided with vacuum assistance. The regulated drain valve 72 controls the drain rate as required. The presently preferred drain rate is about one gallon per minute.
Once the chamber has been drained, the introduction of inert gas is discontinued and the vacuum valve 76 is adjusted to maintain the vacuum at a level of between about 500 and about 760 mm of Hg. Preferably the vacuum in the chamber is maintained at about 600 mm of Hg. After a regulated amount of time, ranging from about 1 to about 5 minutes, the vacuum valve 76 is closed and heating of the chamber is discontinued. After the vacuum value has been closed, the inert gas inlet valve 82 is opened, allowing an inert gas, preferably nitrogen, to backfill into the chamber until the pressure within the chamber has returned to normal atmospheric pressure or slightly above. This completes the drying cycle and the fluid tight seal on the chamber is released and allowed to open. The wafers 20 and the interior surfaces 36 of the process chamber 10 are dry and void of water, water vapor and water vapor condensate at the completion of the process. | A process for drying semiconductor wafers or similar substrates maintains the substrates in a static position to avoid the generation of undesired particulate. The substrates are maintained within the apparatus at an angle of approximately 30° from the vertical to facilitate complete drainage of the processing fluid. According to this invention, the substrates are positioned in the chamber of the apparatus at the appropriate angle, the chamber is closed in a fluid tight seal and filled with the processing fluid, until the fluid overflows through a vacuum valve. While maintaining the chamber completely filled, vacuum aspiration is continued to degas the chamber. While continuing vacuum aspiration of the chamber, a vacuum assisted drain valve is opened, and clean dry inert gas is introduced above the draining fluid. The draining step assures that any droplets remain with the draining fluid so that the substrates emerge dry as the fluid drains away. The inert gas flow is discontinued and vacuum aspiration is maintained briefly after the chamber has drained. The vacuum aspiration is discontinued and the chamber is repressurized to essentially ambient pressure prior to opening the chamber to remove the dry substrates. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates a pulsator for a washing machine, and more particularly to a pulsator for a washing machine which is improved in its structure to enhance washability and to prevent material of items from being tangled.
2. Description of the Prior Art
A conventional washing machine includes a rotating basket with a pulsator at its bottom which is adapted to cause washing water to be whirled to agitate items being washed.
However, since the above-mentioned washing machine carries out washing only by a water vortex caused by the pulsator, the washing machine has drawbacks in that a wash item such as cloth is severely twisted thereby to be damaged easily and is not washed evenly thereby causing washing efficiency to be lowered.
A technique for overcoming the above drawbacks is disclosed in Korean Patent Publication No. 88-2734 (entitled "pulsating device for a washing machine"). A sectional view of an embodiment of a washer incorporating the above pulsating device is shown in FIG. 1.
As shown in the drawing, an outer case 1 is provided therein with a tub 3 suspended by an elastic suspension mechanism and also is provided under the tub 3 with a motor 4, a transmission assembly and a belt transmission mechanism 6.
The tub 3 is provided therein with a rotating basket 7 for washing and spin drying wash items, and the rotating basket is provided at its bottom with a pulsator 8.
The rotating basket 7 is connected to a driving shaft 9 of the transmission mechanism 5, and the pulsator 8 is connected to a pulsating shaft (not shown) of the transmission mechanism 5 via a reduction mechanism 10 provided at a bottom of the rotating basket 7.
The transmission mechanism 5 has a clutch mechanism 11 by which a rotating force of the motor 4 is transmitted to the pulsating shaft and the driving shaft 9 or is cut off to rotate the pulsator 8 in a washing mode and to rotate the rotating basket 7 together with the pulsator 8 in a spin-dry mode. The pulsator 8 is adapted to repeat forward and reverse rotation, for example, the pulsator is rotated forwardly at 3 turns and then reversely rotated 3 turns and the procedure is repeated.
Referring to FIG. 2, there is shown a plan view of the pulsator. As shown in FIGS. 1 and 2, a base disk portion 12 is constructed as having a disk shape covering a substantial bottom area of the rotating basket 7 and is provided at its upper surface with four blade portions 13 extended radially and upward. Provided at the center portion of the base disk portion 12 is a center post portion 14 which protrudes upward beyond the blade portions 13.
The center post portion 14 is provided at its upper end with a shaft connecting portion 15 aligned with the center of base disk portion 12, and the shaft connecting portion 15 is connected to an output shaft 10a of the reduction mechanism 10.
As again shown in FIG. 2, the center post portion 14 has an elliptic shape in horizontal section the center of which is eccentrically positioned from the rotating center of the base disk portion 12 (the center of the shaft connecting portion 15).
The above-constructed pulsating device for a washing machine can enhance with complexity of the agitated water current as compared with a conventional vortex thereby to increase washing efficiency and also can carry out a shaking wash, a rubbing wash, a pressing wash and reverse of cloth by means of a force of the center post. Accordingly, the device can enhance agitating efficiency and washing efficiency.
However, although the above pulsating device for a washing machine may enhance washing efficiency, it has a limited ability for increasing the complexity of water current and thus a limited ability for increasing washing efficiency. That is, when the amount of the above-mentioned eccentricity of the center post 14 is too much, a load applied to the motor is increased. Conversely, when the amount of eccentricity is to small, water current is simplified (less complex) thereby decreasing washing efficiency.
SUMMARY OF THE INVENTION
Therefore, the present invention is made in view of the above-described prior art problems and an object of the invention is to provide an improved pulsator for a washing machine which can generate a complex water current to enhance washing efficiency and can prevent damage of cloth items due to tangling of the cloth.
In accordance with an embodiment of the present invention, the above object of the invention can be accomplished by providing a pulsator for a washing machine comprising: a base member rotatably mounted in a rotating basket; a plurality of agitating blades protruded upward from the base member; and an agitating post eccentrically positioned from the center of the base member and protruded upward beyond the agitating blades, the agitating post having an upper inclined surface.
In accordance with another embodiment of the invention, the above object of the invention can be accomplished by providing a pulsator for a washing machine comprising: a base member rotatably mounted in a rotating basket; an agitating post eccentrically positioned from the center of the base member and protruded upward; and a plurality of agitating blades parallel to a line connecting the center of the base member to the center of the agitating post and positioned on a half of the base member, the blades being protruded upward.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and aspects of the invention will become apparent from the following description of an embodiment with reference to the accompanying drawings in which:
FIG. 1 is a vertical sectional view of a washing and dehydrating machine incorporating a conventional pulsator;
FIG. 2 is a plan view of a rotating basket and the pulsator of FIG. 1;
FIG. 3 is a plan view of a pulsator according to a first embodiment of the present invention;
FIG. 4 is a sectional view taken along lines 4--4 of FIG. 3;
FIG. 5 is a plan view of a pulsator according to a second embodiment of the present invention;
FIG. 6 is a sectional view taken along lines 6--6 of FIG. 5;
FIG. 7 is a plan view of a pulsator according to a third embodiment of the present invention;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 7; and
FIG. 9 is a sectional view taken along lines 9--9 of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail by referring to the accompanying drawings hereinafter.
First Embodiment
FIG. 3 is a plan view showing a first embodiment of a pulsator for a washing machine according to the present invention and FIG. 4 is a sectional view taken along lines 4--4 of FIG. 3.
With reference to the drawings, the pulsator 100 according to the invention comprises a base disk 101 forming a base member for the pulsator, a plurality of agitating blades 102 protruded upward from the base disk 101, and an agitating post 110 having an elliptic shape in horizontal section and an upper inclined surface the center of which is eccentrically positioned from a rotating center "O" of the base disk 101 and protruded upward beyond the agitating blades 102.
In this embodiment, the base disk 101 is concave downward at its center portion. That is, the base disk 101 is inclined down to its center so a the plurality of recesses 105 for containing water are defined by the base disk 101 and the agitating blades 102. A reinforcing cylindrical rib 132 is formed at lower surfaces of the base disk 101 and the agitating blades 102.
Each of the agitating blades 102 is radially extended and protruded upward from the upper surface of the base disk 101 and has first and second slopes 111 and 112 forming both of its sides and third, fourth and fifth slopes 113, 114 and 115 forming its outer, top and inner edges.
The first and second slopes 111 and 112 have predetermined inclined angles with respect to vertical central planes of the agitating blades 102. The fourth slope 114 is located at a middle portion of the upper edge of the agitating blade 102 and is slightly inclined down to the outside. The third and fifth slopes 113 and 115 are inclined down to the outside and inside respectively and have predetermined inclined angles.
The agitating post 110 is constructed such that its center is eccentrically positioned from the rotating center "O" of the pulsator 100 by a predetermined distance "L", and its upper surface 121 has a rectangular or elliptic shape and a predetermined inclined angle A (0°-75°). In this embodiment, the upper surface 121 is inclined down from the center of the post 110 to the rotating center of the agitator 100.
The agitating post 110 is formed at its upper end with a coupling hole 122 such that the center of the coupling hole 122 is aligned with the center of the base disk 101. The coupling hole 122 is adapted to couple the pulsator 100 to a driving shaft (not shown) by means of coupling member inserted therein.
The base disk 101 is provided beneath its center potion with a fitting hole 103 in which the driving shaft for transmitting rotating force of the motor to the pulsator 100 is fitted and is provided on its center portion with a coupling hole 104 in which a coupling member (not shown) is inserted. The agitating post 110 is formed at its lower flange portion with a plurality of coupling holes 130 for coupling the agitating post 110 to the base disk 101, and is cut out at positions corresponding to inner ends of the agitating blades 102.
Alternatively, the agitating blades 102 may be constructed such that inner ends of the blades are not overlapped with the agitating post 110, and also the agitating blades 102 may be cut out at portions overlapped with the agitating post 110. The agitating post 110 is tightly secured to the base disk 101 by means of coupling members 131.
In this embodiment, although the agitating post 110 is described as being coupled to the base disk 101 by means of coupling members, the agitating post 110 may be integrally formed with the base disk 101. In this instance, the fitting hole 103 is extended to the upper surface 121 of the agitating post 110 so that the pulsator 100 can be coupled to the driving shaft (not shown).
Operation of the pulsator for a washing machine according to the embodiment of the invention will be described hereinafter.
Upon operating the clutch, driving force of the motor is transmitted to the pulsator, thereby causing the pulsator to be rotated forwardly and reversely. As the pulsator 100 is rotated forwardly and reversely, washing water and wash items are driven upward by the first and second slopes 111 and 112 of the agitating blades 102. The washing water and the wash items agitated by the first and second slopes 111 and 112 are dispersed upwardly along the first and second slopes 111 and 112, thereby generating a vortex in the water.
At this time, the washing water and the wash items are driven and dispersed by centrifugal force. Since the agitating blades 102 have the main top slopes 113, 114 slightly inclined down to the radial outside, the washing water and the wash items are more efficiently dispersed outward. Therefore, the washing water and the wash items are raised along a side wall of the rotating basket 7 (see FIG. 1). At the same time, the washing water and the wash items are also dashed and driven by side slopes 120a and 120b of the agitating post 110 eccentrically mounted on the pulsator 100, thereby generating a vortex. Since the side slopes 120a and 120b of the agitating post 110 are asymmetrically formed with respect to the rotation center "O" of the base disk 101, the rotation of the agitating post 110 causes turbulence of the washing water.
The washing water and the wash items driven upward are lowered above the agitating post 110. At this time, since the upper surface 121 of the agitating post 110 is inclined, the descending water and wash items reach the upper surface 121 with a time difference. Also, the water and the wash items collide against both rounded ridges 120c, 120d of the agitating post 110 and thus are dispersed outward.
In this instance, since both rounded ridges C, D, respectively, which are of the agitating post 110 have inclined angles different from each other, the water and wash items dispersed from the both rounded ridges have dispersion manners different from each other, so that phenomenon that there occurs a large water current can not be formed (i.e., there occurs a separation of flow). Thus, a large water current pattern about the post can not be formed. Accordingly, the washing water and the wash items are unevenly dispersed toward both sides and thus a cloth-type wash item is not tangled but rather is evenly unfolded.
As described above, since the pulsator for a washing machine does not cause washing water to be whirled concentrically about a certain rotation axis in a manner similar to the prior art but causes complex turbulence of the washing water crossing over a rotation axis and varying in its whirling manner as time passes, by means of the eccentric agitating post having the inclined upper surface, cloth is evenly unfolded and spread, thereby improving washing performance, shortening washing time and preventing cloth from becoming tangled.
By way of suggestion, a principle that turbulence is generated by the agitating post having the inclined upper surface is introduced from the Rossby wave theory. C. G. Rossby is a man who studied geophysics, and proposed the Rossby wave theory in view of the fact that rotation of atmosphere on the earth about the rotation axis is not uniform but continuously varies according to the passage of time because the surface of the earth is inclined with regard to the rotation axis of the earth at all regions besides the polar regions.
The Rossby wave theory is what is proposed by C. G. Rossby, in 1936, and states that when a rotating surface is inclined with regard to the rotation axis by a predetermined angle, fluid does not form symmetrical and concentric rotating current but forms asymmetrical current varying according to the passage of time.
The theory is integrated into a greater whole by H. P. Greenspan, a professor of the department of applied mathematics of M.I.T. who is an authority in the field of rotating current theory, and thus is settled as an indispensable theory with regard to rotating current.
Second Embodiment
FIG. 5 is a plan view showing another embodiment of a pulsator for a washing machine according to the present invention and FIG. 6 is a sectional view taken along lines 6--6 of FIG. 5.
With reference to the drawings, the pulsator 100' according to the invention comprises a base disk 101' forming a base member for the pulsator, a plurality of parallel agitating blades 102' protruded upward from a half of the base disk 101', and an agitating post 110' having an elliptic shape in horizontal section the center of which is eccentrically positioned from a rotating center "O" of the base disk 101' and protruded upward beyond the agitating blades 102'.
In this embodiment, the base disk 101' is a circular plate and is concave downward at its center. That is, the base disk 101' is protruded upward at its outer periphery to form a recess 105' for containing washing water. A reinforcing cylindrical rib 132' is also formed at lower surfaces of the base disk 101' and the agitating blades 102.
The agitating blades 102' are provided on a half of the base disk 101', that is, a left half opposite to a right half of the base disk 101' (with reference to FIG. 5), the dividing line for the halves being where the center of the agitating post 110' is located. Inner ends of the agitating blades 102' lie on a straight line and the outer ends lie on a circumferential line F. Accordingly, as one goes from the middle blade to an outer blade, the agitating blade 102' is continuously reduced in its length. The middle blade lies along radius of the agitator, which radius bisects one half of the agitator. The remaining blades extend parallel to the middle blade.
Each of the agitating blades 102' has first and second slopes 111' and 112' forming both sides and third, fourth and fifth slopes 113', 114' and 115' forming its outer, top and inner edges.
The first and second slopes 111' and 112' have predetermined inclined angles with respect to vertical central planes of the agitating blades 102'. The fourth slope 114' is located at a middle portion of the upper edge of the agitating blade 102' and is slightly inclined down to the outside. The third and fifth slopes 113' and 115' are inclined down to the outside and inside respectively and have predetermined inclined angles.
The agitating post 110' is constructed such that its center is eccentrically positioned from the rotating center "O" of the pulsator 100' by a predetermined distance "L", and its upper surface 121' has a rectangular or elliptic shape.
The agitating post 110' is formed at its upper end with a coupling hole 122' such that the center of the coupling hole 122' is aligned with the center of the base disk 101'. The coupling hole 122' is adapted to couple the pulsator 100' to a driving shaft (not shown) by means of coupling member inserted therein.
The base disk 101' is provided beneath its center potion with a fitting hole 103' in which the driving shaft for transmitting rotating force of the motor to the pulsator 100' is fitted and is provided on its center portion with a coupling hole 104' in which a coupling member (not shown) is inserted. The agitating post 110' is coupled to the base disk 101' by means of a plurality of coupling members 131', and is cut out at a portion 110A overlapped with an inner end of the middle agitating blade 102'.
Alternatively, the middle agitating blade 102' may be constructed such that inner end of the blade is not overlapped with the agitating post 110', or the inner and of the middle agitating blade 102' may be cut out.
In this embodiment, although the agitating post 110' is described as being coupled to the base disk 101' by means of coupling members, the agitating post 110' may be integrally formed with the base disk 101'. In this instance, the fitting hole 103' is extended to the upper surface 121' of the agitating post 110' so that the pulsator 100' can be coupled to the driving shaft (not shown).
Operation of the pulsator for a washing machine according to the second embodiment of the invention will be described hereinafter.
Upon operating the clutch, driving force of the motor is transmitted to the pulsator, thereby causing the pulsator to be rotated forwardly and reversely. As the pulsator 100' is rotated forwardly and reversely, washing water and cloth items are driven upward by the first and second slopes 111' and 112' of the agitating blades 102'. The washing water and the cloth agitated by the first and second slopes 111' and 112' are dispersed along the first and second slopes 111' and 112', thereby generating a vortex in the water.
The washing water and the cloth disposed above the other half of the base disk 101' on which the agitating blades 102' are not provided are lightly rubbed by the pulsator 100'. Some of the water and cloth collide with both side slopes 120a' and 120b' of the agitating post while some of the water and cloth collide not head-on but obliquely with the first and second slopes 111' and 112' of the agitating blades 102' to be dispersed outward. Accordingly, the wash items are washed by a beating action and a rubbing action and are disposed upward and turbulence is generated in the washing water. That is, a complex current is generated above the base disk 101' by the half of the base disk 101' on which the agitating blades 102' are provided, by the other half of the base disk, and by the eccentric agitating post 110'.
Therefore, the washing water and the wash items are raised along a side wall of the rotating basket 7 (see FIG. 1) and then lowered above the agitating post 110'. The lowering washing water and wash items collide with the outer circumference of the upper surface 121' of the post 110' and dispersed outward. The outer dispersion is not uniform due to the complex current. Accordingly, the washing water and the wash items are unevenly dispersed toward both sides and thus the wash items are not tangled but evenly unfolded.
As described above, since the pulsator for a washing machine according to the second embodiment does not cause washing water to be whirled concentrically about a certain rotation axis in a manner similar to the prior art but causes complex turbulence of the washing water varying in its whirling manner as time passes by means of the eccentric agitating post and the blades, a cloth item is evenly unfolded and spread, thereby improving washing performance, shortening washing time and preventing tangle of cloth.
Third Embodiment
FIG. 7 is a plan view showing still another embodiment of a pulsator for a washing machine according to the present invention, FIG. 8 is a sectional view taken along line 8--8 of FIG. 7 and FIG. 9 is a sectional view taken along line 9--9 of FIG. 7.
As shown in the drawings, the third embodiment of the invention is different from the second embodiment in that a base disk 101' forming a base member of the pulsator has a crescent-shaped protrusion 200" protruded upward at a periphery of a half of the base disk 101' on which agitating blades 102" are not provided. The protrusion is most high at a point crossed by a major axis F of an elliptic sectional shape of the agitating post 110". From its highest point to both of its sides, the protrusion 200" is continuously lowered. The ridge line "H" of the protrusion 200" defines an arc as viewed from above. Therefore, the protrusion 200" includes a first surface 203" slightly inclined downwardly inwardly from the ridge line H and a second surface 205" inclined downwardly outwardly from the line H.
According to the third embodiment, since an additional complex current is provided by the protrusion 200", the washing water and wash item are more complicatedly dispersed by centrifugal force and are easily raised.
As apparent from the above description, since the pulsator for a washing machine according to the first embodiment of the invention (FIGS. 3 and 4) has the eccentric agitating post with the inclined upper surface to cause complex current, it is possible to increase washing efficiency.
Also, since the pulsator according to the second and third embodiments of the invention (FIGS. 5-9) has the agitating blades provided at a half of the base disk and the eccentric agitating post the center of which is positioned at the other half to cause complex current, it is possible to increase washing efficiency.
While the preferred forms of the present invention has been described, it is to be understood that various modification will be apparent to those skilled in the art without departing from the spirit of the invention.
Particularly, although the agitating post has been depicted only as being coupled to the base disk in the above embodiments, it is also capable of achieving the objects of the invention if integrally formed with the base disk.
Also, it will be obvious that various changes in the number, structure and size (height, length and the like) of the agitating blades of the invention may be made.
In the second and third embodiments, although the agitating posts are described only as having an upper horizontal surfaces, it is possible for them to have inclined surfaces similarly to the first embodiment. | An agitator for a washing machine includes a base, an agitating post extending eccentrically upwardly from the base, and agitating blades upstanding from the base. An upper surface of the agitating post is inclined with respect to horizontal by an angle up to 75 degrees. The blades extend radially in circumferentially spaced relationship around the entire base. Alternatively, the blades could extend parallel to one another on only one half of the base, the other half including an upward protrusion extending circumferentially at a location adjacent an outer periphery of that other half. | 3 |
This application is a continuation of co-pending application PCT/EP 95.01177, filed Mar. 29, 1995.
BACKGROUND OF THE INVENTION
This invention relates to an electric pressing iron, including an iron body made of cast aluminum containing silicon and provided with an electric heating means, and a surface formed by an aluminum oxide coating and defining the ironing surface of the pressing iron.
The brochure "HART-COAT", AHC/83 issue, by the firm of A.H.C.-Oberflachentechnik Munchen GmbH of 81369-Munchen, Euckenstraβe 4, describes application examples relating to the surface protection of aluminum materials by means of an anodic oxidation, particularly a "HART-COAT" coating. As stated in this brochure, anodic oxidation produces a very hard aluminum oxide coating on the surface of the aluminum material, which coating is wear- and corrosion-resistant, hard, has good sliding properties and withstands the effects of high temperatures. The brochure further states that for the application of such oxide coatings to aluminum parts, "ironing soles" are, among other applications, also suitable (5th page of the brochure).
SUMMARY OF THE INVENTION
In accordance with the present invention, it is proposed producing this aluminum oxide coating by anodizing the soleplate, thereby transforming the surface of the soleplate into an aluminum oxide coating. For this purpose, a plate-shaped soleplate made of an aluminum material with a low silicon content is used, which is then attached to the iron body such as to have good thermal contact with the iron body. Using a soleplate made of aluminum with a low silicon content in accordance with the invention enables an aluminum oxide coating to be obtained which is superior in appearance, perfect and free from defects, and which--upon attachment to the iron body and completion to form a pressing iron--results in an electrically operable pressing iron which in respect of its ironing surface meets many of the requirements made on it, including resistance to corrosion and wear, very good hardness, good sliding ability, no problems of adhering to the material being ironed, good temperature resistance, high insulation, etc. By selecting aluminum as material, a particularly lightweight sandwich construction of iron body and soleplate results.
With the pressing iron constructed in accordance with the present invention, not only the above-mentioned advantages may be achieved, but also an ironing surface results which exhibits an extremely uniform coloring while having a high degree of purity and a good surface quality. A soleplate with a coating of such high quality, in addition to affording low-cost quantity production, also affords relative ease of attachment to the iron body. In particular, there is hardly any discoloration of the soleplate surface due to the effect of high temperatures and prolonged use, so that also the positive visual impression of the ironing surface is maintained unchanged for a long period of time.
Preferably, laminated rolled sheets of a wrought aluminum alloy are suitable, in particular of the aluminum-manganese-magnesium (AlMg 4.5 Mn), aluminum-magnesium (AlMg 3), aluminum-copper-magnesium (AlCuMg 1), etc. types. Rolled sheets of this type are practically silicon-free, enabling an absolutely homogeneous aluminum oxide coating to be produced. The amounts of alloying materials added to the aluminum should not be higher than 5%, preferably be lower than 3%.
The present invention provides for smoothing of the surface of the soleplate prior to the manufacture of the aluminum oxide coating, preferably to a roughness height less than or equal to 0.1 μm. Advantageously, this high surface finish may be accomplished, for example, by means of a grinding or polishing operation. Polishing or grinding the soleplate prior to the fabrication of an aluminum oxide coating has the advantage that, after fabrication of the soleplate with aluminum oxide, the amount of stock to be removed from the surface in order to achieve the specified final surface roughness is less than would be the case in the absence of a prior polishing or grinding operation. Because less material is removed, a relatively thin aluminum oxide coating may be selected, without the need to wear part of this hard coating away completely by a subsequent polishing operation, in order to obtain the desired roughness height. Thus, in spite of the surface roughness aimed at, a closed and consequently corrosion-protected aluminum oxide coating is obtained. The removal of aluminum from the soleplate prior to its being coated with aluminum oxide down to a roughness height of less than 0.1 μm may be effected extremely rapidly in practice, since the aluminum surface of the soleplate in uncoated and accordingly still very soft condition may be smoothed or machined with ease.
Preferably, an ironing surface is obtained which is capable of withstanding major loads without appreciable damage and is protected against corrosion extremely well. With a prior treatment of the surface of the soleplate in accordance with claim 3, even the smallest thickness (20 μm) of the aluminum oxide coating is still sufficient for the surface to be subsequently abraded down to a roughness height of less than 0.1 μm, without any bare spots being exposed locally.
Preferably, complete abrasion of the aluminum oxide coating in the area of the steam discharge ports is prevented from occurring during polishing of the surface of the aluminum oxide coating to the predetermined roughness height, considering that the polishing process removes a specifically substantially higher amount of material at the edges than it does on a planar, relatively smooth surface. Advantageously, the outer edge area of the soleplate has a radius greater than or equal to 0.3 mm, preferably 0.5 mm. The two approaches of the invention which include machining the surface of the bare soleplate, as by grinding or polishing, to a predetermined roughness height prior to fabricating the aluminum oxide coating, and providing the transition areas at the edges with a sufficiently round configuration, produce the result that also with a low thickness of the aluminum oxide coating the subsequent polishing operation will not wear away this material completely in the critical areas, such as at the edges. Moreover, a smaller amount of stock removal from a very hard aluminum oxide coating also reduces machining time.
In accordance with a further aspect of the invention, the individual steam discharge ports terminate in annular steps that are recessed relative to the ironing surface. Considering, however, that the diameters of the annular steps in the transition areas to the ironing surface are greater than the diameters of the recessed steam discharge ports, a larger radius may be selected at these locations. The larger radius of the edge area prevents that during the subsequent polishing operation at unchanged polishing speed the amount of aluminum oxide removed in this area is locally appreciably higher than in the planar areas of the ironing surface. By contrast, however, if the edge areas were sharp-edged, the aluminum oxide coating would be abraded down completely.
Preferably, several steam discharge ports open into a bead, so that the bead periphery merging with the surface of the soleplate encompasses a whole group of steam discharge ports, preferably between two and five. The outer periphery of the bead so formed allows a considerably greater curvature as well as a rounded peripheral area. This advantage, in turn, enables larger radii to be selected in the peripheral area of the bead, as a result of which the polishing operation treats the aluminum oxide coating in this peripheral area gently, that is, without wearing it down completely.
In accordance with a further aspect of the invention, a particularly scratch-and wear-resistant soleplate is provided. Preferably, a soleplate with a sufficiently good sliding ability without excessive adhesion is provided.
Preferably, an electrical ground connection of the soleplate to the iron body or to ground is ensured. These voids may be produced either by subsequently grinding the electrically non-conducting aluminum oxide coating, or by masking individual areas of the soleplate prior to its immersion in an acid bath, that is, prior to fabricating the aluminum oxide coating.
According to a method of manufacturing an electric pressing iron, the soleplate, prior to being coated with aluminum oxide may be pretreated in a particularly easy and economical manner by means of a grinding or polishing operation, because the bare aluminum surface is very soft and may be therefore machined to the specified roughness height within a minimum of time. This first machining operation reduces the surface roughness already at a stage before the aluminum oxide coating is applied, such that following application of the aluminum oxide coating, the resulting ironing surface requires very little subsequent treatment for roughness reduction. This results in substantially shorter polishing periods until the desired roughness height is reached on the very hard ironing surface which is the aluminum oxide coating, thereby reducing the cost of the soleplate.
In addition to this advantage, another advantage results in that in particular in the edge areas that are exposed to higher loads per unit area, the aluminum oxide coating is not worn away completely. It is precisely edges, as compared to planar and smooth surfaces, that in a polishing operation are exposed to higher surface loads by the grinding or polishing wheels or brushes, whereby the amount of abrasion of the aluminum oxide coating is necessarily higher in these areas at constant polishing speed. In order to counteract this disadvantageous phenomenon, either the polishing pressure could be reduced as the tool approaches the edges, which, however, is a very difficult task in practice, or--as shown in a further feature of the invention --the transition areas or edges could be rounded to such an extent that in the polishing operation the load per unit area decreases in these edge areas.
Preferably, the soleplate is bonded to the iron body particularly firmly. In this method, the steam discharge ports are at the same time sealed against the edge of the steam passageways formed in the iron body, thus ensuring that steam exits exclusively through the steam discharge ports. Still further, the adhesive coating of the silicone adhesive is so thin that as much heat as possible continues to be introduced from the iron body into the soleplate. As adhesive, a two-component adhesive is used to which aluminum oxide is admixed (in amounts of 70%, approximately). This establishes an intimate connection and provides for good heat conduction between the iron body and the soleplate.
Preferably, areas not to be provided with an aluminum oxide coating may be masked by a masking means during the anodizing operation. This obviates the necessity of subsequent operations to obtain electrically conducting voids.
An embodiment of the invention will be described in greater detail in the following with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view, on an enlarged scale, of the layer construction of an iron body provided with a soleplate;
FIG. 2 is a partial longitudinal sectional view of the surface of the soleplate as it appears following the first surface finishing operation;
FIG. 3 is a partial longitudinal sectional view of the surface of the soleplate as it appears following application of the anodic coating; and
FIG. 4 is a partial longitudinal sectional view of the surface of the soleplate as it appears following polishing of the surface of the anodic coating.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 of the drawings, there is shown an iron body 1 constructed of pressure die cast aluminum and having steam discharge ports 11 which are distributed proximally to its peripheral edge and establish steam communication with the opening 19 formed in the iron body 1 and the steam generating chamber (not shown). As becomes apparent from FIGS. 1 to 4, the ironing surface 6 is shown face up as if the pressing iron was turned upside down, that is, turned by 180°. The iron body 1 is made of cast aluminum to which silicon is admixed for the purpose of improved material flow as it is cast in the die or some other mold.
An electric heating means 4 for heating the iron body 1 is cast integral with the iron body 1 of FIG. 1. A soleplate 3 stamped from rolled sheet is bonded to the surface 5 of the iron body 1 by means of a heat-resistant silicone adhesive 7 having good heat-conducting properties. In addition to the adhesive 7, mechanical fastening means may be provided as, for example, sheet-metal tabs formed on the soleplate 3, which for the purpose of attaching the soleplate 3 during assembly are bent such as to embrace the iron body 1 in positive engagement therewith, which is, however, not shown in the drawings. Among other functions, the adhesive 7 also serves to seal the soleplate 3 relative to the iron body 1 in the area of the steam discharge ports 11.
According to FIG. 1, the outer surface 15 of the soleplate 3 is provided with an aluminum oxide coating 2, which, with the exception of voids 14, preferably covers the whole outer surface 15. Following attachment of the soleplate 3 to the iron body 1, the voids 14 establish a metallic connection with the surface 5 of the iron body 1.
All of the steam discharge ports 11 terminate in openings 19 which are formed in the iron body 1 and may have a common longitudinal axis 20. It is, however, also conceivable to provide the opening 19 in the form of an upwardly open passageway in which the steam discharge ports 11 terminate. This obviates the provision of individual steam bores in the iron body 1 to be connected with the steam discharge ports 11, thus facilitating the manufacture of the iron body 1 during the process of casting the iron body 1 or enabling a less intricate mold to be used. Adjoining the steam discharge port 11 via an edge area 13 is a bead 12 that surrounds the steam discharge port 11 and merges, via the edge area 9 of a radius R, with the horizontally extending surface 8 of the soleplate 3. In the absence of a peripheral bead 12, the steam discharge port 11 may also merge directly with the surface 8 of the soleplate 3 via radius R, as indicated schematically in FIG. 1 by the dashed lines 16.
FIG. 2 is a partial longitudinal cross-sectional view on an enlarged scale, showing the soleplate 3 in the area of its outer surface 8, yet in a condition as it appears following the first grinding or polishing operation of the surface 8, but still prior to anodizing the surface 8. FIG. 3 is a cross-section of the surface 6 of the aluminum oxide coating 2 on the soleplate 3, as it results on the surface 8 of the soleplate 3 upon immersion of the soleplate 3 of FIG. 2 in an anodic bath (not shown). The resulting roughness height Ra is even lower than it would be if the surface 8 of the soleplate 3 had not been ground or polished in a prior operation according to FIG. 2. FIG. 4 is a cross-section of the surface 6 of the aluminum oxide coating 2, as it results from polishing the surface of the aluminum oxide coating 2 of FIG. 3.
The method of manufacturing the soleplate is as follows:
To begin with, the surface 5 of the iron body 1 is sized as by face-pressing, and washed in an alkaline solution for degreasing, with the roughness height of the surface 5 being greater than 1 μm for improved adhesion of the adhesive 7. In operations independent thereof, the soleplate 3 is stamped from rolled sheet of a low silicon content, and the area around the steam discharge ports 11 is embossed, deep-drawn or otherwise deformed depending on the configuration of the annular groove or bead, while at the same time also forming the transition areas to the desired radii R and r of 0.5 to 1 mm, approximately.
Independently thereof, the outer surface 8, which at a later stage serves as base for the ironing surface 6, is ground or polished according to FIG. 2 until a roughness height Ra not exceeding 1 μm results, as specified in the invention.
Subsequently, the soleplate 3 is immersed in an anodic bath (not shown), producing on the outer surface 8 of the soleplate 3 an aluminum oxide coating 2 of a thickness of preferably between 35 and 45 μm and a Vickers hardness of preferably 480 DPH 0.5. If it is desired to leave particular areas on the outer surface 15 uncoated with aluminum oxide 2, as, for example, the voids 14, these areas are masked as by wax, enamel, silicone, or some other masking means. In this manner, these areas 14 are not affected by aluminum oxide 2. Degreasing or cleaning operations are applied depending on the individual requirements preceding or following each operation.
Subsequent to the anodic bath which lasts about until the roughness value Ra of 0.5 μm as illustrated in FIG. 3 is obtained on the surface 6 of the aluminum oxide coating 2, a polishing operation is performed in which the surface 6 of the aluminum oxide coating 2 is polished to the roughness height Ra of less than 0.1 μm, as illustrated in FIG. 4. Then the upper face 17 to be bonded to the iron body 1 is provided with a temperature-resistant silicone adhesive 7 having good heat conducting properties, and is pressed onto the surface 5 of the iron body 1. At the same time, additional sheet-metal tabs (not shown) formed on the soleplate 3 may be bent to such an extent as to embrace the iron body 1 in a positive-engagement relationship therewith. In this manner, the soleplate 3 is also mechanically connected with the iron body 1, in addition to the bond formed by the adhesive 7.
The soleplate 3 including the iron body 1 thus completed is then ready for assembly with the further necessary parts (not shown) to form a pressing iron. In operation of the pressing iron, the electric heating means 4 cast integral with the iron body 1 during the process of casting the iron body generates heat which enters the soleplate 3 on passing through the adhesive 7 and the aluminum oxide coating 2 adjacent to the adhesive 7, whence this heat is once again transferred through the outer aluminum oxide coating 2 to the ironing surface 6. During ironing, heat is transferred from this surface to the material being ironed, such as clothes, not shown in the drawings. Because the adhesive 7 is a good heat conductor and in intimate contact with the soleplate 3, heat transference to the soleplate 3 is good. | An electric pressing iron in which a plate-shaped soleplate made of an aluminum material with a low silicon content is bonded to the iron body by a temperature-resistant adhesive, wherein the surface of the soleplate is provided with a hard and wear-resistant aluminum oxide coating. Because the soleplate is made of an aluminum material with a low silicon content, anodizing produces an aluminum oxide coating of a particularly uniform coloring, with a temperature-resistant as well as corrosion- and scratch-resistant ironing surface that affords particular economy of manufacture. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 09/886,592 filed Jun. 21, 2001, which is a division of application Ser. No. 09/524,364, filed Mar. 14, 2000, which is a division of application Ser. No. 08/939,779, filed Sep. 29, 1997 (now U.S. Pat. No. 6,047,557), which is a continuation-in-part of application Ser. No. 08/486,118, filed Jun. 7, 1995 (now U.S. Pat. No. 5,741,120).
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to refrigeration systems, compressor control systems and refrigerant regulating valve control systems. More particularly, the invention relates to a refrigeration system employing a pulse width modulated compressor or evaporator stepper regulator controlled by a variable duty cycle signal derived from a load sensor. Preferably an adaptive controller generates the variable duty cycle signal. The compressor has two mechanical elements separated by a seal, and these mechanical elements are cyclically movable relative to one another to develop fluid pressure. The compressor includes a mechanism to selectively break the seal in response to the control signal, thereby modulating the capacity of the system.
The refrigeration system can be deployed as a distributed system in refrigeration cases and the like. The preferred arrangement allows the compressor and condenser subsystems to be disposed in or mounted on the refrigeration case, thereby greatly reducing the length of refrigerant conduit and refrigerant required.
Conventionally, refrigeration systems for supermarket refrigeration cases have employed air-cooled or water-cooled condensers fed by a rack of compressors. The compressors are coupled in parallel so that they may be switched on and off in stages to adjust the system cooling capacity to the demands of the load. Commonly, the condensers are located outside, on the roof, or in a machine room adjacent the shopping area where the refrigeration cases are located.
Within each refrigeration case is an evaporator fed by lines from the condensers through which the expanded refrigerant circulates to cool the case. Conventionally, a closed-loop control system regulates refrigerant flow through the evaporator to maintain the desired case temperature. Proportional-integral-derivative (PID) closed loop control systems are popular for this purpose, with temperature sensors and/or pressure sensors providing the sensed condition inputs.
It is common practice within supermarkets to use separate systems to supply different individual cooling temperature ranges: low temperature (for frozen foods, ice cream, nominally −25F.); medium (for meat, dairy products, nominally +20F.); high (for floral, produce, nominally +35 to +40F.). The separate low, medium and high temperature systems are each optimized to their respective temperature ranges. Normally, each will employ its own rack of compressors and its own set of refrigerant conduits to and from the compressors and condensers.
The conventional arrangement, described above, is very costly to construct and maintain. Much of the cost is associated with the long refrigerant conduit runs. Not only are long conduit runs expensive in terms of hardware and installation costs, but the quantity of refrigerant required to fill the conduits is also a significant factor. The longer the conduit run, the more refrigerant required. Adding to the cost are environmental factors. Eventually fittings leak, allowing the refrigerant to escape to atmosphere. Invariably, long conduit runs involve more pipefitting joints that may potentially leak. When a leak does occur, the longer the conduit run, the more refrigerant lost.
There is considerable interest today in environmentally friendly refrigeration systems. Shortening the conduit run is seen as one way to achieve a more environmentally friendly system. To achieve this, new condenser/compressor configurations and new control systems will need to be engineered.
Re-engineering condenser/compressor configurations for more environmentally friendly systems is not a simple task, because system efficiency should not be sacrificed. Generally, the conventional roof-mounted condenser system, supplied by condensers, benefits from economies of scale and is quite efficient. These systems serve as the benchmark against which more environmentally friendly systems of the future will need to be measured.
To appreciate why re-engineering an environmentally yet efficient system has proven so difficult, consider these thermodynamic issues. The typical refrigeration case operates in a very unpredictable environment. From a design standpoint, the thermal mass being cooled is rarely constant. Within the supermarket environment, the temperature and humidity may vary widely at different times of day and over different seasons throughout the year. The product load (items in the refrigeration case) can also change unpredictably. Customers removing product and store clerks replenishing product rarely synchronize. Outside the supermarket environment, the outdoor air temperature and humidity may also vary quite widely between day and night and/or between summer and winter. The capacity of the system must be designed for the harshest conditions (when the condenser environment is the hottest). Thus systems may experience excess capacity in less harsh conditions, such as in the cool evenings or during the winter.
Periodic defrosting also introduces thermal fluctuations into the system. Unlike thermal fluctuations due to environmental conditions, the thermal fluctuations induced by the defrost cycle are cause by the control system itself and not by the surrounding environment.
In a similar fashion, the control system for handling multiple refrigeration cases can induce thermal fluctuations that are quite difficult to predict. If all cases within a multi-case system are suddenly turned on at once—to meet their respective cooling demands—the cooling capacity must rapidly be ramped up to maximum. Likewise, if all cases are suddenly switched off, the cooling capacity should be ramped down accordingly. However, given that individual refrigeration cases may operate independently of one another, the instantaneous demand for cooling capacity will tend to vary widely and unpredictably.
These are all problems that have made the engineering of environmentally friendly systems more difficult. Adding to these difficulties are user engineering/ergonomic problems. The present day PID controller can be difficult to adapt to distributed refrigeration systems. Experienced controls engineers know that a well-tuned PID controller can involve a degree of artistry in selecting the proper control constants used in the PID algorithm. In a large refrigeration system of the conventional architecture (non-distributed) the size of the system justifies having a controls engineer visit the site (perhaps repeatedly) to fine tune the control constant parameters.
This may not be practical for distributed systems in which the components are individually of a much smaller scale and far more numerous. By way of comparison, a conventional system might employ one controller for an entire multi-case, store-wide system. A distributed system for the same store might involve a controller for each case or adjacent group of cases within the store. Distributed systems need to be designed to minimize end user involvement. It would therefore be desirable if the controller were able to auto configure. Currently control systems lack this capability.
The present invention provides a distributed refrigeration system in which the condenser is disposed on the refrigeration case and serviced by a special pulse width modulated compressor that may be also disposed within the case. If desired, the condenser and compressor can be coupled to service a group of adjacent refrigeration cases, each case having its own evaporator. The pulse width modulated compressor employs two mechanical elements, such as scroll members, that move rotationally relative to one another to develop fluid pressure for pumping the refrigerant. The compressor includes a mechanism that will selectively break the seal between the two mechanical elements, thereby altering the fluid pressure developed by the compressor while allowing the mechanical elements to maintain substantially constant relative movement with one another. The compressor can be pulse width modulated by making and breaking the fluid seal without the need to start and stop the electric motor driving the mechanical elements.
The pulse width modulated compressor is driven by a control system that supplies a variable duty cycle control signal based on measured system load. The controller may also regulate the frequency (or cycle time) of the control signal to minimize pressure fluctuations in the refrigerant system. The on time is thus equal to the duty cycle multiplied by the cycle time, where the cycle time is the inverse of the frequency.
The refrigeration system of the invention has a number of advantages. Because the instantaneous capacity of the system is easily regulated by variable duty cycle control, an oversized compressor can be used to achieve faster temperature pull down at startup and after defrost, without causing short cycling as conventional compressor systems would. Another benefit of variable duty cycle control is that the system can respond quickly to sudden changes in condenser temperature or case temperature set point. The controller adjusts capacity in response to disturbances without producing unstable oscillations and without significant overshoot. Also, the ability to match instantaneous capacity to the demand allows the system to operate at higher evaporator temperatures. (Deep drops in temperature experienced by conventional systems at overcapacity are avoided.)
Operating at higher evaporator temperatures reduces the defrost energy required because the system develops frost more slowly at higher temperatures. Also, the time between defrosts can be lengthened by a percentage proportional to the accumulated runtime as dictated by the actual variable duty cycle control signal. For example, a sixty percent duty cycle would increase a standard three-hour time between defrosts to five hours (3/.60=5).
The pulse width modulated operation of the system yields improved oil return. The refrigerant flow pulsates between high capacity and low capacity (e.g. 100% and 0%), creating more turbulence which breaks down the oil boundary layer in the heat exchangers.
Another benefit of the variable duty cycle control system is its ability to operate with a variety of expansion devices, including the simple orifice, the thermal expansion valve (TXV) and the electronic expansion valve. A signal derived from the expansion device controller can be fed to the compressor controller of the invention. This signal allows the variable duty cycle control signal and/or its frequency to be adjusted to match the instantaneous operating conditions of the expansion device. A similar approach may be used to operate variable speed fans in air cooled condenser systems. In such case the controller of the invention may provide a signal to control fan speed based on the current operating duty cycle of the compressor.
Yet another benefit of the invention is its ability to detect when the system is low on refrigerant charge, an important environmental concern. Low refrigerant charge can indicate the presence of leaks in the system. Low charge may be detected by observing the change in error between actual temperature and set point temperature as the system duty cycle is modulated. The control system may be configured to detect when the modulation in duty cycle does not have the desired effect on temperature maintenance. This can be due to a loss of refrigerant charge, a stuck thermal expansion valve or other malfunctions.
For a more complete understanding of the invention, its objects and advantages, refer to the following specification and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system block diagram of a prior art refrigeration system configuration;
FIG. 2 is a block diagram of a refrigeration system in accordance with the present invention;
FIG. 3 is a cross-sectional view of an embodiment of the pulse width modulated compressor, shown in the loaded state;
FIG. 4 is a cross-sectional view of the compressor of FIG. 3, shown in the unloaded state;
FIG. 5 is another embodiment of a refrigeration or cooling system in accordance with the present invention;
FIG. 6 is a block diagram of the controller;
FIG. 7 is a block diagram showing how the controller may be used to modulate an evaporator stepper regulator;
FIG. 8 is a block diagram of the signal conditioning module of the controller of FIG. 6;
FIG. 9 is a block diagram of the control module of the controller of FIG. 6;
FIG. 10 is a state diagram depicting the operating states of the controller;
FIG. 11 is a flowchart diagram illustrating the presently preferred Pl control algorithm;
FIG. 12 is a waveform diagram illustrating the variable duty cycle signal produced by the controller and illustrating the operation at a constant frequency;
FIG. 13 is a waveform diagram of the variable duty cycle signal, illustrating variable frequency operation;
FIG. 14 is a series of graphs comparing temperature and pressure dynamics of system employing the invention with a system of conventional design;
FIG. 15 is a block diagram illustrating the adaptive tuning module of the invention;
FIG. 16 a is a flowchart diagram illustrating the presently preferred operation of the adaptive tuning module, specifically with respect to the decision whether to start tuning;
FIG. 16 b is a flowchart diagram illustrating the presently preferred process performed by the adaptive tuning module in the integration mode;
FIG. 16 c is a flowchart diagram illustrating the operation of the adaptive tuning module in the calculation mode;
FIG. 17 is a state diagram illustrating the operative states of the adaptive tuning module;
FIG. 18 is a block diagram illustrating the fuzzy logic block of the adaptive tuning loop;
FIG. 19 is a membership function diagram for the fuzzy logic block of FIG. 18;
FIG. 20 is a truth table relating to the membership function of FIG. 19 as used by the fuzzy logic block of FIG. 18;
FIG. 21 is an output membership function diagram for the fuzzy logic block of FIG. 18; and
FIG. 22 is a schematic illustrating exemplary sensor locations for control-related and diagnostic-related functions of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates how a conventional supermarket refrigeration system is configured. As previously discussed, it is conventional practice to place the compressors 30 and the condenser 32 in a location remote from the refrigeration cases 34 . In this illustration, the compressors 30 are configured in a parallel bank located on the roof 36 of the building. The bank of compressors supply a large condenser 32 , which may be air cooled or water cooled. The condenser supplies liquid refrigerant to a receiver 38 . The receiver 38 , in turn, supplies the individual refrigeration cases, which are connected in parallel, as illustrated. In most implementations a liquid line solenoid valve 40 is used to regulate flow to the associated evaporator 42 . The refrigerant is supplied to the evaporator through a suitable expansion device such as expansion valve 44 . The expansion valve 44 provides a restricted orifice that causes the liquid refrigerant to atomize into liquid droplets that are introduced into the inlet side of the evaporator 42 . The evaporator 42 , located within the refrigeration case 34 , extracts heat from the case and its contents by vaporization of the liquid refrigerant droplets into a gas. The compressors 30 extract this gas by suction and compress it back into the liquid state. The liquid refrigerant is then cooled in the condenser 32 and returned to the receiver 38 , whereupon the cycle continues.
To match cooling capacity to the load, the compressors 30 may be switched on and off individually or in groups, as required. In a typical supermarket arrangement there may be several independent systems, each configured as shown in FIG. 1, to handle different operating temperature ranges. Note that the liquid line 46 and the suction line 48 may each need to be quite lengthy (e.g., up to 150 feet) to span the distance from refrigeration case to roof.
FIG. 2 shows a refrigeration case 34 configured according to the principles of the present invention. The condenser 32 and compressor 30 are both disposed within case 34 or attached thereto. Evaporator 42 and the associated expansion valve 44 are likewise disposed within case 34 . The condenser 32 is provided with a heat removal mechanism 50 by which heat is transferred to ambient. The heat removal mechanism can be a water jacket connected to suitable plumbing for carrying waste heat to a water cooling tower located on the building roof. Alternatively, the heat removal mechanism can be a forced-air cooling system or a passive convection-air cooling system.
The refrigeration system of the invention employs a compressor controller 52 that supplies a pulse width modulated control signal on line 54 to a solenoid valve 56 on compressor 30 . The compressor controller adjusts the pulse width of the control signal using an algorithm described below. A suitable load sensor such as temperature sensor 58 supplies the input signal used by the controller to determine pulse width.
FIGS. 3 and 4 show the details of compressor 30 . FIG. 3 shows the compressor in its loaded state and FIG. 4 shows the compressor in its unloaded state. The solenoid valve 56 switches the compressor between these two states while the compressor motor remains energized. One important advantage of this configuration is that the compressor can be pulse width modulated very rapidly between the loaded and unloaded states without interrupting power to the compressor motor. This pulse width modulated cycling exerts less wear on the compressor, because the motor is not subjected to sudden changes in angular momentum.
Referring to FIGS. 3 and 4, there is shown an exemplary compressor 30 . Compressor 30 may be used within a hermetic scroll compressor such as generally of the type described in assignee's U.S. Pat. No. 5,102,316.
The exemplary compressor 30 includes an outer shell 61 and an orbiting scroll member 64 supported on upper bearing housing 63 and drivingly connect to crankshaft 62 via crank pin 65 and drive bushing 60 . A second non-orbiting scroll member 67 is positioned in meshing engagement with scroll member 64 and axially movably secured to upper bearing housing 63 . A partition plate 69 is provided adjacent the upper end of shell 61 and serves to define a discharge chamber 70 at the upper end thereof.
In operation, as orbiting scroll member 64 orbits with respect to scroll member 67 , suction gas is drawn into shell 61 via suction inlet 71 and thence into compressor 30 through inlet 72 provided in non-orbiting scroll member 67 . The intermeshing wraps provided on scroll members 64 and 67 define moving fluid pockets which progressively decrease in size and move radially inwardly as a result of the orbiting motion of scroll member 64 thus compressing the suction gas entering via inlet 72 . The compressed gas is then discharged into discharge chamber 70 via discharge port 73 provided in scroll member 67 and passage 74 .
In order to unload compressor 30 , solenoid valve 56 will be actuated in response to a signal from control module 87 to interrupt fluid communication to increase the pressure within chamber 77 to that of the discharge gas. The biasing force resulting from this discharge pressure will overcome the sealing biasing force thereby causing scroll member 67 to move axially upwardly away from orbiting scroll member 64 . This axial movement will result in the creation of a leakage path between the respective wrap tips and end plates of scroll members 64 and 67 thereby substantially eliminating continued compression of the suction gas.
A flexible fluid line 91 extends from the outer end of passage 90 to a fitting 92 extending through shell 61 with a second line 93 connecting fitting 92 to solenoid valve 56 . Solenoid valve 56 has fluid lines 82 and 84 connected to suction line 83 and discharge line 85 and is controlled by control module 87 in response to conditions sensed by sensor 88 to effect movement of non-orbiting scroll member 67 between the positions shown in FIGS. 3 and 4.
When compression of the suction gas is to be resumed, solenoid valve 56 will be actuated so as to move scroll member 67 into sealing engagement with scroll member 64 .
The refrigeration case embodiment of FIG. 2 may be packaged as a self-contained unit. While that may be a desirable configuration for many applications, the invention is not restricted to stand alone, self-contained refrigeration case configurations. Rather, the invention lends itself to a variety of different distributed refrigeration systems. FIG. 5 shows an example of such a distributed system.
Referring to FIG. 5, a single compressor 30 and condenser 32 can service several distributed refrigeration cases or several distributed cooling units in a heating and cooling (HVAC) system. In FIG. 5 the refrigeration cases or cooling system housings are shown as dashed boxes, designated 34 a , 34 b , and 34 c . Conveniently, the compressor 30 and condenser 32 may be disposed within or attached to one of the refrigeration cases or housings, such as refrigeration case or housing 34 a.
Each refrigeration case or housing has its own evaporator and associated expansion valve as illustrated at 42 ( a, b, c ) and 44 ( a, b, c ). In addition, each refrigeration case or housing may have its own temperature sensor 58 ( a, b, c ) supplying input information to the compressor controller 52 . Finally, a pressure sensor 60 monitors the pressure of the suction line 48 and supplies this information to compressor controller 52 . The compressor controller supplies a variable duty cycle signal to the solenoid valve 56 as previously described.
The multiple case or multiple cooling unit embodiment of FIG. 5 shows how a single compressor can be pulse width modulated by compressor controller 52 to supply the instantaneous demand for cooling. The temperature sensors 58 ( a, b, c ) collectively provide an indication of the load on the system, as does pressure sensor 60 . The controller adjusts the pulse width of the control signal to modulate the compressor between its high capacity and low capacity states (100%, 0%) to meet the instantaneous demand for refrigerant.
As an alternate control technique, one or more of the suction lines exiting the evaporator can be equipped with an electrically controlled valve, such as an evaporator pressure regulator valve 45 c . Valve 45 c is coupled to controller 52 , as illustrated. It may be supplied with a suitable control signal, depending on the type of the valve. A stepper motor valve may be used for this purpose, in which case controller 30 would supply a suitable signal to increment or decrement the setting of the stepper motor to thereby adjust the orifice size of the valve. Alternatively, a pulse width modulated valve could be used, in which case it may be controlled with the same variable duty cycle signal as supplied to the compressor 30 .
Controller 52 is not limited to solely compressor control applications. The variable duty cycle control signal can also be used to control other types of refrigerant flow and pressure control devices, such as refrigerant regulating valves. FIG. 7 shows such an application, where the output of controller 52 supplies control signals to evaporator stepper regulator 43 . This device is a fluid pressure regulator that is adjusted by stepper motor 45 . The evaporator stepper regulator (ESR) valve 43 adjusts the suction pressure to thereby adjust the capacity of the system.
A block diagram of the presently preferred compressor controller is illustrated in FIG. 6. A description of the various signals and data values shown in this and successive figures is summarized in Table 1 below.
TABLE I
Default
No.
Variable Name
Value
Description
1
Signal Conditioning:
Sensor Alarm
False
Indicates Sensor Reading is not
within expected range
Sensor Mode
Min
User configuration to indicate if
Min/Max/Avg is performed for
all temperature Sensors
Sampling Time (Ts)
0.5 sec
Rate at which Signal
conditioning block is executed
Control Type
T/P Type
if controlled by only Temp. or
both Temp. & Pressure
2
Control Block:
Sensor Alarm
False
Same as before
System Alarm
False
Generated by Adaptive Block
indicative some system problem
SSL
0
Steady state loading %
Defrost Status
False
Whether system is in defrost
Pull_Down_Time
0
Time taken to pull down after
defrost
Gain (K)
7
Gain used in PI algorithm
Integral Time (Ti)
100
used in PI
Control Time (Tc)
10 Sec
used in PI
Control Set Pt. (St)
0 F.
used in PI
Operating State
1
What state the machine is
operating at
3
Defrost Control
Defrost Status
False
If defrost status of the case
Defrost Type
External
If the defrost is from external
timer or Internal clock of
controller
Defrost Interval
8 hrs
Time between defrost
Defrost Duration
1 hr
Defrost Duration
Defrost Termination
50 F.
Termination temperature for
Temp.
defrost
At the heart of the controller is control block module 102 . This module is responsible for supplying the variable duty cycle control signal on lead 104 . Module 102 also supplies the compressor ON/OFF signal on lead 106 and an operating state command signal on lead 108 . The compressor ON/OFF signal drives the contactors that supply operating current to the compressor motor. The operating state signal indicates what state the state machine (FIG. 10) is in currently.
The control block module receives inputs from several sources, including temperature and pressure readings from the temperature and pressure sensors previously described. These temperature readings are passed through signal conditioning module 110 , the details of which are shown in the pseudocode Appendix. The control block module also receives a defrost status signal from defrost control module 112 . Defrost control module 112 contains logic to determine when defrost is performed. The present embodiment allows defrost to be controlled either by an external logic signal (supplied through lead 114 ) or by an internal logic signal generated by the defrost control module itself. The choice of whether to use external or internal defrost control logic is user selectable through user input 116 . The internal defrost control uses user-supplied parameters supplied through user input 118 .
The preferred compressor controller in one form is autoconfigurable. The controller includes an optional adaptive tuning module 120 that automatically adjusts the control algorithm parameters (the proportional constant K) based on operating conditions of the system. The adaptive tuning module senses the percent loading (on lead 104 ) and the operating state (on lead 108 ) as well as the measured temperature after signal conditioning (on lead 122 ). Module 120 supplies the adaptive tuning parameters to control block 102 , as illustrated. The current embodiment supplies proportional constant K on lead 124 and SSL parameter on lead 126 , indicative of steady-state loading percent. A system alarm signal on lead 126 alerts the control block module when the system is not responding as expected to changes in the adaptively tuned parameters. The alarm thus signals when there may be a system malfunction or loss of refrigerant charge. The alarm can trigger more sophisticated diagnostic routines, if desired. The compressor controller provides a number of user interface points through which user-supplied settings are input. The defrost type (internal/external) input 116 and the internal defrost parameters on input 118 have already been discussed. A user input 128 allows the user to specify the temperature set point to the adaptive tuning module 120 . The same information is supplied on user input 130 to the control block module 102 . The user can also interact directly with the control block module in a number of ways. User input 132 allows the user to switch the compressor on or off during defrost mode. User input 134 allows the user to specify the initial controller parameters, including the initial proportional constant K. The proportional constant K may thereafter be modified by the adaptive tuning module 120 . User input 136 allows the user to specify the pressure differential (dP) that the system uses as a set point.
In addition to these user inputs, several user inputs are provided for interacting with the signal conditioning module 110 . User input 138 selects the sensor mode of operation for the signal conditioning module. This will be described in more detail below. User input 140 allows the user to specify the sampling time used by the signal conditioning module. User input 142 allows the user to specify whether the controller shall be operated using temperature sensors only (T) or temperature and pressure sensors (T/P).
Referring now to FIG. 8, the signal conditioning module is shown in detail. The inputs (temperature and/or pressure sensors) are shown diagrammatically at 144 . These inputs are processed through analog to digital convertor 146 and then supplied to the control type selector 148 . Temperature readings from the temperature and/or pressure sensors are taken sequentially and supplied serially through the analog to digital convertor. The control type selector codes or stores the data so that pressure and temperature values are properly interpreted.
Digital filtering is then applied to the signal at 150 to remove spurious fluctuations and noise. Next, the data are checked in module 152 to ensure that all readings are within expected sensor range limits. This may be done by converting the digital count data to the corresponding temperature or pressure values and checking these values against the pre-stored sensor range limits. If the readings are not within sensor range an alarm signal is generated for output on output 154 .
Next a data manipulation operation is performed at 156 to supply the temperature and/or pressure data in the form selected by the sensor mode user input 138 . The current embodiment will selectively average the data or determine the minimum or maximum of the data (Min/Max/Avg). The Min/Max/Avg mode can be used to calculate the swing in pressure differential, or a conditioned temperature value. The average mode can be used to supply a conditioned temperature value. These are shown as outputs 158 and 160 , respectively.
FIG. 9 shows the control block module in greater detail. The conditioned temperature or pressure signal is fed to calculation module 162 that calculates the error between the actual temperature or pressure and the set point temperature or pressure. Module 162 also calculates the rate of change in those values.
The control block module is designed to update the operating state of the system on a periodic basis (every T c seconds, nominally once every second). The Find Operating State module 164 performs this update function. The state diagram of FIG. 10 provides the details on how this is performed. Essentially, the operating state advances, from state to state, based on whether there is a sensor alarm (SA) present, whether there is a defrost status signal (DS) present and what the calculated error value is. The Find Operating State module 164 supplies the operating state parameter and the Pull Down Time parameter to the decision logic module 166 .
Referring to FIG. 10, the Find Operating State module 164 advances from state to state as follows. Beginning in the initial state 168 the module advances to the normal operating state 170 after initialization. It remains in that state until certain conditions are met. FIG. 10 shows by label arrows what conditions are required to cycle from the normal operating state 170 to the defrost state 172 ; to the pull down state 174 ; to the sensor alarm pull down state 176 ; to the sensor alarm operating state 178 and to the sensor alarm defrost state 180 .
The decision logic module 166 (FIG. 9) determines the duty cycle of the variable duty cycle signal. This is output on lead 182 , designated % Loading. The decision logic module also generates the compressor ON/OFF signal on lead 184 . The actual decision logic will be described below in connection with FIG. 11 . The decision logic module is form of proportional integral (PI) control that is based on an adaptively calculated cycle time T cyc . This cycle time is calculated by the calculation module 186 based on a calculated error value generated by module 188 . Referring back to FIG. 6, the conditioned pressure differential signal on lead 122 (Cond dP) is supplied to the Calculate Error module 188 (FIG. 9) along with the pressure differential set point value as supplied through user input 136 (FIG. 6 ). The difference between actual and set point pressure differentials is calculated by module 188 and fed to the calculation module 186 . The adaptive cycle time T cyc is a function of the pressure differential error and the operating state as determined by the find operating state module 164 according to the following calculation:
T cyc(new) = T cyc(old) + K c * Error . . . (1)
where:
K c : proportional constant; and
Error: (actual - set point) suction pressure swing.
The presently preferred PI control algorithm implemented by the decision logic module 166 is illustrated in FIG. 11 . The routine begins at step 200 by reading the user supplied parameters K, T i , T c and S t . See FIG. 6 for a description of these user supplied values. The constant K p is calculated as being equal to the initially supplied value K; and the constant K i is calculated as the product of the initially supplied constant K and the ratio T c/ T i .
Next, at step 202 a decision is made whether the absolute value of the error between set point temperature and conditioned temperature (on lead 190 , FIG. 9) is greater than 5° F. If so, the constant K p is set equal to zero in step 204 . If not, the routine simply proceeds to step 206 where a new loading percent value is calculated as described by the equation in step 206 of FIG. 11 . If the load percent is greater than 100 (step 208 ), then the load percent is set equal to 100% at step 210 . If the load percent is not greater than 100% but is less than 0% (step 212 ) the load percent is set equal to 0% at step 214 . If the load percent is between the 0% and 100% limits, the load percent is set equal to the new load percent at step 216 .
The variable duty cycle control signal generated by the controller can take several forms. FIGS. 12 and 13 give two examples. FIG. 12 shows the variable duty cycle signal in which the duty cycle varies, but the frequency remains constant. In FIG. 12, note that the cycle time, indicated by hash marks 220 , are equally spaced. By comparison, FIG. 13 illustrates the variable duty cycle signal wherein the frequency is also varied. In FIG. 13, note that the hash marks 220 are not equally spaced. Rather, the waveform exhibits regions of constant frequency, regions of increasing frequency and regions of decreasing frequency. The variable frequency illustrated in FIG. 13 is the result of the adaptive modulation of the cycle time T cyc .
FIG. 14 graphically shows the benefits that the control system of the invention has in maintaining tighter temperature control and higher suction pressure with improved system efficiency. Note how the temperature curve 222 of the invention exhibits considerably less fluctuation than the corresponding temperature curve 224 of a conventional controller. Similarly, note that the pressure curve 226 of the invention has a baseline well above that of pressure curve 228 of the conventional controller. Also, the peak-to-peak fluctuation in pressure exhibited by the invention (curve 226 ) is much smaller than that of the conventional controller (curve 228 ).
The controller of the invention operates at a rate that is at least four times faster (typically on the order of at least eight times faster) than the thermal time constant of the load. In the presently preferred embodiment the cycle time of the variable duty cycle signal is about eight times shorter than the time constant of the load. By way of non-limiting example, the cycle time of the variable duty cycle signal might be on the order of 10 to 15 seconds, whereas the time constant of the system being cooled might be on the order of 1 to 3 minutes. The thermal time constant of a system being cooled is generally dictated by physical or thermodynamic properties of the system. Although various models can be used to describe the physical or thermodynamic response of a heating or cooling system, the following analysis will demonstrates the principle. Modeling the thermal time constant of the system being cooled.
One can model the temperature change across the evaporator coil of a refrigeration system or heat pump as a first order system, wherein the temperature change may be modeled according to the following equation:
Δ T=ΔT ss [1 -exp (- t/γ )]+Δ T 0 exp (-τ/γ).
where:
ΔT=air temperature change across coil
ΔT ss =steady state air temperature change across coil
ΔT 0 =air temperature change across the coil at time zero
t=time
γ=time constant of coil. The transient capacity of the unit can be obtained by multiplying the above equation by the air mass flow rate (m) and specific heat at constant pressure (C p ) and integrating with respect to time.
Generally, it is the removal of the refrigerant from the evaporator that controls the time required to reach steady state operating condition, and thus the steady state temperature change across the condenser coil. If desired, the system can be modeled using two time constants, one based on the mass of the coil and another based on the time required to get the excess refrigerant from the evaporator into the rest of the system. In addition, it may also be desirable to take into account, as a further time delay, the time lag due to the large physical distance between evaporator and condenser coils in some systems.
The thermal response of the evaporator coil may be modeled by the following equation:
= {fraction (1/2+L )}[( 1 -e υ γ 1 )+(1 -e υ γ 2 )]
where:
=temperature change across coil/steady state temperature change across coil
t=time
γ 1 =time constant based on mass of coil
γ 2 =time constant based on time required to remove excess refrigerant from evaporator
In practice, the controller of the invention cycles at a rate significantly faster than conventional controllers. This is because the conventional controller cycles on and off in direct response to the comparison of actual and set-point temperatures (or pressures). In other words, the conventional controller cycles on when there is demand for cooling, and cycles off when the error between actual and set-point temperature is below a predetermined limit. Thus the on-off cycle of the conventional controller is very highly dependent on the time constant of the system being cooled.
In contrast, the controller of the invention cycles on and off at a rate dictated by calculated values that are not directly tied to the instantaneous relation between actual and set-point temperatures or pressures. Rather, the cycle time is dictated by both the cycle rate and the duty cycle of the variable duty cycle signal supplied by the controller. Notably, the point at which the controller cycles from on to off in each cycle is not necessarily the point at which the demand for cooling has been met, but rather the point dictated by the duty cycle needed to meet the demand.
Adaptive Tuning
The controller Geneva described above can be configured to perform a classic control algorithm, such as a conventional proportional-integral-derivative (PID) control algorithm. In the conventional configuration the user would typically need to set the control parameters through suitable programming. The controller may also be of an adaptive type, described here, to eliminate the need for the user to determine and program the proper control parameters.
Thus, one important advantage of the adaptive controller is its ability to perform adaptive tuning. In general, tuning involves selecting the appropriate control parameters so that the closed loop system is stable over a wide range of operating conditions, responds quickly to reduce the effect of disturbance on the control loop and does not cause excessive wear of mechanical components through continuous cycling. These are often mutually exclusive criteria, and a compromise must generally be made. In FIG. 18 (and also FIG. 6) there are two basic control loops: the refrigeration control loop and the adaptive tuning loop. The refrigeration control loop is administered by control block module 102 ; the adaptive loop is administered by adaptive tuning module 120 . Details of the adaptive tuning module 120 are shown in FIGS. 15, 16 a - 16 c and 17 . The presently preferred adaptive tuning module uses a fuzzy logic control algorithm that will be described in connection with FIGS. 18-20.
Referring to FIG. 15, the adaptive tuning module performs basically three functions. First, it decides whether to perform adaptive tuning. This is handled by module 240 . Second, it gathers the needed parameters for performing adaptive tuning. This is handled by module 242 . Third, it calculates the adaptive gain used by the control loop. This is handled by module 244 .
Module 240 bases the decision on whether to start tuning upon two factors: the current operating state of the system and the control set point. The flowchart of FIG. 16 a shows the steps involved in this decision. Module 242 integrates key parameters needed for the calculations performed by module 244 . Essentially, module 242 inputs the percent loading, the temperature and pressure values and the set point temperature. It outputs the following data: S_ER (the total number of conditioned temperature and pressure data points that are within 0.5 degrees or 1 Psig of the set point value), S_Close (the total number of percent loading data points that goes to zero percent during a given sampling interval, e.g. 30 min.), S 13 Open (the total number of percent loading data points that goes to 100% in the sampling interval) and SSLP (a moving average or rolling average of the percent loading during the sampling interval). Module 242 is responsive to a tuning flag that is set by module 240 . Module 242 performs the integration of these key parameters when signaled to do so by the tuning flag. FIG. 16 b shows the steps involved in performing integration of these key parameters.
Finally, the calculation block takes the data supplied by module 242 and calculates the adaptive gain using the process illustrated in FIG. 16 c.
The adaptive tuning module 120 will cycle through various operating states, depending on the state of a timer. FIG. 17 is a state diagram showing how the presently preferred embodiment will function. Note that the sequence transitions from the initialization mode to either the integration mode or the no tuning mode, depending on whether the tuning flag has been set. Once in the integration mode, the system performs integration until the timer lapses (nominally 30 minutes), whereupon the calculation mode is entered. Once the calculations are completed the timer is reset and the system returns to the initialization mode.
The block diagram of the adaptive scheme is shown in FIG. 18 . There are two basic loops—The first one is the PID control loop 260 that runs every “dt” second and the second is the adaptive loop 262 that runs every “ta” second. When the control system starts, the PID control loop 260 uses a default value of gain (K) to calculate the control output. The adaptive loop 262 , checks the error e(t) 264 every “ta” seconds 266 (preferably less than 0.2 * dt seconds). At module 268 if the absolute value of error, e(t), is less than desired offset (OS), a counter Er 13 new is incremented. The Offset (OS) is the acceptable steady-state error (e.g. for temperature control it may be +/1°F.). This checking process continues for “tsum” seconds 270 (preferably 200 to 500 times dt seconds). After “tsum” seconds 270 , the value Er_new is converted into percentage (Er_new% 272 ). The parameter Er_new% 272 indicates the percentage of sampled e(t) that was within accepted offset (OS) for “tsum” time. In other words, it is a measure of how well the control variable was controlled for past “tsum” seconds. A value of 100% means “tight” control and 0% means “poor” control. Whenever Er_new% is 100%, the gain remains substantially unchanged as it indicates tighter control. However, if Er_new happens to be between 0 and 100%, adaptive fuzzy-logic algorithm module 274 calculates a new gain (K_new 276 ) that is used for next “tsum” seconds by the control algorithm module 278 .
In the preferred embodiment, there is one output and two inputs to the fuzzy-logic algorithm module 274 . The output is the new gain (K_new) calculated using the input, Er_new%, and a variable, Dir, defined as follows:
Dir=Sign [( ER-new % − ER _ old %)*( K — new −K-old )] . . . (2)
where:
Sign stands for the sign (+ve, −ve or zero) of the term inside the bracket;
Er_new% is the percentage of e(t) that is within the offset for past “tsum” seconds;
Er_old% is the value of Er 13 new% in “(tsum-1)” iteration;
K_new is the gain used in “tsum” time; and
K_old is the gain in (tsum-1) time.
For example, suppose the controller starts at 0 seconds with a default value of K=10 and, ta=1 seconds, tsum=1000 seconds and OS=1. Suppose 600 e(t) data out of a possible 1000 data was within the offset. Therefore, after 1000 sec, Er_new%=60 (i.e., 600/1000*100), K_new=10. Er_old% and K_old is set to zero when the adaptive fuzzy-logic algorithm module 274 is used the first time. Plugging these numbers in Eq.(2) gives the sign of the variable “Dir” as positive. Accordingly, the inputs to the adaptive fuzzy-logic module 274 for the first iteration are respectively, Er_new%=60 and Dir=+ve.
The next step is to perform fuzzification of these inputs into fuzzy inputs by using membership functions.
Fuzzification
A membership function is a mapping between the universe of discourse (x-axis) and the grade space (y-axis). The universe of discourse is the range of possible values for the inputs or outputs. For ER 13 new% it is preferably from 0 to 100. The value in the grade space typically ranges from 0 to 1 and is called a fuzzy input, truth value, or a degree of membership. FIG. 19 shows graph 300 which contains the membership functions for the input, Er_new%. Er_new% is divided into three linguistic variables—LARGE ( 304 ), MEDIUM ( 306 ) AND SMALL ( 308 ). For Er_new%=60, the fuzzy inputs (or degree of membership function) are—0.25 of LARGE and 0.75 of MEDIUM. The input variable “Dir” is well defined (+ve, −ve or zero) and thus does not require a membership function in this application. The next step is to create the “Truth Table” or Rule Evaluation.
Rule Evaluation
Rule evaluation takes the fuzzy inputs from the fuzzification step and the rules from the knowledge base and calculates fuzzy outputs. FIG. 20 shows the rules as truth table. For the first column and first row, the rule is: “IF ER—new% is LARGE AND Dir is NEGATIVE THEN New Gain is NO CHANGE (NC)” (i.e. if the percentage of e(t) data that is within the offset (OS) for last “tsum” seconds is LARGE and the direction (DIR) is NEGATIVE/ZERO then do not change the existing K value (NO CHANGE)).
In the example, because ER_new% has fuzzy inputs LARGE (0.25) AND MEDIUM (0.75) with POSITIVE Dir, the rules that will be used are:
IF ER_new% is LARGE (0.25) AND Dir is POSITIVE THEN New Gain is NO CHANGE (NC=1)
IF ER_new% is MEDIUM (0.75) AND Dir is POSITIVE THEN New Gain is POSITIVE SMALL CHANGE (PSC=1.2)
Defuzzification
Finally, the defuzzification process converts the fuzzy outputs from the rule evaluation step into the final output by using Graph 310 of FIG. 21 . Graph 310 , uses the following labels =“NBC” for negative big change; “NSC” for negative small change; “NC” for no change; “PSC” for positive small change; and PBC for positive big change. The Center of Gravity or centroid method is used in the preferred embodiment for defuzzification. The output membership function for change in gain is shown in FIG. 21 .
The centroid (the Fuzzy-Logic Output) is calculated as: Centroid = K_new · [ ∑ μ ( x ) all . x · x ∑ μ ( x ) all . x ]
Where:
(x) is the fuzzy output value for universe of discourse value x.
In our example, the output (K_new) becomes Output = 10 · [ 0.25 ( 1 ) + 0.75 ( 1.2 ) 0.25 + 0.75 ] ≈ 11.50
Once the three steps of fuzzification, rule evaluation, and defuzzification are finished and the output has been calculated, the process is repeated again for new set of Er_new%.
In the above example, after the first 1000 sec, the adaptive algorithm calculates a new gain of K_new=1 1.50. This new gain is used for the next 1000 sec (i.e. from t=1000 to 2000 sec in real time) by the PID control loop. At t=1001 sec, counter Er_new is set to zero to perform counting for the next 1000 seconds. At the end of another 1000 seconds (ie. at t=2000 seconds), Er_new% is calculated again.
Suppose this time, Er_new% happens to be 25. This means, by changing K from 10 to 11.5, the control became worse. Therefore, it would be better to change gain in the other direction i.e. decrease the gain rather than increase. Thus, at t=2000 sec. Er_new%=25, Er_old%=60 (previous value of Er_new%), K_new=11.5 and K_old=10 (previous value of K). Applying Eq.(2), a negative “Dir” is obtained. With Er_new% of 25 and Dir=Negative, the fuzzy-logic calculation is performed again to calculate a new gain for the next 1000 seconds. The new value of gain is K_new=7.76 and is used from t=2000 to 3000 seconds by the PID Loop.
Suppose for the third iteration i.e. from t=2000 to 3000 seconds, Er_new% comes out to be 95% (which represents tighter control). Performing the same fuzzy-logic operation gives the same value of K_new, and the gain remains unchanged until Er_new% again degrades.
Exemplary Applications
Both pulse width modulated (PWM) Compressors and electronic stepper regulator (ESR) Valves can be used to control evaporator temperature/pressure or evaporator cooling fluid (air or water) temperature. The former controls by modulating the refrigerant flow and the latter restricts the suction side to control the flow. Referring back to FIG. 18, the block diagram of the control system for such an actuator working in a refrigeration system 279 is shown. In FIG. 18 one and preferably up to four temperatures of evaporator cooling fluid or one evaporator suction pressure (generally shown at 282 ) is sampled every dt seconds. A sampling time of dt=10 seconds was found to be optimum for both the applications. After processing by the analog to digital module 284 , the sampled signal is then reduced to one number by taking the average or the minimum or the maximum of the four temperatures depending on the system configuration or the user preference at module 286 . Typically, in a single actuator (PWM/ESR) systems where the complete evaporator coil goes into defrost at one time, averaging of control signal is preferred. In a multiple evaporator-single actuator system where defrost of evaporator coils does not occur at the same time, minimum is the preferred mode. The value obtained after avg/min/max is called conditioned signal. At comparison module 288 this is compared with the desired set point to calculate the error, e(t).
The control algorithm used in the loop is a Proportion-Integral (PI) control technique (PID). The PI algorithm calculates the valve position (0-100%) in case of ESR or calculates the percentage loading (O to 100%) in case of PWM compressor. A typical integral reset time, Ti, for both the actuators is 60 seconds. The gain is tuned adaptively by the adaptive loop. The adaptive algorithm is turned off in the preferred embodiment whenever: the system is in defrost; is going through pull-down; there a big set point change; sensor failure has been detected; or any other system failure is detected.
Consequently, the adaptive algorithm is typically used when the system is working under normal mode. The time “ta” preferably used is about 1 seconds and “tsum” is about 1800 seconds (30 minutes).
Diagnostics Related to PWM Compressor/ESR Valves
Referring to FIG. 22, a discharge cooling fluid temperature sensor 312 (Ta), an evaporator coil inlet temperature sensor 314 (Ti) and an evaporator coil exit temperature sensor 316 (To) can provide diagnostic features for the evaporator control using PWM/ESR. The Inlet temperature sensor 314 can be anywhere in evaporator coil 318 . However, the preferred location is about one third of the total evaporator length from the evaporator coil distributor 320 .
Using these three temperature sensors, system learning can be performed that can be used for diagnostics. For example, diagnostics can be performed for ESR/PWM when it is used in a single evaporator along with an expansion valve. In this example, the following variables are tracked every “tsum” second in the adaptive loop. The variables can be integrated just after ER_new integration is done in the adaptive loop.
N-Close: Number of times Valve position /PWM loading was 0%.
N-Open: Number of times Valve position/PWM loading was 100%.
MAVP: The moving average of the Valve position /PWM loading for “tsum”seconds.
SSLP: The steady-state Valve position /PWM loading is set equal to MAVP if for the “tsum”duration ER_new% is greater than 50%.
dT: Moving average of the difference between Ta and Ti (Ta-Ti).
SH: Moving average of the difference between To and Ti (To-Ti) in the said duration. This is approximately the evaporator superheat.
N_FL: Number of times To was less than Ti during the said duration i.e. “tsum” seconds. This number will indicate how much the expansion valve is flooding the evaporator.
In addition, Pull-down time after defrost, tpd, is also learnt. Based on these variables, the following diagnostics are performed: temperature sensor failure; degraded expansion valve; degraded ESR valve/PWM Compressor; oversized ESR/PWM; undersized ESR/PWM; and no air flow.
Temperature Sensor Failure
Failures of temperature sensors are detected by checking whether the temperature reading falls within the expected range. If PWM/ESR is controlled using Ta as the control variable, then when it fails, the control is done as follows. The above said actuator is controlled based on Ti, or the Ta values are estimated using the learned dT (i.e., add dT to Ti value to estimate Ta). During pull down, the valve/PWM can be set to full-open/load for the learned pull-down time (tpd). If Ti also fails at the same time or is not available, the actuator is opened 100% during pull down time and then set to steady-state loading percent (SSLP) after pull-down-time. An alarm is sent to the supervisor upon such a condition.
Degraded Expansion Valve
If an expansion valve sticks or is off-tuned or is undersized/oversized, the following combinations of the tracked variable can be used to diagnose such problems. N_FL >50% and ER_new% >10% indicate the expansion valve is stuck open or is off-tuned or may be even oversized and thus is flooding the evaporator coil. An alarm is sent upon such a condition. Moreover, SH>20 and N_FL=0% indicate an off-tuned expansion valve or an undersized valve or the valve is stuck closed.
Degraded ESR Valve/PWM Compressor
A degraded ESR is one that misses steps or is stuck. A degraded PWM Compressor is one whose solenoid is stuck closed or stuck open. These problems are detected in a configuration where defrost is performed by setting the ESR/PWM to 0%. The problem is detected as follows.
If ER_new% >50% before defrost and during defrost Ti <32F and SH >5 F., then the valve is determined to be missing steps. Accordingly, the valve is closed by another 100% and if Ti and SH remain the same then this is highly indicative that the valve is stuck.
If ER_new%=0 and N_Close is 100% and Ti <32F and SH >5F. then PWM/ESR is determined to be stuck open. If ER_new%=0 and N_Open is 100% and Ti >32 F and SH >5 F. then PWM/ESR is determined to be stuck closed.
Over-sized ESR/PWM
If N_Close >90% and 30% <ER_new% <100%, then an alarm is sent for oversized valve/PWM Compressor.
Under-sized ESR/PWM
If N_Open >90% and ER_new% =0 and SH >5, then an alarm is sent for undersized valve/PWM Compressor.
No Air Flow
If N_Open =100%, ER_new%=0, SH <5 F. and Ti <25 F. and N_FL>50%, then either the air is blocked or the fans are not working properly.
Additionally, these diagnostic strategies can also be applied to an electronic expansion valve controller.
The embodiments which have been set forth above were for the purpose of illustration and were not intended to limit the invention. It will be appreciated by those skilled in the art that various changes and modifications may be made to the embodiments discussed in this specification without departing from the spirit and scope of the invention as defined by the appended claims.
Appendix
Pseudocode for performing signal conditioning Repeat the following every Ts Seconds: Read User Inputs:
-Sampling Time (Ts)
-Control Type (P or T)
-Sensor Mode (Avg/Min/Max) Perform Analog to Digital Conversion (ADC)
-on all (four) Temp. Sensor Channels
output data as Counts Digitally Filter Counts
-Ynew =0.75 * Yold +0.25 * Counts
-output data as Filtered Counts Convert Filtered Counts to Deg F. Test if at least one Sensor is within normal operating limits
-e.g. within −40 and +90F.
If none are within limit--Set Sensor Alarm to TRUE
Else Perform Avg/Min/Max operation based on Sensor Mode If Control Type is NOT a T/P Control Type
Then End Signal Conditioning Routine (until next Ts cycle)
Else (Control Type is T/P) Do the Following: Perform ADC on Pressure Sensor Channel
-output data as Counts Digitally Filter Counts
-Ynew =0.75 * Yold +0.25 * Counts
-output data as Filtered Counts Convert Filtered Counts to Psig Test if pressure Sensor is within normal operating limits
-e.g. within 0 and +200
If not within limit:
Set dP=dP Set Pt.
Else:
Calculate dP=Pmax-Pmin Set Sensor Alarm to Conditioned T/dP End Signal Conditioning Routine (until next Ts cycle) | A diagnostic system includes a controller adapted for coupling to a compressor or electronic stepper regulator valve. The controller produces a variable duty cycle control signal to adjust the capacity of the compressor or valve position of the electronic stepper regulator valve as a function of demand for cooling. The diagnostic system further includes a diagnostic module coupled to the controller for monitoring and comparing the duty cycle with at least one predetermined fault value indicative of a system fault condition and an alert module responsive to the diagnostic module for issuing an alert signal when the duty cycle bears a predetermined relationship to the fault value. | 5 |
This Application claims priority to U.S. provisional patent application Ser. No. 60/631,655 filed Nov. 30, 2004 entitled “Broad Energy-Range Ribbon Ion Beam Collimation Using a Variable-Gradient Dipole” the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
The disclosed methods and apparatus relate generally to the construction and use of magnetic focusing and correction elements for modifying the intensity distribution of ions within ribbon beams and more particularly to the introduction of magnetic-field modification coils that can be added to uniform and non-uniform field magnetic dipole deflectors for providing auxiliary variable magnetic field focusing and the reduction of the effects of space-charge forces.
BACKGROUND OF THE INVENTION
The process of ion implantation is a critical manufacturing element used by the semiconductor industry. Implantation makes possible precise modification of the electrical properties of well-defined regions of a semiconducting work-piece by introducing selected impurity atoms, one by one, with a velocity such that they penetrate the surface layers and come to rest at a specified depth below the surface. The characteristics that make implantation such a useful processing procedure are threefold: First, the concentration of the introduced charged dopant atoms can be accurately measured by straight-forward integration of the incoming electrical charge delivered to the work-piece; secondly, the patterning of dopant atoms can be precisely defined using photo-resist masks; finally, the fabrication of layered structures becomes possible by varying the ion energy.
The ion species used for silicon implantation include arsenic, phosphorus, germanium, boron and hydrogen. The required implant energies range from below 1 keV (kilo-electron volts) to several hundred keV. Ion currents used range from microamperes to multi-milliamperes. Projecting to the future, demands are for greater productivity (elevated ion intensities); implantation at energies well below 1 keV; improved precision of uniformity and ion-incidence angle-control at the wafer.
During the last decade there has been an industry shift towards the use of D.C. ribbon-beams. This technology arranges that dopant ions arrive at a semiconducting wafer as part of a uniform-intensity beam that is organized into a long, small-height stripe that simultaneously implants uniformly the whole width of a semiconductor wafer. This geometry makes possible uniform implantation of a wafer during a single pass under the ribbon beam. The advantages of ribbon beam technology are substantial: (1) Batch implantation of multiple wafers and the use of large spinning discs is no longer necessary as the energy density at the wafer is low. (2) Wafers move slowly along a single linear path, avoiding issues of damage to delicate circuit components related to collision of heavy particles that arrive at the wafer surface.
U.S. Pat. No. 5,350,926 entitled “High current ribbon beam ion implanter” and U.S. Pat. No. 5,834,786, entitled “Compact high current broad beam ion implanter”, both issued to N. White et al., present aspects of ribbon beam technology. Implanters, generally designed according to these principles, are manufactured by Varian Semiconductor Equipment Associates of Gloucester, Mass.
Referring to FIG. 2 it can be seen that in a typical ribbon beam tool a first magnetic deflector directs wanted-mass ions through a mass-resolving aperture where unwanted species from the ion source are rejected. Downstream of this aperture the emitted fan-shaped beam, now comprising only wanted ions, is parallelized by a second magnet and transformed to the ribbon length needed for implanting a specific wafer diameter. A deceleration system beyond the mass rejection aperture is included to reduce the energy of ions arriving at the wafer; the purpose being to allow the use of ion source extraction energies that are best suited for efficient source extraction and high transmission efficiency through the mass-resolving aperture.
In a ribbon beam implanter the control of space charge is a central issue. These effects are manifest mainly downstream of the deceleration region and are particularly troubling in the region of the second magnetic deflector where the presence of a magnetic field makes it difficult for the beam potential to trap the necessary neutralizing electrons: Captured electrons have difficulty moving across the magnetic field lines but can easily escape to the poles unless some form of electron trapping is present. Also, there is evidence that electron temperatures grow within magnetic fields further increasing electron losses. Thus, as a consequence of inadequate neutralization, the boundaries of the beam tend to expand allowing ions to be intercepted at the magnet poles or at the walls of the vacuum chamber.
Space charge problems have been recognized since the days of the Manhatten Project's development of the Uranium Bomb. An historical review, including the impact of space charge on that project, has been written by William E. Parkins and published on page 45 of the March 2005 edition of the magazine Physics Today. Further background for these processes can be found in a book entitled ‘Large Ion Beams’ written by A. T. Forrester and published by John Wiley and Sons in 1988. The above referenced book presents data and calculations on pages 139 to 153 concerning the manner in which ions ‘peel away’ from the outside of a drifting low-energy ion beam. In addition, data is included concerning the difficulties of achieving space charge neutralization within magnetic fields and the manner in which the ion-beam potential is raised as it passes through a magnetic field. Other authors who discuss space charge effects include V. Dudnikov in U.S. Pat. No. 6,329,650 and F. Sinclair, et al. in U.S. Pat. No. 5,814,819.
The solution which provides at least partial neutralization of the effects of space-charge expansion depends upon the fact that the same electric field distribution that causes the boundaries of a positive ion beam to expand because of space-charge effects is also an electric field distribution that attracts negative ions or electrons towards the center of an ion beam. However, even when created within the beam potential itself, these electrons tend to concentrate near the center of the positive ion beam leaving peripheral regions somewhat short of electrons, causing a tendency for ions to ‘peel-away’ from the outer edges of a ribbon beam. This peeling effect will be accentuated by the fields generated between image charges at the surface of a narrow vacuum envelope and non-neutralized positive ions within the beam itself.
In the energy range above ˜15 keV interactions between fast beam ions and residual gas molecules usually provides sufficient secondary electrons that the space-charge density of the ion beam is largely neutralized. However, magnets whose focusing properties are satisfactory for deflecting ion beams having energy above ˜15 keV may not provide acceptable transmission in the energy region below 5 keV, due to the above space charge effects. Additional magnetic field components may be needed for compensating residual space charge effects and for improving beam transmission through magnetic fields, the central theme of the present patent disclosure.
SUMMARY
Historically, the design of most existing commercial implanters includes magnetic deflectors that have predetermined ion focusing properties. These properties are established by the shapes of the coils and the magnet poles and generally can only be adjusted in a minor way, if at all, during implanter operation. Thus, when space-charge forces cause an expansion of the outer beam boundaries and consequent ion interception at the vacuum chamber or magnetic poles there is no procedure for introducing compensating compression forces.
The present patent disclosure describes a method and apparatus for superimposing variable magnetic focusing fields onto a uniform or indexed dipole deflecting field. These additions, thought of as perturbations to the main dipole field, are designed to introduce compression effects that provide approximate compensation for out-of-the-median-plane space charge expansion forces present in large-width ribbon beams. (Increases in ribbon length can be adjusted using other procedures). It will be recognized by those familiar with the art that, provided saturation does not occur, the magnetic fields necessary to produce supplemental focusing can be adjusted with little effect on the underlying dipole contribution allowing such perturbing fields to be increased or decreased at will and be turned on only when required for low-energy operation.
It has previously been confirmed that such active focusing elements can be useful during magnetic mass analysis when compensation is needed for combating the disruptive effects of space charge. In a patent disclosure by V. M. Benveniste in U.S. Pat. No. 5,554,827 entitled “Method and Apparatus for Ion Beam Formation in an Ion Implanter” an apparatus for filtering unwanted particles from a narrow ion beam compensates space-charge effects by adding adjustable quadrupole fields to a basic dipole field. Space charge expansion is compensated for circular cross-section ion beams by superimposing blocks of independently adjustable magnetic quadrupole fields along the centerline of the deflected ion beam locus, defined by the dipole field needed for conventional mass separation. However, when the transverse dimensions of the ion beam become comparable to the radius of curvature in the dipole field, as is the case for a broad ribbon beam, the above quadrupole field method does not have desirable linear optical transport properties.
Both positive and negative quadrupole and sextupole focusing fields have been widely used as beam transport elements. Techniques for introducing selected multipole field components into a single beam transport component has been described in an article entitled “The design of magnets with non-dipole field components”, authored by N. White et al. and published in the journal Nuclear Instruments and Methods, volume A258, (1987), pages 437-442. A supplementary publication authored by Harald A. Enge entitled ‘Deflecting Magnets’, found on pages 203-264 of Volume II of the book entitled ‘Focusing of Charged Particles’, edited by A. Septier, and published by Academic Press (1967), describes the optical properties of indexed magnets.
The introduction of variable positive focusing in the y-direction of an indexed collimating magnet is the objective of the present invention. As background the above referenced article by Enge points out that if the deflecting magnetic field at the median plane, B(r), has the form
B ( r )= B 0 ( r/R 0 ) −n
the optical transfer characteristics are identical to those of linear optical lenses. [Here, B 0 is the field at the central trajectory (at radius R 0 ), r is the radius where the field is measured and n is the index of the field-gradient]. When n=0 the deflecting magnetic field is uniform; when n is made negative, defocusing is introduced to trajectories traveling in the median plane and positive focusing is introduced to trajectories traveling in planes at right angles to the median plane (the y-direction); when n is positive focusing is reversed.
In the present invention, which is primarily related to efficient collimation of large width ribbon beams, pole-face windings have been introduced to modify the basic dipole field index and add additional variable positive focusing in the y-direction. The pole-face windings consist of a multiplicity of different area coils, (ampere-turn generators), that are mounted on or recessed into the pole surfaces. In the preferred embodiment the shape of an individual coil is defined by a single conductor oriented approximately along the ion-beam path with its ends being coupled to radial conductors that extend beyond the inside curved boundaries of the magnetic pole. Here, the radial conductors are connected to a suitable power source or connected in series or parallel with other coils. If necessary, individual coils may consist of several turns connected in series or parallel to increase ampere turns and thus the magnetic field gradient developed across the pole.
The key to introducing a supplementary field gradient is that the ensemble of subsidiary windings do not completely overlap each other but rather are wound as a stepped structure across the whole width of the magnet pole with the maximum coil overlap and thus the additional focusing magnetic field being a maximum on the inside of the curve and a minimum at the outside. The spacing between windings establishes the local shape of the n-value gradient which those skilled in the art will recognize does not have to be identical to that of the underlying dipole index. In this manner, the uniform magnetostatic potential difference between the poles of the underlying dipole field is modified to become a distribution that varies as a function of the radius, producing a variable field distribution that enhances or subtracts from the in-built focusing of the underlying indexed-dipole collimation magnet.
While an aberration-corrected single-index magnet is most appropriate design for the collimator magnet shown in FIG. 2 it will be recognized by those skilled in the art that by arranging multiple regions along the ion path where the n value of a deflection magnet changes at least once from positive to negative, or vice versa, overall positive focusing can be introduced that will simultaneously provide positive focusing in both the median plane and the direction at right angles.
BRIEF DESCRIPTION OF THE DRAWINGS
For better understanding of the present invention, reference is made to the accompanying drawings which are incorporated herein by reference:
FIG. 1 A Beam Coordinate System
FIG. 2 Optical Schematic for a Simplified Ribbon Beam Implanter.
FIG. 3 Tapered Gap Focusing
FIG. 4 Supplemental Field Generation
FIG. 5 Single Supplemental Field Distribution
FIG. 6 Dual Supplemental Magnetic Field Generation
FIG. 7 Pole-Face Windings
FIG. 8 A Doublet Collimator
FIG. 9 A Triplet Collimator
DETAILED DESCRIPTION
FIG. 1 illustrates the beam coordinate system used in the following discussions. The X-axis is always aligned with the front surface of the ribbon-beam, 120 , and along the beam's long axis. The Z-axis is tangential to the central trajectory of the ribbon beam, 110 , and is always coincident with the central trajectory. At each point along the beam path the orthogonal Cartesian Y-axis also lies in the surface, 120 , and along the ribbon beam's narrow dimension.
FIG. 2 presents a schematic of the preferred embodiment of a D.C. ribbon-beam implanter. It can be seen that there are two magnetic deflections along the beam path, 201 and 202 . The first magnetic deflection, 201 , directs wanted-mass ions leaving the ion source, 220 , through a mass-resolving aperture, 203 . Unwanted species, 210 , are rejected at the walls of the vacuum chamber or at the mass-resolving aperture, 203 . The selected ions, 204 , are directed into the succeeding optical elements, 211 and 202 , comprising a deceleration stage, 211 , and a collimating magnet, 202 . The collimating magnet, 202 , rejects high-energy neutral particles generated in the deceleration gap. It also provides the positive focusing needed for transforming the diverging ion beam passing through the mass selection slit, 203 , to substantially parallel trajectories at the wafer implantation location, 206 .
Referring again to FIG. 2 it can be seen that the wanted ions leaving the source pass through the opening between the jaws of the mass rejection slits, 203 , to form a well-defined source of wanted ions from which almost all of the background particles, 210 , have been removed. The opening between the mass rejection slits, 203 , is shaped to match the emittance of the ion beam; namely, a narrow cross section of the beam in the horizontal dispersive plane and a tall aperture at right angles in the non-dispersive direction. The transmitted beam through this slit has the form of a uniform fan when viewed from above the x-z plane. The fan of ions, 204 , subtends an angle at the mass slit necessary to form the desired ribbon-beam length at the wafer plane, 206 . In the out-of-plane direction the trajectories of ions transmitted through the aperture 203 , are substantially parallel to the x-z plane. On leaving the mass resolving slit, 203 , the ions drift for a short distance and then enter the deceleration region, 211 . Here, ions are retarded to the energy required for implantation at the wafer, 206 . An important function of this deceleration stage, 211 , is to allow extraction of ions from the ion source at energies that are best suited for efficient ion-source extraction and high transmission efficiency through the mass resolving slit.
Referring again to FIG. 2 it can be seen that the ions leaving the deceleration region, 211 , are directed into the collimator magnet, 202 . Here, the positive optical strength of this magnetic deflector, 202 , transforms the fan-shaped beam to a group of parallel trajectories required for implantation at the wafer, 206 .
FIG. 3 shows how focusing that can be introduced in a deflection magnet if the radial gap between the poles, 301 , 302 , is tapered radially. It can be seen that, because the pole surface represents an equipotential, in the z-direction (out of the page) the field acting on the trajectory 310 , is less than that acting on the trajectory 311 , causing the deflection radius of curvature to be greater for trajectory 310 than for 311 . Thus, focusing in the x-direction is weakened, compared to that observed in a uniform field magnet; negative focusing has been introduced to the median plane trajectories. In the vertical direction it can be seen that, because of symmetry, the magnetic field lines, B , must cross the median plane, 304 , normally. Away from this plane, in the y-direction, an x-component of the deflecting field develops with this x-component increasing linearly with the y-distance away from the median plane, 304 , changing sign at the median plane. The effect is the production of a focusing field component in the direction along the dipole field lines that increases linearly with distance from the median plane. It can be seen that as positive focusing in the x-z plane is reduced, positive focusing in the y,z plane increases correspondingly.
Referring again to FIG. 3 , it should be emphasized that ability to actively vary the index of the magnetic deflection field—the shape of the tapered opening between the poles—can be used to provide a compensating compressive effect upon ion beams that are expanding towards the poles and losing ions there because of the effects of space-charge forces.
It will be recognized by those skilled in the art that by arranging that, along the ion path of a deflection magnet, the field index of the tapered pole gap changes at least once from positive to negative or negative to positive, positive focusing can be introduced in both the median plane and the direction at right angles.
FIG. 4 shows an embodiment of the principles used to produce the field distribution needed for introducing variable focusing of a ribbon beam and the beam compression needed to minimize space-charge effects. It can be seen that a series of ever decreasing-area coils, 401 , 402 , 403 , 404 , etc, each enclosed by a conductor, or a plurality of conductors having the same shape, are superimposed layer by layer, so that the ampere turns generated by each layer add together in those regions where layers overlap to produce a perturbing field. Arrangements of such overlapping coils can be used to modify the base dipole-field index and add variable positive focusing in the y-direction.
The key to introducing such supplementary field gradients is that the ensemble of subsidiary windings do not completely overlap each other but rather are wound as a stepped structure across the whole width of the magnet pole. In one embodiment the overlapping coils will have a maximum number sections overlapping on the inside of the ion beam deflection curve and a minimum number of sections along the outside of the curve.
The preferred embodiment involves the use of the above field generating technology but extends the concept in-as-much as the zero perturbing field regions are present along the ribbon-beam center-line, instead of at one edge of the ribbon beam as described above. Using this geometry, two supplementary field maxima are generated: One is on the inside and the other on the outside of the ribbon beam. It should be emphasized that the current direction through coils on the two sides are such that the sign of the supplementary magnetic field perturbations are positive on one side of the central trajectory and negative on the other. These two maxima can be controlled independently to introduce higher order deflections. Those skilled in the art will recognize that even higher order contributions can be introduced by individually varying the current passing through individual loops.
Referring again to FIG. 4 it can be seen that an increasing field perturbation is typically defined by a group of single conductors, 410 , 411 , 412 , 413 etc. that are approximately oriented along the direction of the ion-beam. The ends of each of these conductors are coupled to radial wires, 420 , that extend across the width of the underlying magnetic pole to regions outside the curved boundaries of the magnetic pole. Here, the radial conductors are connected to a suitable power source or connected in series or parallel with other coils. In the preferred embodiment the conductor 410 would be close to the central trajectory. Referring again to FIG. 4 it can be seen that a growing magnetic B -field pattern is created for equal loop currents when the spacing of the conductors 410 , 411 , 412 and 413 etc. increases linearly as a function of radial location. However, it should be noted that non-uniform spacing can lead to the introduction of sextupole and octopole contributions. It should also be noted that it is possible to power the above element individually or in groups making possible active introduction of higher order corrections. It can be seen that the uniform magnetostatic potential difference between the poles of the underlying dipole field is thus modified by the supplementary coils which produce a distribution that can be varied as a function of the radius. Such changes enhance or subtract from the in-built focusing index of the underlying dipole magnet.
FIG. 5 shows schematically the method for generating supplemental magnetic fields that complements an underlying uniform dipole field. As an example, the underlying field for a uniform magnetic field would have the value shown by the dotted line, 503 , across the width of the pole. The stacking of the coils is illustrated schematically as the layered pattern, 501 , to produce the total field vectors across the pole, 511 . It can also be seen that in its simplest embodiment the auxiliary fields introduce an additional component to the dipole field at the center of the pole, 506 , having the differential increase, 510 .
FIG. 6 shows a second embodiment. It will be seen that the stacked field generators, described previously in FIG. 4 , are divided into two section which are placed end-to-end with zero height close to the central trajectory. The stacked generators, 601 , have currents circulating in a direction that enhances the field, 603 , developed by an underlying uniform-field dipole magnet. The second set, 602 , are shown schematically below the magnetic-field zero line to indicate that the currents through these coils circulate in the opposite direction to that of the coils, 601 , producing a further supplementary field pattern that reduces the underlying dipole field.
FIG. 7 shows the preferred embodiment as applied to wafer implantation, 703 , 206 . Variable supplementary focusing fields are added to the fields generated by an underlying indexed or uniform dipole magnet, 202 , 705 . It can be seen that the auxiliary magnetic-field generating coils are symmetrically disposed about the central beam trajectory, 702 , and consist of a number of circumferential conductors mounted directly on the magnetic poles, 705 , or recessed into shallow slots machined into these poles. The conductors located in trenches, 710 , are connected to the power sources, 701 , 704 by suitable radial current feeds located along the sides of the magnet pole, as shown. Those skilled in the art will recognize that it may be necessary to hide these conductors in a manner that arranges that residual fields be shielded from the beam. Through each of these coils, which may consist of several turns, currents circulate in the directions shown by the arrows, 711 .
FIG. 8 shows the manner in which variable focusing fields can add to the uniform dipole fields of a collimator magnet. The technique employs a number of independent surface coils that are mounted directly onto the magnetic poles 705 , or are recessed in shallow slots 710 machined into the poles 705 . The auxiliary field distribution is produced by superimposing the changing magnetostatic potentials produced by a number of successively smaller overlapping coils superimposed onto the fundamental dipole field. Around each of these coils, which may consist of several turns, currents 740 , 741 circulate as shown, producing the wanted auxiliary fields.
It can be seen that the largest coil extends between the pole edge and the distant pole edge. It can be seen that each of the auxiliary coils has a similar construction consisting of equi-spaced circumferential conductors that connect the two radial current feed conductors on both sides of each sub assembly 730 , 731 . The remaining connecting leg for each coil, which may include the current supply 721 , 722 , is located beyond the pole edge. For the auxiliary coils to produce additional positive focusing in the median plane of a single element 730 or 731 , the auxiliary field in such an element must increase with radius and, thus, the common current return circuits is preferably located beyond the maximum radius, R max . For increases in divergent focusing in the median plane, the reverse holds. In this case, it can be seen that the connecting circumferential legs are on the inside of the minimum pole radius R min .
Referring again to FIG. 8 , it can be seen that both types of focusing field are represented in each of the sections 730 and 731 . It is well known to those skilled in the art that by arranging along the beam trajectory such a sequence of positive and negative field gradients, an ion optical array can be formed that can produce stigmatic focusing in both median and vertical planes.
FIG. 9 shows the pattern of pole channels on the surface of a 70-degree deflection collimator magnet using a three-element focusing collimator—negative-positive-negative in the median plane. The advantage of adding the extra section is that the focal strengths can be equal in both x and y directions. | A method and apparatus satisfying growing demands for improving the intensity of implanting ions that impact a semiconductor wafer as it passes under an ion beam. The method and apparatus are directed to the design and combination together of novel magnetic ion-optical transport elements for implantation purposes for combating the disruptive effects of ion-beam induced space-charge forces. The design of the novel optical elements makes possible: (1) Focusing of a ribbon ion beam as the beam passes through uniform or non-uniform magnetic fields; (2) Reduction of the losses of ions comprising a d.c. ribbon beam to the magnetic poles when a ribbon beam is deflected by a magnetic field. | 7 |
BACKGROUND
1. Technical Field
The present disclosure relates generally to a salad making device, and more particularly to an integrated device for making fruit or vegetable salad, in which the fruits or vegetables contained can also be cleaned and cut.
2. Description of Related Art
When people host guests at home, they often provide the guests with fruits such as apples or pears after a meal. However, a whole apple or a whole pear is too much for one just after finishing the meal. Further, having a single kind of fruit, such as an apple or a pear, may not be as appealing to the guests as having different kinds of fruit. Therefore, a vegetable and/or fruit salad is usually provided instead of the single fruit.
Generally, a process of making salad includes cleaning the fruits or vegetables; cutting the fruits or vegetables into different shapes such as a cube, a slice, or a shred; putting the cut fruits or vegetables into a container and adding salad dressing; and stirring the mix of the salad dressing and the cut fruit or vegetables. Such process utilizing a lot of instruments such as containers, knives/cleavers, and utensils which are also needed to be cleaned after making the salad, is so time-consuming and troublesome.
SUMMARY
An object of the present disclosure is to provide an integrated cleaning and cutting device for making salad, in which the salad material can be cleaned, cut and stored within the single device, thus reducing the numbers of vessels and instruments used during the making of salad and simplifying the process of making salad.
The integrated cleaning and cutting device provided in the present disclosure includes a case, a cover covering the case, a basket received in the case, with a plurality of palings formed thereon, and a basket shelter, such as a wave shape basket shelter, mounted on the basket, wherein a drive mechanism is coupled to the cover for driving the basket to rotate in the case, and a cutting mechanism is fitted in the cover adapted for cutting salad material, which comprises a blanking hole communicated with the basket in the case.
In the integrated cleaning and cutting device, the drive mechanism comprises a shaft inserted in a middle of the cover, with the bottom end thereof affixed to the middle of the basket shelter, and the top end thereof rotationally engaged with a wheel embedded in a top surface of the cover, the wheel having a handle to operate the wheel to rotate.
In one of the embodiments of the integrated cleaning and cutting device, a plurality of planet gears are formed on side walls of the wheel, and a plurality of gears are formed on the top end of the shaft such that the plurality of gears of the shaft engages with the planet gears of the wheel to form a planet gear mechanism between the wheel and the shaft.
In the integrated cleaning and cutting device, a brake block is embedded in the top surface of the cover and located at a lateral side of the wheel for decelerating the rotating of the wheel.
In the integrated cleaning and cutting device, a plurality of orientation grooves are defined in the edges of the basket shelter for engagingly receiving the basket.
In the integrated cleaning and cutting device, an opening is defined in the cover, and the cutting mechanism further comprises a cutting board fitted in the opening, the cutting board having blades mounted thereon, and the blanking hole being designed in the basket shelter to correspond to the opening of the cover.
In the integrated cleaning and cutting device, the cutting mechanism further comprises a scrub rod with a plurality of pins formed at bottom end thereof adapted for inserting into the salad material.
In the integrated cleaning and cutting device, a slideway is defined above the opening of the cover, and the cutting mechanism further comprises a scrub board having a slide rail at bottom thereof for matching the slideway, and a plurality of pins formed at the bottom thereof adapted for inserting into the salad material.
In the integrated cleaning and cutting device, a grab handle extends from the scrub board opposite to the slide rail of the scrub board.
In the integrated cleaning and cutting device, a scrub rod is embedded in the grab handle with a plurality of additional pins formed at bottom thereof adapted for inserting into the salad material.
Multiple beneficial effects can be obtained by utilizing the present device described hereinafter. The cleaning fluid can be filled in the case with a cover sealed thereon. The salad material such as apples or pineapples can be contained in the basket with palings formed thereon, and further contained in the case and cleaned by the cleaning fluid. The drive mechanism coupled to the cover can be conveniently operated by the handle to drive the basket to rotate in the case, whereby the salad material is cleaned in the rotating basket. In addition, the cleaned salad material can be cut on the cutting mechanism fitted in the cover and directly fall into the basket via a blanking hole of the basket shelter from the cutting mechanism communicated with the basket. The cut salad material can be taken out from the case at one time by taking the basket out of the case, and put into a stirring container, in which salad dressing may be added to be stirred with the cut salad material to make salad. Utilizing the present device solely, one can both clean and cut the salad material. Furthermore, the basket having an artistic appearance can be directly used as a vessel for serving the salad. Thus, the plurality of containers and instruments conventionally used in making salad is reduced. Further, the case can contain some clean water while the salad material is being cut, so that the cut salad material is immersed therein, to prevent the cut salad material being oxidized from contacting with the atmosphere, and so that the cut salad material retains freshness.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 is an isometric, assembled view of an integrated cleaning and cutting device in accordance with a first embodiment of the present disclosure.
FIG. 2 is an exploded view of the integrated cleaning and cutting device of FIG. 1 .
FIG. 3 is a cross-sectional view of the integrated cleaning and cutting device of FIG. 1 .
FIG. 4 is a view similar to FIG. 3 , in which a scrub board of the integrated cleaning and cutting device is assembled.
FIG. 5 is an isometric solid view of the integrated cleaning and cutting device in FIG. 4 .
FIG. 6 is an exploded view of a cover of the integrated cleaning and cutting device of FIG. 1 .
FIG. 7 is a schematic view of a cutting board of an integrated cleaning and cutting device in accordance with a second embodiment of the present disclosure.
FIG. 8 is a schematic view of a cutting board of an integrated cleaning and cutting device in accordance with a third embodiment of the present disclosure.
FIG. 9 is an enlarged view of part II in FIG. 4 .
FIG. 10 is a schematic view of the scrub board of the integrated cleaning and cutting device in FIG. 4 .
FIG. 11 is an enlarged view of part I in FIG. 3 .
DETAILED DESCRIPTION
FIGS. 1-3 illustrate an integrated cleaning and cutting device in accordance with a first embodiment of the present disclosure. The integrated cleaning and cutting device comprises a case 1 , a cover 2 covering the case 1 , a basket 3 received in the case 1 and a basket shelter 4 mounted on the basket 3 . The case 1 is sealed by the cover 2 to avoid the cleaning fluid spilling out of the case 1 at the time of cleaning salad material such as fruits or vegetables contained therein. The basket shelter 4 prevents the fruits or vegetables sliding out of the basket 3 , and drives the basket 3 to rotate in the case 1 . The basket 3 has a plurality of palings 5 to allow the cleaning fluid to flow throughout.
Referring to FIGS. 2 , 3 , 4 , 5 and 11 , a drive mechanism is coupled to the cover 2 for driving the basket 3 rotating in the case 1 . Specifically, a convex bulge 6 protrudes upwardly from a middle bottom of the case 1 . Corresponding to the bulge 6 of the case 1 , a concave dent 7 is defined in a middle bottom of the basket 3 . The basket 3 is rotatably received in the case 1 with the bulge 6 inserted in the dent 7 . The basket 3 and the case 1 have no other parts contacted with each other except the attachment of the bulge 6 and the dent 7 . In an alternative embodiment, a shaft can be formed in the middle bottom of the case 1 to match an axle hole defined in the middle bottom of the basket 3 to render the basket 3 rotates in the case 1 around the shaft.
The drive mechanism comprises a shaft 21 rotatably inserted in the middle of the cover 2 , and a wheel 22 bringing the shaft 21 to rotate. A handle 23 is formed on the wheel 22 . The bottom end of the shaft 21 is connected with the center of the basket shelter 4 , and the top end of the shaft 21 is engaged with the wheel 22 via gears to form a planet gear mechanism. In detail, as shown in FIGS. 2 , 3 and 11 , a chuck 33 is located beneath the cover 2 and rotatably connects the shaft 21 and the cover 2 together. After the shaft 21 inserted through the middle of the basket shelter 4 , a nut 34 is engaged with the bottom end of the shaft 21 to rigidly connect the shaft 21 and the basket shelter 4 together. A plurality of claws 35 are formed at bottom end of the handle 23 . A hole 36 is defined in a top surface of the wheel 22 biasing the center thereof. The claws 35 are inserted into the hole 36 to thereby secure the handle 23 on the wheel 22 eccentrically.
As shown in FIGS. 2 , 3 , 5 and 11 , a receiving room 24 is defined in the top of the cover 2 for receiving the wheel 22 therein. A sleeve 25 is formed at the center of the receiving room 24 . A spindle 26 is formed at the middle bottom of the wheel 22 and rotatably received in the sleeve 25 , whereby the wheel 22 can rotate in the receiving room 24 around the sleeve 25 when driving the handle 23 along a circumferential direction of the wheel 22 . The top end of the shaft 21 is exposed in the receiving room 24 and forms a plurality of external gears 28 thereon. A plurality of internal gears 27 are formed in an inner side of the side walls of the wheel 22 to engage with the external gears 28 of the shaft 21 . A planet gear mechanism is thus obtained between the shaft 21 and the wheel 22 after the wheel 22 is positioned in the receiving room 24 , and the shaft 21 is rotated following the rotating of the wheel 22 . A diameter of the internal gears 27 of the wheel 22 is larger than that of the external gears 28 of the shaft 21 , thus, the rotating speed of the shaft 21 is greater than that of the wheel 22 , whereby a high rotating speed of the shaft 21 (i.e., of the basket 3 ) is easily performed, and the cleaning fluid contained in the case 1 is stirred adequately by the basket 3 , which is beneficial for cleaning the salad material in the case 1 . In an alternative embodiment, the external gears can be formed outside of the spindle 26 and engaged with the internal gears formed on the shaft 21 to perform the rotating of the shaft 21 following the rotating of the wheel 22 , and the speed ratio of the shaft 21 to the wheel 22 can be designed to obtain a desired rotating speed of the basket 3 . In another alternative embodiment, the spindle 26 can also be aligned with the shaft 21 , that is, the wheel 22 can be directly connected with the top end of the shaft 21 , wherein the wheel 22 can bring the shaft 21 to rotate.
In use, the salad material such as various kinds of fruits and vegetables are put into the basket 3 . Cleaning fluid such as water or cleaning solution is filled in the case 1 . The basket 3 with the salad material is put into the case 1 and sealed with the cover 2 . Preferably, the basket 3 and the basket shelter 4 are configured to be revolving bodies, such that the basket shelter 4 conveniently engages with the basket 3 . In addition, edges of the basket shelter 4 connecting to the basket 3 are configured to be waved in shape, which automatically guides the basket shelter 4 to engage with the basket 3 . Further, the bottom face of the basket shelter 4 is uneven, which can force the salad material floating in the cleaning fluid to move up and down, to adequately clean the salad material. During cleaning, the shaft 21 is rotated following the rotating of the wheel 22 by driving the handle 23 . The basket shelter 4 rotates via the shaft 21 due to the connection with the bottom end of the shaft 21 , which also drives the basket 3 to rotate around the bulge 6 in the case 1 , since the basket shelter 4 also connects the basket 3 . The cleaning fluid in the case 1 is stirred by the basket 3 , on which the plurality of palings 5 are formed, to clean the salad material. Then, the salad material can be taken out from the case 1 at one time by taking out the basket 3 , instead of taking out pieces of salad material one by one. At last, the cleaning fluid is poured out from the case 1 .
In the present embodiment, a transverse hole 30 is defined in a side wall of the receiving room 24 to communicate with a vertical hole 31 defined in the top surface of the cover 2 . A brake block 32 made of elastic material is received in the vertical hole 31 . The rotation of the wheel 22 and the basket 3 can be actively stopped by pressing the block 32 to deform and protrude from the transverse hole 30 to scrub the side wall of the wheel 22 . Thus, the continuous rotation of basket 3 in the case 1 causing spilling of the cleaning fluid after opening the cover 2 can be prevented.
Referring to FIGS. 4 , 5 and 6 , a cutting mechanism is furnished on the cover 2 for cutting the salad material. Due to the drive mechanism on the cover 2 being a planet gear mechanism, the wheel 22 can be located on a lateral side of the cover 2 instead of the center thereof, and the cutting mechanism can be located on another lateral side of the cover 2 to fully exploit the space of the cover 2 and form a compact construction. Specifically, a step 41 is formed at the other lateral side of the cover 2 , with an opening 42 defined therein. The cutting mechanism comprises a cutting board 44 detachably fitted in the opening 42 of the step 41 , with a plurality of blades 43 mounted thereon. Corresponding to the opening 42 , a plurality of blanking holes 8 are defined in the basket shelter 4 for the cut salad material to fall into the case 1 . The salad material is cut into a predetermined shape by the blades 43 when sliding on the cutting board 44 . As shown in FIG. 6 , the salad material is cut into strips with a cross-section thereof being rectangular in shape. FIG. 7 shows a cutting board 44 of the device in accordance with a second embodiment, and the salad material is cut by such a cutting board 44 into strips with a cross-section thereof being petaling in shape. FIG. 8 shows a cutting board 44 of the device in accordance with a third embodiment, and the salad material is cut by such a cutting board 44 into flakes. As described above, the device can be equipped with different cutting boards 44 having different blades 43 to cut the salad material into different shapes, adding to the artistic appearance of the salad.
Referring to FIGS. 6 , 7 and 8 , a plurality of guiding grooves 45 are preferably defined in the cutting board 44 , an elongated direction of which being aligned with the sliding direction of the salad material. Therefore, the salad material is guided to slide in a single direction and a changeable sliding direction caused by an uneven force is prevented to ensure a uniform shape of the cut salad material.
Referring to FIGS. 4 , 6 and 9 , a slideway 46 is defined above the opening 42 of the step 41 for a scrub board 47 sliding therein. A plurality of pins 48 protrude downwardly from the bottom of the scrub board 47 . Specifically, a secondary step 49 formed in one side of the step 41 and a baffle plate 50 formed at an opposite side of the step 41 cooperatively define the slideway 46 therebetween. Corresponding to the slideway 46 , a slide rail 51 is formed at the bottom of the scrub board 47 . When cutting the salad material, the pins 48 of the scrub board 47 are inserted into the salad material, and the scrub board 47 with the salad material is slid in the slideway 46 back and forth to thereby cut the salad material into a desired shape such as flakes or strips etc. Referring to FIG. 5 , the plurality of blanking holes 8 are preferably arranged circumferentially in the basket shelter 4 . In the present embodiment, a plurality of concaved portions are formed in the basket shelter 4 due to a plurality of orientation grooves 29 being defined in the edges of the basket shelter 4 connecting the basket 3 . The blanking holes 8 are defined preferably in the bottoms of the concaved portions to be configured as a funnel shape, such that the cut salad material easily falls into the basket 3 and does not fall between the case 1 and the basket 3 along the basket shelter 4 .
Referring to FIGS. 6 , 9 and 10 , a tubal grab handle 52 extends upwardly from the scrub board 47 for conveniently operating the scrub board 47 to slide in the slideway 46 . A scrub rod 53 is inserted in the grab handle 52 . In detail, a tunnel 54 is defined in the grab handle 52 for embedding the scrub rod 53 therein. Similar to the pins 48 of the scrub board 47 , a plurality of pins 55 extend downwardly from the bottom of the scrub rod 53 . The scrub rod 53 can be barely utilized with the pins 55 thereof inserting into the salad material to directly slide back and forth on the cutting board 44 when the salad material has a large volume, while the salad material becomes thin after being cut for a moment, the remaining salad material can be removed off the scrub rod 53 and secured on the bottom of the scrub board 47 to slide in the slideway 46 for further cutting. Thus, the salad material with different thicknesses is conveniently cut in the device.
Referring to FIGS. 1 , 2 and 3 , the step 41 , in which the cutting mechanism is set forth, is mounted by a lateral cover 56 . The lateral cover 56 is consistent with the cover 2 to form a uniform appearance of the device, functioning as a shield to prevent dusts entering into the device, and to avoid damage by the blades 43 of the cutting board 44 when the cutting mechanism is not in use.
It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the disclosure or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the disclosure. | An integrated cleaning and cutting device includes a case, a cover sealed the case, a basket received in the case, and a basket shelter mounted on the basket. A plurality of palings is formed on the basket. A drive mechanism is accumulated in the cover for driving the basket to rotate in the case. A cutting mechanism is fitted in the cover for cutting salad material. The cutting mechanism includes a blanking hole communicating with the basket in the case. The salad material is cleaned in the basket by the rotating of the basket in the case. On the other hand, the salad material can be cut and stored in the device, in which the basket and the cutting mechanism are equipped. Since the device has multiple functions such as cleaning, cutting and storage, it is utilitarian in use. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of and claims priority to U.S. non-provisional patent application having application Ser. No. 13/045,300 and filing date of 10 Mar. 2011, now U.S. Pat. No. ______, which is a continuation of and claims priority to U.S. non-provisional patent application having application Ser. No. 12/627,753 and filing date of 30 Nov. 2009, now U.S. Pat. No. 7,937,073, which is a continuation of and claims priority to U.S. non-provisional patent application having application Ser. No. 11/213,571 and filing date of 26 Aug. 2005, now U.S. Pat. No. 7,634,253, each application being hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to data service portability between wireless operators for a wireless communication device, and more specifically to dynamically updating data session authentication credentials of the wireless communication device as applicable to various wireless operators.
BACKGROUND OF THE INVENTION
[0003] In a typical wireless portable communication device, a common data application using a common data service available across multiple wireless operator's networks, such as BlackBerry™, instant messaging (“IM”), multimedia messaging service (“MMS”), and/or push-to-talk over cellular (“PoC”) available on Internet and/or a private network, is loaded at the manufacturer. Such wireless portable communication devices are shipped to multiple wireless service operators who require the use of different data authentication credentials for the common data application. For example, in a Code-Division Multiple Access (“CDMA”) 2000 1× Radio Transmission Technology (“1×RTT”) network, where 1× refers to a single radio channel, for a third generation (“3G”) mobile system, a network access identifier (“NAI”) is used for a point-to-point protocol (“PPP”), and in a General Packet Radio Service (“GPRS”), an access point name (“APN”) is used for a packet data protocol (“PDP”) contexts.
[0004] For a particular wireless service operator, a specific data authentication is generally hard-coded into the wireless portable communications devices allocated for the particular wireless service operator as an operator customization. This method is the accepted practice in the industry, as it is highly desirable from a user's perspective, and obviates any need for the user to maintain knowledge of data authentication credentials. For example, an APN specifying a wireless bearer path for e-mail over one wireless service operator would be different from an APN for e-mail over another wireless service operator regardless of the fact that these wireless service operators may use the same server on the Internet. With local number portability laws in certain jurisdictions, such as those in the United States and European Union, subscribers are now allowed to switch wireless carriers while retaining the same telephone numbers in some circumstances. Generally, the local number portability relates to subscriber identification module (“SIM”) lock for Global System for Mobile communications (“GSM”) and GPRS networks, or Mobile Directory Number (“MDN”) access as compared to International Mobile Subscriber Identity (“IMSI”) in CDMA networks. However, with the prevalence of data centric wireless portable communication devices, some subscribers may wish not only to retain the current telephone numbers with a new wireless service provider, but also to continue using the same wireless portable communication devices and its data applications with the new wireless communication service provider.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is an exemplary environment in which a wireless portable communication device in accordance with at least one of the preferred embodiments may be practiced;
[0006] FIG. 2 is an exemplary flowchart illustrating a process in the wireless portable communication device for maintaining up-to-date authorization credentials for accessing the common data application in accordance with at least one of the preferred embodiments;
[0007] FIG. 3 is an exemplary block diagram of the wireless portable communication device configured to maintain appropriate authentication credentials required for the common data application in the current service network in accordance with at least one of the preferred embodiments; and
[0008] FIG. 4 is an exemplary flowchart illustrating a process in the wireless communication network for providing current authentication credentials required for the common data application accessible through the wireless communication network in accordance with at least one of the preferred embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] A wireless portable communication device receives an up-to-date authentication credentials required for a common data application in a wireless communication network in which the wireless portable communication device is currently registered. The up-to-date authentication credentials may include a list of a plurality of wireless communication networks mapped against the up-to-date authentication credentials. The wireless portable communication device may receive the up-to-date authentication credentials periodically at a predetermined interval, based upon a predetermined condition, or by requesting the up-to-date authentication credentials. The up-to-date authentication credentials are then prioritized over existing authentication credentials, and are used for the common data application in the wireless communication network in which the wireless portable communication device is currently registered. The wireless communication network, which requires authentication credentials for the common data application, keeps the required authentication credentials up to date, and transmits the up-to-date authorization credentials periodically at a predetermined interval, based upon a predetermined condition, or in response to receiving a request for the up-to-date authentication credentials. The wireless communication network allows the wireless portable communication device having the up-to-date authentication credentials a use of the common data application.
[0010] FIG. 1 is an exemplary environment 100 in which a wireless portable communication device 102 in accordance with at least one of the preferred embodiments may be practiced. The wireless portable communication device 102 is presently shown to be located in a first coverage area 104 supported by a first wireless communication network 106 , which is adjacent to a second coverage area 108 supported by a second wireless communication network 110 . The wireless portable communication device 102 has default authentication credentials for a common data application such as an e-mail application, which is maintained in a common service 112 , accessed through the first wireless communication network 106 . While the wireless portable communication device 102 is within the first coverage area 104 and is registered to the first wireless communication network 106 , the wireless portable communication device 102 , having the default authentication credentials fully compatible with the first wireless communication network 106 , properly accesses the common data application. However, as the wireless portable communication device 102 moves from the first coverage area 104 to the second coverage area 108 and re-registers to the second wireless communication network 110 , the default authentication credentials of the wireless portable communication device 102 may not be compatible to access the common data application in the second wireless communication network 110 . For an exemplary case where the user is permanently changing his subscription to the operator of the wireless communication network 110 , the wireless portable communication device 102 therefore needs to able to update the default authentication credentials to new authentication credentials that are compatible in the second wireless communication network 110 before being able to properly access the common data application. Further, the first wireless communication network 106 may change the default authentication credentials from time to time, and may cause the wireless portable communication device 102 to fail to access the common data application properly. Therefore, the wireless portable communication device 102 needs to be able to maintain up-to-date authentication credentials.
[0011] FIG. 2 is an exemplary flowchart 200 illustrating a process in the wireless portable communication device 102 for maintaining up-to-date authorization credentials for accessing the common data application in accordance with at least one of the preferred embodiments. The wireless portable communication device 102 has default authentication credentials required for the common data application in a default service network, which is the first wireless communication network 106 . The process begins in block 202 , and the wireless portable communication device 102 receives a data session configuration file, which includes authentication credentials in block 204 . The wireless portable communication device 102 may typically receive the data session configuration file wirelessly from the current wireless communication network, but it may alternatively receive the data session configuration file by downloading from the internet. The data session configuration file may further include a list of a plurality of service networks mapped against the received authentication credentials for use with the common data application. This plurality applies as the user subscriptions to a plurality of wireless network operators change. The wireless portable communication device 102 may receive the data session configuration file based upon various conditions. The wireless portable communication device 102 may transmit a request to receive the data session configuration file, or may receive the data session configuration file based upon a predetermined condition. For example, the wireless portable communication device 102 may receive the data session configuration file upon registering to the current service network using a common registration channel, upon failing to properly access the common data application in the current service network, or upon roaming from the default service network to the current service network. The wireless portable communication device 102 may also autonomously receive the data session configuration file periodically.
[0012] The wireless portable communication device 102 may further determine the compatibility associated with the wireless portable communication device 102 , a subscriber identity module in the wireless portable communication device 102 , and the current wireless communication network, and may receive the data session configuration file based upon the compatibility. The subscriber identity module may be one of a Subscriber Identity Module (“SIM”) used in networks based upon Global System for Mobile Communications (“GSM”), a Removable User Identification Module (“R-UIM”) used in networks based upon Code Division Multiple Access (“CDMA”), or any other similar subscriber identification module.
[0013] In block 206 , the wireless portable communication device 102 prioritizes the authentication credentials between the default authentication credentials and the received authentication credentials. For example, as previously shown in FIG. 1 , when the wireless portable communication device 102 receives new authentication credentials as a result of moving from the first wireless communication network 106 to the second wireless communication network 110 requiring the new authorization credentials to access the common data application, the new received authorization credentials are prioritized over the default authorization credentials. Once prioritized, the default authentication credentials may be overwritten with the received authentication credentials, making the received authentication credentials as new default authentication credentials. Alternatively, both the default authentication credentials and the received authentication credentials are stored in the wireless portable communication device 102 , and may be available for later usage. In block 208 , the wireless portable communication device 102 uses the authentication credentials having higher priority for the common data application in the current service network. The authorization credentials may be re-prioritized when the wireless portable communication device 102 moves back to the first wireless communication network 106 . The process then ends in block 210 .
[0014] FIG. 3 is an exemplary block diagram 300 of the wireless portable communication device 102 configured to maintain appropriate authentication credentials required for the common data application in the current service network in accordance with at least one of the preferred embodiments. A battery, a display, a keypad, a speaker, a microphone, an antenna, and other normally associated components are understood to be present but are not specifically shown with the wireless portable communication device 102 for simplicity. The wireless portable communication device 102 has in memory 302 default authentication credentials, which are required for the common data application in a default service network, such as the first wireless communication network 104 . The wireless portable communication device 102 has a configuration file receiver 304 , which is configured to receive a data session configuration file. The data session configuration file includes authentication credentials, and may further include a list of a plurality of service network mapped against the received authentication credentials for use with the common data application. A prioritization module 306 is coupled to the configuration file receiver 304 and to the memory 302 , and is configured to prioritize between the default authentication credentials and the received authentication credentials. A credential selector 308 is coupled to the prioritization module 306 , and is configured to select the authentication credentials having higher priority for the common data application in the current service provider. A credential transmitter 310 is coupled to the credential selector 308 , and is configured to transmit the selected authorization credentials for the common data application in the current service network. The wireless portable communication device 102 may further have a request transmitter 312 , which is coupled to the configuration file receiver 304 and is configured to transmit a request to receive the data session configuration file. The memory 302 may be further coupled to the credential selector 308 , and be further configured to be overwritten with the authentication credentials selected by the credential selector 308 . The memory 302 may comprise volatile and non-volatile memory modules, having the default authentication credentials programmed in the non-volatile memory module and having the received authentication credentials in the volatile memory module.
[0015] The wireless portable communication device 102 , specifically the configuration file receiver 304 , may be further configured to receive the data session configuration file based upon various predetermined conditions. For example, the configuration file receiver 304 may be configured to receive the data session configuration file upon registration of the wireless portable communication device 102 to the current service provider using a common registration channel, upon failure of the wireless portable communication device 102 to properly access the common data application in the current service provider, or upon the wireless portable communication device 102 roaming from the default service network to the current service network. The configuration file receiver 304 may be further configured to autonomously receive the data session configuration periodically. Further, the bearer path may be entirely independent from the wireless network for receipt of the configuration file, for example, it may be downloaded off of the internet to the wireless portable communication device 102 .
[0016] The wireless portable communication device 102 may further comprise a subscriber identity module 314 such as a Subscriber Identity Module (“SIM”) used in networks based upon Global System for Mobile Communications (“GSM”) and a Removable User Identification Module (“R-UIM”) used in networks based upon Code Division Multiple Access (“CDMA”) or via the service programming implemented directly on the wireless portable communication device 102 where no R-UIM is present. The subscriber identity module 314 is coupled to the credential selector 308 , and is configured to provide information to the current service network, such as the first wireless communication network 106 regarding the identity of a subscriber and associated services. Although typically a wireless portable communication device and its subscriber identity module are associated with the same wireless communication network provider, because the subscriber identity module is fully or partially compatible with similar wireless portable communication devices, the subscriber identity module associated with one wireless communication service provider may be used with a wireless portable communication device associated with another wireless communication service provider. Further, as a result of roaming or user subscription changes to other operators, such a combination of the wireless portable communication device and the subscriber identity module may register and operate in yet another wireless communication service provider's network. The configuration file receiver 304 may further be configured receive the data session configuration file based upon the compatibility among the wireless portable communication device 102 , the subscriber identity module 314 , and the current wireless communication network.
[0017] FIG. 4 is an exemplary flowchart 400 illustrating a process in the wireless communication network 106 for providing current authentication credentials required for the common data application accessible through the wireless communication network 106 in accordance with at least one of the preferred embodiments. The first wireless communication network 106 is simply referred as the wireless communication network 106 for this illustration. The process begins in block 402 , and the wireless communication network 106 maintains the current, or up-to-date, authentication credentials indicative of currently required authentication credentials for the common data application in block 404 . The wireless communication network 106 may maintain the current authentication credentials in various ways including, but not limited to, acquiring the current authentication credentials by communicating with common data service 112 periodically, and receiving the current authentication credentials from the common data service 112 as they are updated. The wireless communication network 106 then detects a predetermined condition for transmitting a data session configuration file in block 406 .
[0018] Alternatively, the common data service 112 may detect the predetermined condition through the wireless communication network 106 . The data session configuration file includes the current authentication credentials, and may further include a list of a plurality of wireless communication networks mapped against the appropriate authentication credentials for use with the common data application. The predetermined condition to be detected in block 406 for transmitting the data session configuration may be one of various predetermined conditions including, but not limited to, receiving a request for the data session configuration file, receiving a registration of a wireless portable communication device using a common registration channel, determining a registered wireless portable communication device failing to properly access the common data application, and reaching a predetermined periodic transmission time interval. As one of the predetermined conditions, the wireless communication network 106 , or the common data service 112 , may further determine the compatibility associated with a wireless portable communication device registered in the wireless communication network 106 , such as the wireless portable communication device 102 , a subscriber identity module in the wireless portable communication device 102 , and the wireless communication network 106 itself. The subscriber identity module may be one of a Subscriber Identity Module (“SIM”) used in networks based upon Global System for Mobile Communications (“GSM”), a Removable User Identification Module (“R-UIM”) used in networks based upon Code Division Multiple Access (“CDMA”), or any other similar subscriber identification module.
[0019] Upon detecting one of the predetermined conditions in block 406 , the wireless communication network 106 , or the common data service 112 , transmits the data session configuration file in block 408 , generally only to the wireless portable communication device 102 , which triggered the predetermined condition detection process. Alternatively, the wireless communication network 106 , or the common data service 112 , may broadcast the data session configuration file periodically to all wireless portable communication devices currently registered to the wireless communication network 106 . Upon receiving the current authentication credentials from the wireless portable communication device 102 in block 410 , the wireless communication network 106 allows the wireless portable communication device 102 proper access to the common data application in block 412 . The process then terminates in block 414 .
[0020] While the preferred embodiments of the invention have been illustrated and described, it is to be understood that the invention is not so limited. Numerous modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims. | Techniques in a wireless device for use in accessing a common data application with a service network which is external to a plurality of wireless networks are described. The device receives a data session configuration file which includes a list of the plurality of wireless networks mapped against authentication credentials associated with each wireless network. The device communicates with a current one the wireless networks. The device selects from the list one of the authentication credentials that is associated with the current wireless network. The device submits, via the current wireless network, the selected authentication credentials for establishing a packet data session via the current wireless network. The device then accesses, via the current wireless network using the packet data session, the common data application with the service network which is external to the current wireless network. | 7 |
CROSS REFERENCE
This is a divisional application, of Ser. No. 901,336, filed May 1, 1978, now U.S. Pat. No. 4,252,458, issued Feb. 24, 1981 which is a continuation-in-part of Ser. No. 684,348, 5-7-76, now U.S. Pat. No. 4,086,946, issued May 2, 1978, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention belongs to the field of locking a male member within a female member such as locking the rod end of a hydraulic cylinder to a rod end coupler.
Description of the Prior Art
The apparatus of the prior art had used methods such as set screws which either locally deform threads and cylinder walls, or press directly against the male member to be locked. Most such apparatus have involved threaded engagement but splines and tapered smooth cylindrical bores are also used. Jam nuts have also been used with apparatus such as rod end couplers and reciprocating machines. The set screws have the disadvantage of damaging the threads on a threaded male member and the jam nuts have proven ineffective for use on such items as self-aligning rod end couplers.
Although the locking apparatus may be used with any male/female member pair to be locked, a preferred embodiment in a self-aligning rod end coupler will be discussed. This is not intended to in any way limit the invention. Most self-aligning couplers have features which allow some degree of inaccuracy in linearly aligning the rods to be coupled. A spherical surface within the coupler allows to a limited degree what is known in the industry as spherical movement and axial float. This self-aligning feature is defeated, however, when the rod ends are not tightly locked into the coupler.
Existing methods have proven substantially ineffective in maintaining proper rod to coupler locking. Since the rod ends cannot be exactly linearly aligned, two costly results are observed where the coupling loosens from ineffective locking
(1) cylindrical bearing wear and rod seal wear occur in the hydraulic cylinder attached to the rod, due to side loads and binding;
(2) machinery is deflected due to weight shifts from misalignment of the rod ends; and,
(3) binding in the rod coupler and the machinery.
Precision bore equipment has been used to avoid these difficulties, however, manufacturing of such close tolerances is both expensive and time consuming. Furthermore, even precision bore equipment has proven ineffective for many applications.
The rod end coupler embodiment may be used in any application where a sliding movement is required.
SUMMARY OF THE INVENTION
The present invention avoids the inconveniences of couplers and other apparatus which are provided with deformable inserts, since a locking apparatus according to the present invention can be easily threaded into position (where the bore and male member are threaded) for assembly of elements upon a threaded male member, and once in position, can easily be locked in such a position until disassembly is required. In a locking coupler, according to the present invention, the amount of locking force is not predetermined and can be adjustably controlled to any value required. In addition, there is no risk of causing any damage to the thread of a threaded male member because of the uniform distribution of the locking force along a significant portion of the entire axial length of the threaded bore of the female member.
The locking apparatus, according to the present invention, does not require any auxiliary lock nut or lock washer; is applicable to any conventional or nonconventional type of locking apparatus such as couplers, reciprocating machines, transfer machines, and the like; and results in assembly which is neat in appearance, occupies little room, does not cause any interference with tools generally used for torquing such as wrenches and spanners, and provides a safe assembly with any amount of locking effect desired.
The present invention thus provides a locking apparatus which may be made of any otherwise conventional body such as couplers, tapered fitted cylinders, and the like, which by uniform deformation of the wall of the female member of the apparatus once the male member has been inserted into position, causes a uniform clamping and locking effect of the female member upon the threaded male member with which it is engaged, and which, by generally requiring uniform deformation of threaded bores, splines, and the like within the elastic limit of the material of the apparatus, enables the wall of the bore of the female member to return to its original configuration prior to removing the male member from its engagement whenever dismantling is required. Furthermore, the locking force created by the locking self-aligning coupler embodiment of the present invention is uniformly distributed along a significant portion of the entire length of a threaded bore of a threaded locking self-aligning coupler, thereby generating a substantially greater clamping and locking effect than heretofore available by conventional self-aligning couplers. Furthermore, the locking coupler of the present invention is of simple structure, is easy to manufacture by conventional machining means, is substantially low in cost, is neat in appearance, and is reusable indefinitely.
Other objects and advantages of the present invention will become apparent to those skilled in the art when the following description of the best embodiment contemplated in practicing the invention is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example of the use of the locking apparatus in the form of a rod end coupler, here shown locked onto the rod end of a hydraulic cylinder;
FIG. 2 is a longitudinal cross-sectional view as seen from line 2--2 in FIG. 3;
FIG. 3 is a plan view of a locking coupler according to the present invention, showing radially inserted set screws in recesses leading into the slots and additionally showing the preferable depth of a circular groove radially extending from the inside diameter of the coupler's annular member;
FIG. 4 is a plan view of a locking coupler according to the present invention, showing wedging means longitudinally inserted in the slots and also showing the preferable depth of the circular groove.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIG. 1, an example of a rod end coupler 30 utilizing locking according to the present invention is shown locked on the threaded end of the rod 11 of the hydraulic cylinder 10. In the example illustrated, set screws 13 are utilized to lock the annular body member 14 onto the threaded rod end 12 of the hydraulic cylinder 10.
FIG. 2 shows a self-aligning rod end coupler in detail, employing set screws for locking both the annular body member 14 to a threaded rod end and for locking the coupler housing 15 to the annular body member 14. A threaded recess is provided on the periphery of the annular body member near the end of said member. A set screw is threadably inserted therein. A slot 24a is formed longitudinally from the end of the annular body member 14 and near the inside diameter of the annular body member 14 in such a way that a resilient segment portion 26 is formed between the slot 24a and the inside diameter of the annular body member 14.
When set screw 13a is driven tight in the threaded recess provided therefor, the inner thread of annular body member 14 tightly engages threaded shaft portion therein, thus holding the annular body member 14 secured to the threaded rod end. When it is desired to remove a rod end from the threaded bore of the annular body member 14, the set screw 13a is backed up and the inside threaded diameter of the annular body member 14 is released from tight engagement with the threaded rod end.
The circular groove 25 is located in such a way that insertion of the wedging means 13a deflects only that segment portion 26 between the circular groove and the end face 23 of the annular body member 14. It is thus apparent from this description that the preferred embodiment of the invention exhibits the ability to provide substantially greater locking forces than the prior art because of the ability of the annular body member 14 (referring again to FIG. 2) to deform uniformly along its entire axial threaded bore length from the end face of annular member 14 to where the circular groove 25 intersects both the slot 24a and the internal threaded bore of annular member 14. Extensive testing has shown the deformation to be uniform in character so that the threaded annular member 14 locks up along the entire axial length of this axial deformation. Each and every thread between the end face of annular member 14 and the circular groove 25 locks up on each and every thread of an inserted rod end. It is this uniform deformation which allows the annular member 14 to exhibit a substantially greater locking force than the prior art. As earlier described, non-uniform deformation along the axial length of a locking member such as annular member 14 can cause highly localized forces resulting in damage to threaded rod ends and also resulting in poor holding force.
FIG. 2 shows a cylindrical housing 15 with an annular rod member 17 mounted therein. The annular rod member 17 typically has a threaded end 18 of smaller diameter than the small diameter portion of the bore of the cylindrical housing 15. The annular rod members also have a larger rod end mounted within the housing 15. The larger rod end will have a spherical surface on either the innermost end at 20 to spherically cooperate with the cylindrical body 21, or a spherical surface 16 on the shoulder between the larger and smaller diameter portions of the annular rod member to spherically cooperate with the spherical surface at 19, or both 16 and 20. The inner cylindrical body 21 is mounted within the housing 15 flush against both the surface 20 and the end face of the annular body member 14. As shown in FIG. 1, the annular rod member 17 may have an intermediate shoulder wih flat surface such as 32, notches, or other means permitting the annular rod member 17 to be held in place for engagement with a female body to be threaded on the threaded end 18 of the annular rod member 17.
Referring to FIG. 3, at least one slot and preferably a plurality of slots such as 24 are formed in the annular body member 14. The slots may be straight, or arcuate as illustrated, and it is contemplated that they may extend from one face of the annular body member 14 through the entire longitudinal thickness of the annular body member to the other face thereof, or at least partly from one face into the annular body member 14. It is important to note that although the slots 24 may be straight or arcuate, they may not intersect the threaded bore of the annular body member 14 along its axial length from face to face or any portion thereof. A circular groove, depicted as 25, is cut on the surface of the threaded bore of the annular body 14. The circular groove 25 is preferably located at a position away from the face of annular body member 14 which engages a threaded rod end, so that the circular groove will intersect the slots 24 at a predetermined longitudinal position corresponding approximately to the bottom of the threaded recess where the set screws 13 are inserted.
FIG. 3 illustrates radially inserted set screws 13, inserted from the periphery of the annular body member 14. Deformation of the resilient segment portions 26 is accomplished by pressure between the walls 27 and 28 with the set screws 13. The set screws 13 are accepted into recesses from the periphery of the annular body member 14 which recesses enter the slots 24. After the annular body member 14 has been tightly engaged upon a male member such as threaded rod end 12 (of FIG. 1), each set screw 13 is tightened in such a manner that it causes the resilient segment portions 26 to deform as earlier described. Also, as earlier described, the deformation of the resilient segment portions 26 from the internal walls 27 is controllable and variable in degrees depending upon the amount of torque applied to the threaded set screws 13. For example, set screw 13a may be inserted to a lesser depth than set screw 13b and to a greater depth than set screw 13c. Again, the deformation of the internal threaded bore is designed to be within the normal elastic modulus of the substance forming the annular body member 14 such that when the set screws 13 are unthreaded from the recess in the periphery of annular body member 14, the internal walls 27 of the annular body member 14 are allowed to assume their original position, thereby allowing the internal threaded bore of annular body member 14 to assume its original circular shape and permitting a rod end such as threaded rod end 12 to be disengaged from the annular body member 14.
FIG. 4 illustrates a different embodiment of the invention whereby the wedging means to provide deformation of the resilient segment portion 126 is accomplished by longitudinally inserting the wedging means 113 into the slots 124 from the end face of an annular body member such as 114. After a rod end has been tightly inserted into the bore of annular body member 114, the wedging means 113 are inserted to the desired depth in the slots 124. This uniformly radially deflects the resilient portion 126 of the bore wall 129. The deformation of the resilient portion 126 is both controllable and variable in degrees depending upon the amount of torque applied when inserting wedging means 113. The deformation of the internal bore 129 is designed to be within the normal elastic modulus of the substance forming the annular body member 114 such that when the wedging means 113 is withdrawn from the slot 124, the internal wall 127 of the annular body member 114 is allowed to assume its original position, thereby allowing the internal bore 129 to assume its previous circular shape and permits the annular body member 114 to be disengaged from a rod end or other male member inserted therein.
In the examples of the invention illustrated, the slots 24 are substantially concentric with the threaded bore of the annular body member 14. This provides for a symmetrical design and facilitates cutting of the slots by means of an appropriate milling cutter; the annular body members being mounted on a threaded mandrel on a machine table and the milling cutter effecting a cut while the table is rotated an appropriate number of degrees. Although the example of locking self-aligning rod end couplers, according to the invention, has been shown provided with three slots, it is obvious that in some applications only one slot 24 may be required, and in other configurations, especially where the annular body member 14 has a substantially large diameter and when, additionally, a strong locking action is desired, more than three slots may be provided in the annular body member.
It is preferable to have the slots 24 disposed relatively close to the threaded bore of the annular body member such that the metal, or other material, of the annular body member 14 between the slot and the peripheral surface of the annular body member 14 has greater rigidity than the metal of the annular body member between the slots 24 and the threaded bore of the annular body member 14, i.e. the resilient segment portion. The recesses for radially inserted wedging means, whether threaded or unthreaded, are preferrably formed equidistant from the ends of the slots, but they need not be centrally disposed relative to the opposite walls of the slots 24 and they may even be formed in only one of such opposite walls.
It will be readily apparent to those skilled in the art, that the locking apparatus of the invention may be modified by omitting the internal thread shown in FIG. 2 to form a modified locking apparatus or rod end coupler which can be fitted on an unthreaded shaft, thus providing a locking ring. Further, the locking apparatus of the invention may be modified by providing a splined internal bore which can be fitted on a splined shaft, thus providing a means of locking splined male and female members. Still further, and as shown, the locking apparatus may be used more than once on a given piece of equipment such as with set screws 22 and 13a of FIG. 2. | A novel locking apparatus is provided for use on self-aligning rod end couplers, reciprocating machines, hydraulic cylinders, transfer machines, and the like. The apparatus comprises at least one slot in an end face of an outer body and means for uniformly deforming a wall of the slot so as to obtain a uniform deformation of the wall of an annular bore, thereby locking and clamping the outer body upon an annular body engaged within the annular bore. | 5 |
RELATED APPLICATIONS
This application is a continuation-in-part application of my copending application Ser. No. 904,562 filed May 10, 1978 for SPLIT CYCLE ENGINE now abandoned.
BACKGROUND
1. Field of the Invention
This invention relates to air standard engines and, more particularly, to an air standard engine apparatus and method, wherein pressurized air to drive an expansion engine is compressed generally isothermally within a refrigerant-cooled compressor/heat exchanger and the resulting high pressure air is stored at ambient temperature to be utilized in the expansion engine to produce mechanical energy after which the air is recycled to the compressor.
2. The Prior Art
Historically, the utilization of chemical energy stored within fossil fuels such as gasoline, diesel fuel, or the like, is accomplished by converting the chemical energy to thermal energy either in an internal or an external combustion engine with the engine converting the thermal energy to mechanical energy in a rotating shaft. The mechanical energy is then utilized directly through the use of transmissions, generators, pulleys, and the like. Therefore, the amount of mechanical energy produced for a particular function is controlled by the amount of thermal energy and, therefore, the amount of fuel consumed in the internal or external combustion engine, accounting for losses and inefficiencies. Accordingly, each engine is designed with a view toward the maximum power output requirements for that particular engine application even though the average work load may be substantially smaller. As a result, the engine is usually over-designed for the particular work requirements with a corresponding waste in fuel consumption during the extended periods of lower power requirements. In recognition of this problem, various energy storage devices have been proposed and include, for example, high-speed flywheels, batteries, air storage tanks, and the like. While air storage tanks present certain advantages, particularly since the storage medium (air) is plentiful, relatively safe, and the capital expenditure for air storage systems is relatively low, the disadvantages are in the various heat losses, particularly the heat of compression, that are incurred. The heat losses represent a lowering of the overall efficiency of the system and, where the heat is retained, an additional work load for the compressor to compress a given volume of air to a given pressure.
In view of the foregoing, it would be an advancement in the art to provide an air standard engine whereby air is compressed and held in a storage reservoir for subsequent expansion and recovery of energy therefrom through an expansion engine, the compression of the air being accomplished at a relatively low temperature by means of a refrigeration system removing thermal energy from the air. It would also be an advancement in the art to provide an air compressor apparatus wherein a refrigerant absorbs thermal energy from the air and at least a portion of that energy is used to increase pressure within the refrigerant to thereby assist in compressing the air. It would also be an advancement in the art to utilize a portion of the compressed air to recover heat from a combustion engine and use the heated air as the combustion air. Such an apparatus and method is disclosed and claimed herein.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
The present invention relates to a split cycle, air standard or pneumatic engine apparatus and method wherein pressurized air for driving the pneumatic engine is stored at high pressure and at ambient temperature for subsequent utilization in the pneumatic or expansion engine and also as a combustion air for a combustion engine. The pressurized air is produced in a refrigerant-assisted air compressor mechanically operated by the combustion engine. Thermal energy is absorbed from the compressed air by the refrigerant and the resulting pressure of the refrigerant is utilized to assist in compressing the air. Cooled exhaust air is recycled from the expansion engine and is utilized to cool the refrigerant thereby reducing the pressure of the refrigerant during the intake stroke of the compressor.
It is, therefore, a primary object of this invention to provide improvements in air standard engines.
Another object of this invention is to provide an improved method for converting thermal energy to mechanical energy.
Another object of this invention is to provide an improved air compressor apparatus wherein thermal energy developed during the compression cycle of the air is absorbed by a refrigerant, the thermal energy absorbed thereby increasing the pressure of the refrigerant to assist in compressing the air.
Another object of this invention is to provide an air compressor apparatus wherein a refrigerant-assisted air compressor is utilized to compress air with the pressure of the refrigerant being lowered by removing thermal energy therefrom with cool exhaust air recycled from the expansion engine.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a schematic illustration of the apparatus of this invention with portions shown in cross section and also broken away to reveal internal construction for ease of presentation and understanding.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is best understood by reference to the drawing wherein like parts are designated with like numerals throughout.
General Discussion
A typical compressor is a reciprocating machine wherein air is compressed in a cylinder. The capacity of a compressor is measured in terms of standard cubic feet of gas and in industrial practice, a standard cubic foot is based on a temperature of 60° F. and an absolute pressure of 30 in. Hg. This corresponds to a molal volume of 378.7 cubic feet/lb mole. While standard compressors handle up to about 2,000 std. cubic feet/min., the capacity of a given machine depends on its volumetric efficiency (the ratio of the volume of gas delivered to the volume swept up by the piston) and which falls as the discharge pressure rises.
Importantly, the air is heated by the work of compression. Because of the heating, the gain in pressure in a single-stage compressor is limited, so that for high discharge pressures, multi-stage compressors are required. In small compressors handling very small amounts of gas, the rise in temperature of the gas on compression may be negligible. When there is no temperature change in the gas, the compression is said to be isothermal. More commonly, however, the gas is considerably hotter at the discharge than at the inlet. When there is no loss of heat to the surroundings, the compression is adiabatic. Accordingly, the power required to compress a gas depends on the inlet temperature, since a hot gas requires more work than a cold one, and on the mechanical efficiency, which is higher with heavy gasses than with light ones. The efficiency varies with the compression ratio, which is the ratio of the absolute discharge pressure to the absolute inlet pressure. In reciprocating compressors, the compression ratio is usually between about 2.5 and 6 in each stage while the adiabatic efficiency is a maximum of 80 to 85 percent at a compression ratio of about 4. In multi-stage compressors, the compression ratio should be the same in each stage, since the power drawn by each stage is the same. Between the stages of multi-stage compressors are intercoolers, which are air or water cooled heat exchangers to remove the heat of compression. Often an aftercooler or aftercondenser follows the last stage.
In summary, when a gas (air) is compressed, its volume is decreased and, therefore, work is done upon it. This work, in addition to the frictional losses of the compressor, must appear as heat. The mass of the compressed air is relatively small and, consequently, compressing the air results in an appreciable rise in temperature. For the most efficient operation of the compressor, this heat should be removed and the air discharged from the compressor as nearly as possible at the temperature at which it enters.
Referring now to the drawing, the split cycle engine apparatus of this invention is shown generally at 10 and includes a combustion engine 12, a first compressor 14, a second compressor 16, a storage tank 18, and an expansion engine 20. The combustion engine 12 is illustrated as a conventional turbine although it should be clearly understood that combustion engine 12 could include a conventional internal combustion (piston) engine, external combustion (steam) engine, or the like. However, for ease of illustration herein, reference will be made to combustion engine 12 being configurated as a conventional turbine.
Combustion engine 12 is a conventional turbine including a turbine rotor 22 rotatably mounted to a shaft 24 and housed in a turbine housing 26. An air heater 30 consisting of a coil of finned tube heat exchanger is wound around a cylindrical baffle 28 and receives pressurized air from inlet line 34. Combustion engine 12 is operated by using as combustion air, compressed air from line 34, controlled by a valve 35, and which passes through air heater 30 to thereafter be mixed with fuel from a fuel inlet 36. Supplemental combustion air is introduced through inlet 41 and controlled by check valve 40 to thereby provide sufficient oxygen for combustion. Additionally, the temperature of air introduced through air heater 30 is controlled by adjustment of its flow rate as set by valve 35 to preclude premature ignition of the fuel and air mixture. The fuel/air mixture is then directed to a combustion chamber 42 and ignited by an igniter apparatus 43. The hot combustion products (indicated schematically herein at 31) pass through a turbine rotor 22 turning the same as is conventional. The hot exhaust gasses, indicated schematically at 32, pass outwardly through the annular space around the baffle 28 and across air heater 30 heating the incoming air. The cooled exhaust is then exhausted to the atmosphere as cooled exhaust 33. A substantial portion of the thermal energy in hot combustion products 31 is therefore converted to mechanical energy turning shaft 34. Shaft 34 is mounted in pillow bearing 25 and is connected by belt 44 to shaft 46. Shaft 46 turns crankshaft 48. Crank 50 converts the rotary motion to a reciprocatory motion of a piston 56 in compressor 14.
Compressor 14 is configurated as a dual function compressor having a cylindrical vessel segregated by a piston 56 into an upper, refrigerant chamber 60 and a lower, compression chamber 58.
A piston rod 54 and a connecting rod 52 interconnect piston 56 to crank 50 so that rotation of crank 50 moves piston 56 in a reciprocatory manner in compression chamber 58 and refrigerant chamber 60. Piston 56 includes piston rings 59 and serves as a divider between the lower compression chamber 58 and the upper, refrigerant chamber 60. Piston 56 is configurated as a bowl-shaped piston having a piston refrigerant basin 57 formed therein to serve as a catchment basin for a body of refrigerant 62. Refrigerant 62 is in intimate thermal contact with the walls of piston 56 to thereby absorb thermal energy from air compressed within compression chamber 58. Thermal energy absorbed by refrigerant 62 volatilizes the same, increasing the pressure in refrigerant chamber 60 and producing a vapor which passes through a refrigerant outlet 67 into finned cooling coils 64. Finned cooling coils 64 are exposed to the ambient and are also in thermal contact with exhaust header 74. Condensed refrigerant is returned through check valve 65 into refrigerant reservoir 70 where it is discharged downwardly through pores 63 and again collects in piston refrigerant basin 57.
Air for compressor 14 is introduced through an inlet 76 into an intake plenum 72 formed as an annular chamber about the upper refrigerant chamber 60 and the lower compression chamber 58. The inlet air is then directed through a finned tube outlet 77, through a check valve 80, and inlet 82 into compression chamber 58. During its traversal of intake plenum 72, the inlet air is first cooled by contact with refrigerant chamber 60 and thereafter absorbs thermal energy from compressed air within compression chamber 58. The air then releases a portion of the absorbed thermal energy through finned outlet tube 77. Finned outlet tube 77 is also interconnected with an outlet header 78 interconnected with compressor 16 so that a multiple set of compressors, compressors 14 and 16, can be utilized.
Downward movement of piston 56 compresses air within compression chamber 58 forcing the same outwardly through outlet 84, check valve 86 into outlet conduit 88. Outlet conduit 88 includes a plurality of fins 89 thereon, the fins 89 serving to dissipate any residual thermal energy therein to the ambient. Thereafter, the compressed air is stored within storage tank 18 for subsequent utilization as will be set forth more fully hereinafter.
Compressed air storage tank 18 is illustrated schematically and is, therefore, shown as being relatively small. However, it is to be expressly understood that compressed air storage tank 18 is configurated as an energy storage reservoir and the capacity thereof will be dictated by the specific design of the overall system. As an energy storage system, compressed air storage tank 18 serves as a "battery" to provide for a simple self-starting of the system. Also, combustion engine 12 can be operated at maximum efficiency with the mechanical energy thus produced being efficiently stored as high pressure air in compressed air storage tank 18. Thus, momentary surges in shaft output demand on shaft 21 of expansion engine 20 are easily met by the reserve capacity of compressed air storage tank 18 without requiring a change in the operation of combustion engine 12. After the demand surge is over, the continued steady state operation of combustion engine 12 replenishes compressed air storage tank 18 so that a relatively small combustion engine 12 can be used to operate the overall system.
The compressed air in compressed air storage tank 18 is stored at ambient temperature as a result of being cooled by thermal contact with refrigerant 62, cold intake air in intake plenum 72, and finned outlet tube 88. The compressed air is directed by a high pressure conduit 90 to a valve 92 operated by a controller 93 and is directed to either forward conduit 94 or reverse conduit 95 into the expansion engine 20.
Expansion engine 20 is a conventional expansion engine and converts the pressure of high pressure air in conduit 90 to mechanical energy by rotation of shaft 21. Advantageously, expansion engine 20 can serve as either a prime mover or a braking mechanism, depending upon the direction the high pressure air from conduit 90 is introduced therein. For example, high pressure air directed through forward conduit 94 drives expansion engine 20 in a forward direction with the exhaust air passing through conduit 95 into exhaust conduit 96. The operator (not shown), through the use of controller 93, may change valve 92 so that the high pressure air from conduit 90 is directed through reverse conduit 95 driving expansion motor engine 20 in the reverse direction with the exhaust directed through conduit 94 into exhaust conduit 96. Accordingly, expansion engine 20 may be used for either a prime mover or a braking mechanism as set forth hereinbefore.
During periods when expansion engine 20 is inoperative or under low power conditions and compressors 14 and 16 are fully operational, additional or makeup air is supplemented to the system as intake air 100 through an intake 98 controlled by a check valve 99. The air, either as intake air 100 or exhaust air from exhaust outlet 96 is directed into exhaust plenum 74 which is in intimate thermal contact through finned tube 64. Advantageously, since the high pressure air in storage tank 18 is at ambient, expansion of the air through expansion engine 20 will result in a substantial cooling of the air. The cooling capability of the air in exhaust header 74 is then utilized for producing condensed refrigerant 62, as set forth hereinbefore.
Advantageously, the refrigerant heat transfer method of this invention provides for an approximately isothermal heat transfer of the heat of compression, thereby significantly reducing the work of compression in compressors 14 and 16. Additionally, the heat input to the refrigerant 62 causes a corresponding increase in pressure of the refrigerant with the positive force therein assisting the downward compression stroke of piston 56. Also, the cooled incoming air through exhaust header 74 causes a decrease in the refrigerant pressure and therefore a reduced pressure in refrigerant chamber 60 with a corresponding reduction in the forces exerted on piston 56 during the intake stroke or upward movement of piston 56.
Compressed air storage tank 18 includes a valve 102 which may be configurated either as a safety valve or an injection valve for initially charging air pressure within compressed air storage tank 18. Additionally, a conventional coupling 104 may be included for the purpose of coupling various pneumatic tools or devices to compressed air storage tank 18. A conventional liquid trap 106 may be included for the purpose of collecting and subsequent removal of condensed refrigerant, water, and the like from compressed air storage tank 18.
Since the production of mechanical energy is split between a compression cycle consisting of combustion engine 12 operating compressors 14 and 16 and an expansion cycle consisting of expansion engine 20 operated by compressed air from compressed air storage tank 18, the overall apparatus of this invention is referred to as a split cycle engine. Importantly, the work required to produce compressed air for compressed air storage tank 18 is substantially reduced by the novel refrigerant coolant/compression assist technique herein.
The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A split cycle engine apparatus and method, the apparatus including a combustion engine, a novel compressor apparatus driven by the combustion engine, a closed-cycle refrigeration system in cooperation with the compressor apparatus, and a pneumatic motor driven by compressed air from the compressor apparatus. Refrigerant in the compressor absorbs thermal energy from compressed air and assists in compressing the air. High pressure air from the compressor is stored in a storage tank and may be used to drive the pneumatic motor or other auxiliary equipment in addition to providing high pressure combustion air for the internal combustion engine. | 5 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to railway track equipment and in particular to a system and method for lubrication of the flanged wheels of rolling stock relative to the track upon which they run. Such systems have been in use for many years and are exemplified, for example, by the Huber et al U.S. Pat. No. 2,238,732 of 04/14/41; the Lutts U.S. Pat. No. 4,214,647 of 07/29/80; and the Lounsberry, Jr. U.S. Pat. No. 4,334,596 of 06/15/82, the disclosures of which patents are incorporated herein by reference.
Systems of the type to which this invention is directed are plagued by the problem of controlling the precise amount of lubricant to be dispensed under all of the varying conditions encountered. For example, the lubricant itself may vary in viscosity from batch-to-batch being stored in the reservoir and this presents problems. Further, the systems are required to operate year round and under varying conditions of temperature so that the lubricant, regardless of its nominal viscosity, will display viscosity variations dependent upon ambient temperature.
Contemporarily, it is considered desirable that the lubricant usually be of relatively high viscosity, e.g., grease, in order for the proper lubrication effect be achieved and since such lubricants will display temperature-sensitivity with respect to viscosity, it is difficult, at best, to so control the lubricating system that the desired amount of lubricant is dispensed in the face of the wide range of temperature conditions to which such systems are subjected.
Accordingly, it is a principal concern of this invention to provide a railway lubricating system and method in which the desired, accurate and proper amount of lubricant is dispensed.
Another object of this invention is to provide a system as above in which the desired amount of lubricant is accurately dispensed irrespective of ambient temperature conditions.
An object of the invention resides in apparatus and method of controlling the amount of lubricant dispensed in a railway lubricating system, which comprises the steps of effecting a test cycle during which lubricant is dispensed in test amount to detect the influence of lubricant viscosity on the system, and then effecting further dispensing cycles each to dispense an accurate and desired amount of lubricant in conformity with the detected influence of lubricant viscosity.
Stated otherwise, it is of concern with respect to this invention to provide a system and method in which an initial setting is made to control the amount of lubricant which is dispensed, such set amount not necessarily being in conformity with the desired amount of lubricant required during a dispensing cycle under the temperature conditions prevailing at the time of setting, in combination with feedback means responsive to lubricant viscosity for altering the value of such initial setting to conform with the desired amount of lubricant to be dispensed under the temperature conditions prevailing at a dispensing time subsequent to the time of setting.
In accord with the above, it is of importance that the pump and drive therefor employed to dispense the lubricant be of a type which may be controlled to assure accuracy of the amount of lubricant dispensed, and that means be provided for detecting the amount of lubricant actually dispensed during a dispensing cycle to provide the necessary feedback by which the control of the pump and its drive is altered to effect dispensing of the desired amount of lubricant.
In accord with this invention, it is preferred that the dispensing pump be of the positive displacement gear type and that the drive means therefor controls the dispensing displacement of the pump, with the dispensing displacement being feedback controlled to assure accuracy of the amount of lubricant dispensed.
Stated otherwise, this invention contemplates controllable drive to a positive displacement pump for each of a sequence of lubricant-dispensing cycles with feedback, determined by the amount of lubricant dispensed during a cycle, for changing the duration of drive for a subsequent cycle in the direction of attaining the desired amount of dispensed lubricant during such subsequent cycle.
Other and further objects of this invention will become apparent as this description proceeds.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a perspective view of the system of this invention associated with a railway rail;
FIG. 2 is a view illustrating the pump and motor unit;
FIG. 3 is a plan view of the shaft encoder and motor;
FIG. 4 is a block diagram illustrating the control system; and
FIG. 5 is a longitudinal section through the clutch mechanism utilized in this invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the system of this invention is shown installed along the right-of-way of a railway system, a part of which is shown including the rail R' supported by the usual ties T to which are attached a number of lubricant applicators 10. The lubricant distribution system for these applicators includes the feed lines 12 and 14, each connected to two of the applicators and also connected with the branch feed line 16 connected as shown to the main feed line 18. The main feed line is coupled as at 20 to the lubricant outlet line 22 feeding from the pump P located on an inner wall or panel 24 of the unit housing H. The space between the walls 24 and 26 houses the microprocessor controller 28 as well as the pump P and the motor M whereas the space between the wall 24 and the rear wall 30 defines the grease hopper or lubricant reservoir R. The reservoir R is provided with a hinged lid L and also located in the space between the walls 24 and 60 is the battery box B having its own hinged lid or cover 34 and housing the battery 32. The housing is provided with the top cover or lid C.
In FIG. 2, the arrangement of the pump and motor on the wall 24 is shown with it being understood that the pump includes an inlet communicating with the reservoir R. The pump P is of the well known rotary gear type and its input shaft is connected through the reversed overrunning clutch 36 and the coupler 38 to the output shaft 40 of the gear reduction unit 42 driven by the motor M. It is to be noted that the clutch 36 is mounted directly on the housing of the pump P, with the effect that whereas the motor M may transmit rotary motion to the pump P, reverse direction rotation of the pump P cannot impart reverse rotation to the motor M, but is locked against such reverse rotation by the pump housing.
As shown in FIG. 5, the clutch includes a drum portion CDI provided with a set screw SC which affixes this drum portion to the pump shaft PS. A second drum portion CD2 is provided with an internal bushing BU rotatably receiving the nose portion NP of the portion CD1 and the portion CD2 is provided with a flange F having openings O through which suitable fasteners are received to secure the flange to the housing of the pump P. The pump shaft PS is thus directly connected to the motor shaft 40 through the coupling 38 so that the motor is free to rotate the pump shaft in one direction of rotation. The normal operation of the clutch would be to connect the flange F to the input so that in one direction of rotation which winds the helical spring HS, the friction surfaces FS are tightly engaged to transmit torque through the flange F and the friction surfaces FS as urged into frictional contact by the winding of the spring. However, as used herein, coupling of the pump shaft PS to the motor shaft 40 is direct in one direction of rotation of the input shaft 40 but if the pump shaft attempts to reverse this direction of rotation, the clutch is so oriented that reverse rotation of the drum portion CD1 will wind the spring HS tightly to couple the two drum portions together through the friction surfaces FS and thus lock the pump shaft to the pump housing against this reverse direction of rotation.
At its upper end, the motor output shaft drives the shaft encoder 44 associated with the optical reader or encoder 46 having the output signal line 48. The shaft encoder is illustrated as having 72 teeth and since the reduction unit 42 is geared 10/1, one rotation of the pump P equals 720 rotations of the motor shaft. Thus, the optical encoder reads in units of 1/720 pump shaft rotations. The dispensing output of the pump P may be, for example, 0.041 pound of lubricant per pump shaft rotation. The motor M is powered over the line 50 under control of the microprocessor 28 as will now be described in conjunction with FIG. 4.
In FIG. 4, the microprocessor 28, which may be a type Z8681PE, is illustrated as connected with the wheel sensor S (see also FIG. 1) to receive trigger signals over the line 52, to the optical encoder 46 over the line 48, and to the setting means 56 over the address selection path 54. The microprocessor is also connected over the path 58 to the ROM 60 in which a plurality of commands are stored, some of which are addressed in accord with the setting selected in the means 56, there being further commands stored in the ROM as will become apparent presently. It is well at this point to specify the general method steps involved. Assuming that the system is in the shut-down mode so that the microprocessor 28 is turned off whereby the only current drain on the battery is that which is required to render the system responsive to an input signal from the sensor S, a first signal from the sensor S (detecting the presence of the first wheel of the train which has passed over the sensor) causes the microprocessor to power up; the second signal from the sensor S (indicating that the second wheel of the train has passed over the sensor) causes the microprocessor to execute the PILOT cycle or mode during which the motor M is powered for a period of time such that the system operates to create backpressure of lubricant in the flexible feed lines; the third signal from the sensor (indicating that the first wheel after the PILOT pulse has passed over the sensor) causes the microprocessor to execute a TEST cycle or mode during which the motor M is powered for a time which should dispense the desired and accurately correct amount of lubricant and in response to which the microprocessor monitors the number of pulses received from the encoder means 46, compares this number of pulses with the number of pulses which should be received (corresponding to the correct or desired amount of lubricant which should be dispensed) and adjusts the number of pulses to that value (which would cause the motor M to be powered for that time sufficient under the conditions present to dispense the accurately correct, desired amount of lubricant) which the system temporarily stores (in a temporary storage register in the microprocessor); the fourth signal from the sensor (and subsequent signals for the train in question) causes the number of pulses dictated by the temporarily stored signal to take control. In this regard, it is to be noted that the adjusted number of pulses which has temporarily been stored causes power to the motor M to be terminated as of the receipt of that encoder pulse which assures that the pump P will dispense the desired quantity of lubricant. It should be noted that termination of power to the motor M is commanded as of the last of the number of pulses stored.
The nominal time during which the motor M is powered in response to the TEST command is usefully based upon the ordinary or room temperature and the nominal viscosity of the lubricant in question. In this regard, the lubricant may possess a nominal low viscosity for "winter" grade lubricant, a higher viscosity for "general purpose" lubricant, and a still higher viscosity for "summer" grade lubricant. The nominal time should take into account such things as the horsepower of the motor, the gear reduction and the capacity of the pump. The inertia effects of the motor, gear reduction unit and the pump will cause some degree of "coast" subsequent to termination of power to the motor M and this, in turn will vary under actual dispensing conditions dependent upon the grade of the lubricant and the ambient temperature. That is, as ambient temperature drops, the stiffer the lubricant and consequently the slower the motor M will rotate. If the ambient temperature is too low, the lubricant may be so stiff that the motor cannot rotate, in which case the microprocessor is programmed (no encoder pulses received) to terminate power to the motor M and indicate such condition and to prevent further attempt to power the motor and thus protect it from damage. The degree of "coasting" may vary from zero or almost zero (no encoder pulses received after termination of power to the motor) to a high value of received encoder pulses, dependent upon the viscosity of the lubricant under the ambient temperature conditions prevailing.
An output path 62 of the microprocessor controls the switching means 64 to power the motor M over the line 50 from the 12 volt line 66 from the battery 32. The switching means is of solid state type and may simply be a power transistor for the DC application illustrated. It is well to point out at this time that AC operation is possible as well, in which case the battery is omitted from the system and an available AC source utilized. In this case, the AC source supplies 120 V AC power from which the necessary 5 V DC for operation of the microprocessor is obtained and, in this case, the switching means 64 may conveniently take the form of a TRIAC. As noted above, there are further command signals which may be stored in the ROM 60 and the microprocessor is programmed to address them as necessary. One of these further stored command is PILOT. The PILOT command is addressed by the microprocessor 28 in response to the second input from the sensor S, as noted above, and the microprocessor 28 then sends a signal onto the line 62 which powers the switching means 64, and thus the motor M, for a period of, say 1/2 seconds. The causes the motor to drive the pump for a time sufficient to create backpressure of lubricant in the feed lines. This is important to assure accuracy of lubricant dispensing in the following sequence of commands. It is to be noted at this time that the PILOT command may be made temperature-dependent, in which case an ambient temperature sensor signal is required to be input to the microprocessor 28. The reason for this temperature dependence is that the lubricant will display increasing viscosity as temperature drops. The mentioned 1/2 second command to the motor has been determined to be adequate down to temperatures of about 10° F. whereas below that temperature, the PILOT command period should increased to about 10 seconds. This step change has been found to be adequate, but it is obvious that the PILOT command period may be made continuously adjustable dependent upon ambient temperature.
The second detection signal by the sensor S (next train wheel sensed after PILOT) causes the microprocessor to address that command signal stored in the ROM 60 as selected by the means 56 and this is the TEST signal command as noted above. This stored command corresponds to the number of encoder pulses which should lead to a known quantity of lubricant to be dispensed by the pump P but in fact is essentially an arbitrary value of the number of encoder pulses which will be received based upon what can be termed as a "best guess", and it is in response to this TEST command that the microprocessor 28 determines the effect of lubricant viscosity on the system via the encoder output. This is done by counting the number of pulses output by the encoder in response to this stored command. The TEST command stored in the ROM is the number of pulses programmed into the ROM corresponding to a selected setting effected by the means 56 and that number of pulses may be designated as N com , that is, the number of pulses output by the encoder before the power to the motor is terminated. As the motor rotates, it is first doing so while power to it is on under the command of the pulses N com and which, due to the large gear reduction noted, will impart sufficient torque on the pump (already backpressured) that the pump will "coast" to some degree after power to the motor is terminated after the encoder feeds back a number of pulses equal to N com , and thus cause the encoder to output a number of additional pulses, N coast . Obviously, the number of N coast pulses is a measure of lubricant viscosity under the conditions then prevailing and will vary dependent upon the lubricant type and ambient temperature. The microprocessor computes N com =N total - N coast , where N total is the number of pulses which will result in the dispensing of the accurate and desired amount of lubricant. The number of pulses N com is then stored in, the temporary register of the microprocessor 28 and this value N com is used as subsequent command outputs by the microprocessor as additional sensor outputs are received.
Pulses from the encoder are shaped so as to be of 5 volt, square wave form having a duration of about 0.01 ms so as to be readily accepted by the microprocessor.
From the above description, it is apparent that when considering an event which consists of passage of a series of railway wheels, the first wheel which is sensed causes the system to power up; the second wheel which is sensed after this powering up takes place is used to create lubricant backpressure; the next wheel sensed causes the system to determine the correct period of "power on" to the motor M; and subsequent wheels sensed cause the system to dispense the accurate and desired amount of lubricant which has been selected. In the event that the velocity of the train is so high that the passage of wheels over the sensor does not provide adequate time for a dispensing operation in response to each wheel sensed, the microprocessor is programmed to accumulate 10 such sensed wheels and defer corresponding dispensing operations for these 10 sensed wheels until such time is available for them. An available time or times may occur between the passage of a front truck of a railway vehicle and the passage of its rear truck, for example, or a total of ten dispensing cycles may be deferred until after the last wheel of the train is sensed.
The microprocessor is also programmed to shut down after a delay of 60 seconds between sensed wheels. This is done to conserve power particularly in the DC embodiment, but also to allow the PILOT and TEST operations to be performed again in the event that a sufficient period of time passes before the next wheel is sensed that temperature conditions may have changed and have rendered the computation performed during the previous TEST cycle to be no longer valid.
In considering this invention, the above disclosure is intended to be illustrative only and the scope and coverage of the invention should be construed and determined by the following claims. | A method and apparatus for controlling the amount of lubricant dispensed in a railway lubricating system wherein a test cycle is effected during which lubricant is dispensed in a test amount to detect the influence of lubricant viscosity on the system, and wherein further dispensing cycles are effected to sequentially dispense an accurate and desired amount of lubricant in conformity with the detected influence of lubricant viscosity. | 1 |
BACKGROUND
Technical Field
The present invention relates to a method for sharing a frequency spectrum between networks, and in particular, to a method for sharing a frequency spectrum between different co-primary networks, and belongs to the field of wireless communications technologies.
Related Art
In recent years, heterogeneous networks (Heterogeneous Network, HetNet) draw widespread attention. A flexible networking mode of heterogeneous networks can satisfy diverse different requirements. Referring to FIG. 1 , deployment of a macro cell (Macro cell) can provide wide area coverage, and deployment of a large quantity of small cells such as a micro cell (Microcell), a pico cell (Pico cell), a cell served by a home NodeB (Femto cell), and the like not only can enhance indoor coverage, but also can provide high-speed access. Compared with a macro base station, a small-cell base station has much lower transmit power. For some indoor small-cell base stations deployed, a radio signal of the base station suffers from great wall-penetration loss after penetrating a building. Consequently, under a condition that geographical locations are isolated, operators of heterogeneous networks can share a frequency spectrum while no strong interference is caused.
Co-primary spectrum sharing (Co-primary Spectrum Sharing) is a new frequency spectrum access mode, and co-primary frequency spectrum sharing that is dynamic and flexible can be implemented between different operators. It is required that two or more wireless frequency band license holders perform negotiation to agree on how to jointly use some authorized frequency bands of the holders. An entire frequency spectrum sharing mode is controlled by a national frequency band management organization. Therefore, a new mode is envisaged: A frequency band management organization no longer exclusively allocates a frequency spectrum resource to one operator, but simultaneously allocates a frequency spectrum resource to multiple potential operators (users). The potential operators (users) are required to jointly use the frequency spectrum resource fairly according to some particular rules. This new frequency spectrum using mode already starts to be discussed by organizations and institutions in the world. For example, it is involved in the discussion of allocating a 3.5 GHz frequency band in a fixed broadband wireless access (Fixed BWA) system by the German Federal Network Agency in May, 2004. In addition, a similar concept is also proposed in the “light licensing” scheme about 3650-3700 MHz by the Federal Communications Commission of America.
FIG. 1 shows a scenario of coverage overlapping between hybrid networks deployed by different operators in the current stage. Both an operator A and an operator B deploy a network in an area. A 1 to A 5 are five small-cell base stations deployed by the operator A, and B 1 to B 4 are four small-cell base stations deployed by the operator B. In the figure, coverage overlapping between networks of the two operators has three cases as follows: A degree of coverage overlapping is high; a degree of coverage overlapping is intermediate; and a degree of coverage overlapping is low, or there is no coverage overlapping. Policies used by different operators to separately deploy networks may be greatly different, and in addition, it is very difficult for different operators to exchange detailed information about network deployment, and a network topology can be estimated only according to some limited insensitive information, to determine a frequency spectrum allocation method. Therefore, if a network coverage topology deployed by different operators can be known, it is of great significance for the operators to negotiate a frequency spectrum allocation policy, and frequency spectrum utilization can be improved.
SUMMARY
In view of disadvantages in the prior art, a technical problem to be resolved in the present invention is to provide a method for sharing a frequency spectrum between networks.
To achieve the foregoing objective of the present invention, the present invention uses the following technical solutions:
A method for sharing a frequency spectrum between networks is provided, used to implement allocation of a shared frequency spectrum between a first network (A) and a second network (B), and comprising the following steps:
measuring a network signal of the second network (B);
calculating, according to the network signal of the second network (B), an indicator indicating a degree at which the first network (A) overlaps with the second network (B), and obtaining network-coverage-topology-based information of the second network (B) according to the network overlapping level indicator (V);
exchanging, by the first network (A) and the second network (B), the network-coverage-topology-based information of the second network (B), and obtaining network-coverage-topology-based information of the first network (A) from the second network (B); and
calculating a frequency spectrum jointly used by the first network (A) and the second network (B).
Compared with the prior art, the present invention has the following technical features:
1. The present invention is applied to share a frequency spectrum resource between different operators/networks/users in a certain range. A shared frequency spectrum resource is reasonably allocated between different operators according to a degree at which network coverage of the different operators overlap, which implements co-primary spectrum sharing, and improves frequency spectrum utilization of an entire communications network.
2. A frequency spectrum can be fairly shared on a co-primary basis, it is ensured that different terminals in an area in which network coverage overlaps can fairly use a frequency spectrum resource, and interests of different operators are safeguarded.
3. Frequency spectrum allocation can be automatically adjusted on a co-primary basis according to different network coverage overlapping degrees, and a suitable operator is enabled to occupy a jointly used frequency spectrum that is reasonable, which has a wide application range, a simple algorithm, and high efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a scenario of coverage overlapping between hybrid networks deployed by different operators in the current stage;
FIG. 2 is a block flowchart of implementing frequency spectrum sharing between different networks;
FIG. 3 is a detailed flowchart of implementing frequency spectrum sharing between different networks according to the present invention;
FIG. 4 is a schematic diagram of allocating a frequency spectrum in a scenario of overlapped coverage of different networks;
FIG. 5 is an exemplary diagram of allocating an exclusively occupied frequency spectrum and a jointly used frequency spectrum in frequency spectrums used by a first network; and
FIG. 6 is a schematic diagram of sharing and allocating a frequency spectrum between different networks.
DETAILED DESCRIPTION
The present invention is described in further detail below with reference to accompanying drawings and specific embodiments.
A method for sharing a frequency spectrum between networks provided in the present invention is applicable to any one of 2G/3G/4G or other future wireless communications networks, co-primary spectrum sharing between multiple operators is currently not yet applied to an existing network such as 2G/3G, but the possibility that this method is applicable to 2G/3G is not excluded. Only a 4G-LTE network is used as an example below to describe a solution of sharing a frequency spectrum between different operators or different networks. The following mainly discusses a case of co-primary networks of different operators, and a case of different co-primary networks of a same operator is similar, which is not described in detail herein again.
The method for sharing a frequency spectrum between networks is mainly applicable to co-primary networks. A reasonable frequency spectrum division solution is provided according to an inter-network coverage overlapping degree of a different operator, to share a frequency spectrum between operators/networks, which is applicable to fairly share a frequency spectrum resource between different operators/networks in a certain range on a co-primary basis. In an area in which coverage of networks overlap, an operator guides a user terminal (User Equipment, UE) to perform measurement on a different operator, where the user terminal is in the area deployed by the operator, estimates, according to a result of the measurement of the different operator, a degree at which coverage of a network deployed by another operator in the area and a network of the present operator overlap, and obtains, according to network overlapped coverage topology information, a solution for allocating a shared frequency spectrum between different operators. Referring to FIG. 2 and FIG. 3 , the present invention is introduced in detail below by using a process of sharing a frequency spectrum between an operator A and an operator B as an example.
An operator classifies small cells into different groups according to geographical locations and coverage areas. When performing group classification, the operator needs to allocate a corresponding group identifier to each group. After group classification, a small cell needs to notify, to a small-cell base station, a group identifier of a group to which the small cell belongs. This method is applicable to a small cell or a macro cell, and may be selected for use according to a service requirement.
Step 1. Different networks separately perform measurement and reporting on a different operator.
A small-cell base station of an operator/a network needs to guide a user terminal of the base station to measure a network signal of a different operator. When the user terminal completes information measurement of the different operator, the user terminal needs to send, according to a predefined format, a measurement report of the different operator to the base station that serves the user terminal. After the base station receives the measurement report of the different operator from the user terminal, the base station forwards the measurement report and a group identifier to an operation and maintenance (Operation and Maintenance, O&M) node of the corresponding operator. The operation and maintenance node performs determining according to the measurement report of the different operator and the group identifier, and evaluates an overlap degree indicator (Overlap Degree Indicator) that indicates a small cell, of the different operator, within a group range that is indicated by the group identifier; and consequently, the operation and maintenance node can determine a network coverage topology of the different operator.
In an embodiment of the present invention, a first operating network/a first network A (which is referred to as a present operator below) and a second operating network/a second network (which is referred to as a different operator below) B are included. It may be understood that the so-called “present operator” and “different operator” are relative to each other, and may be exchanged. A small-cell base station of the present operator A is SeNBA, an operation and maintenance node is O&MA, and a user terminal served by SeNBA is UEA. A small-cell base station of the different operator B is SeNBB, an operation and maintenance node is O&MB, and a user terminal served by SeNBB is UEB. That SeNBA performs measurement and reporting on the different operator is introduced below.
All user terminals UEA of SeNBA perform measurement on the different operator. A user terminal UE A may initiate measurement on the different operator in multiple manners: In a first manner, measurement is performed periodically, and a measurement period is preconfigured by the base station after operators perform negotiation. In another manner, measurement may be triggered by an event, and a trigger event may be that the base station or the UE is strongly interfered. An initiating condition may be set according to a service requirement, and details are not described in detail herein.
At the same time, all user terminals UEB of SeNBB also perform measurement on the different operator. For the purpose of conciseness, FIG. 3 does not show working content of the different operator B (including a user terminal UEB, SeNBB, and the like), and a working manner and working content thereof are the same as that of the present operator A.
SeNBB is a small-cell base station of the different operator measured by UEA. The user terminal UEA measures, according to a reference signal periodically sent by SeNBB, signal strength information, that is, a reference signal received power (Reference Signal Received Power, RSRP) of a corresponding small cell served by SeNBB of the operator B, and after the measurement is completed, UEA sends a network information measurement report of the different operator to the small-cell base station to which UEA belongs. The measurement report of the different operator needs to be sent according to a defined format, and the report includes a SeNBB reference signal received power RSRP received by the user terminal UEA in the measured small cell, an operator identifier/a network identifier (operator ID) and a group identifier (group ID), and an E-UTRAN cell global identifier (E-UTRAN Cell global Identifier, ECGI). In addition, if a measured cell belongs to a closed subscriber group, a closed subscriber group identifier (CSGID) should be further included, and if a measured cell does not belong to a closed subscriber group, a closed subscriber group identifier does not need to be reported.
Step 2. Evaluate, according to a network measurement report of a different operator, an indicator that indicating a degree at which a network of a small cell of a present operator overlaps with a network of a small cell of the different operator.
In step 1, the small-cell base station of the present operator reports the network measurement report of the different operator to the operation and maintenance node to which the base station belongs. The operation and maintenance node can determine, according to different network measurement reports of the small-cell base station, a status of overlapping between a small cell of the different operator B and network coverage of the present operator A. In this embodiment, a network coverage overlap degree indicator is used to indicate a degree at which a small cell deployed by the different operator overlaps with network coverage of the present operator. The overlap degree indicator is obtained in multiple manners. Because a small cell deployed by a different operator may be detected by multiple cells deployed by the present operators, in an embodiment of the present invention, the overlap degree indicator is obtained by using a sum of neighbor relationship values that are multiplied by RSRP weights. A process of calculating the overlap degree indicator is as follows:
If a small cell of the present operator A can obtain through measurement a small cell deployed by the different operator, a reference neighbor relationship value of the small cell of the different operator B is set to 1; or if no small cell can be obtained through measurement, a reference neighbor relationship value is 0. Then, a weight value of a reference signal received power of each small cell of the different operator that is obtained through measurement is calculated. All neighbor relationship values, multiplied by weights, of the small cell of the different operator that is obtained through measurement are finally added to obtain an overlap degree indicator of the small cell. Because the reference neighbor relationship value is 1, only weight values of reference signal received powers, obtained by small-cell base stations SeNBA through measurement, of the small cell of the different operator B need to be added to obtain an overlap degree indicator of the small cell of the different operator B.
In an embodiment of the present invention, the small-cell base station SeNBA forwards, to the corresponding O&M A , a measurement result of the different operator that is obtained by the user terminal UEA. O&M A calculates, according to a network signal measurement result of the different operator, an indicator that indicates a degree at which each small cell of the different operator B that is obtained through measurement overlaps with a network of the present operator A. Therefore, an indicator V that indicates a degree at which a small cell of the different operator B that is obtained through measurement overlaps with a network of the present operator is calculated by using the following formula:
V
x
(
B
)
=
∑
i
=
1
N
W
i
.
(
1
)
x is a sequence number of a base station SeNBB obtained through measurement, i is a sequence number of SeNB A that has a neighbor relationship with the x th SeNBB, N is a quantity of SeNB A that have a neighbor relationship with the x th SeNBB, and Wi is a weight value that is calculated according to a reference signal received power value, reported by a user terminal of the i th base station SeNB A of the present operator, of the x th base station SeNBB of the different operator. The network overlapping level indicator V represents a degree at which a base station of the different operator B that interferes with a small cell of the present operator A interferes with a small cell of the present operator A. In formula 1, weight values are simply added, and another manner may also be used, for example, weighted summation is performed on Wi.
A weight value is directly related to a reference signal received power value obtained by a user terminal through measurement. Table 1 shows a mapping relationship between a weight value W and a reference signal received power RSRP. Some thresholds R 1 , R 2 , and R 3 are first set, and a corresponding weight value is assigned according to RSRP and threshold values. A value is assigned according to a principle that a greater reference signal received power RSRP value indicates a greater weight value. The thresholds may be autonomously set by an operator depending on situations, which is optional and is not described herein.
TABLE 1
Mapping relationship between a weight value
W and a reference signal received power RSRP
RSRP range
W value
RSRP ≧ R 1
1
R 2 ≦ RSRP < R 1
0.8
R 3 ≦ RSRP < R 2
0.5
. . .
. . .
As another mapping relationship between a weight value W and a reference signal received power RSRP, a maximum value R may be acquired according to a RSRP, obtained by user terminals UEA of different SeNB A through measurement, of the base station SeNB B of the different operator, and W i =RSRP i /R. When this mapping relationship is used, in an extreme case in which a degree at which network coverage of two operators overlap is very low, and a value of R is very small, a weight value W i calculated according to W i =RSRP i /R is still very large. To avoid this case, a threshold of R may be set, and if each RSRP obtained by a user terminal UEA of a base station SeNB A of the present operator A through measurement is less than the threshold (that is, a maximum value R is less than the threshold), it is determined that a network coverage overlapping degree is low.
Step 3. Count small cells of the different operator according to the overlap degree indicator.
In the present invention, the overlap degree indicator is an important parameter that indicates a degree at which network signals of small cells of the different operator B and the present operator A overlap. The operation and maintenance node of the present operator A classifies, into several types, small cells that are in a same network and belong to a same group, where the classification is performed based on an overlapping degree according to a value of the overlap degree indicator of the small cell of the different operator B, a network ID of the small cell, and a group ID of the small cell. A quantity of small cells included in each group is counted according to a classification status. According to quantities of small cells having different overlapping degrees, a coverage topology of a network of small cells of the different operator B that are in a group, and a network of the present operator A can be basically determined. During small cell classification, a threshold of an overlap degree indicator needs to be first defined. The threshold is used to classify different coverage overlapping levels of small cells.
Two thresholds of the overlap degree indicator are used as an example below for description. The two thresholds are separately defined as TH 1 and TH 2 , where TH 1 >TH 2 . Therefore, small cells may be classified into three types: high, intermediate, and low according to coverage overlapping degrees by using the two thresholds. A quantity of small cells corresponding to each type is indicated by H, M, and L. If an overlap degree indicator V≧TH 1 , it indicates that a small cell deployed by the different operator B overlaps with network coverage of the present operator A at a high degree. In this case, 1 is added to a quantity of small cells having a high overlapping degree, that is, H=H+1, where H indicates a quantity of small cells that are deployed by the operator B and that overlap at a high degree with network coverage deployed by the present operator A. If an overlap degree indicator TH 2 <V<TH 1 , it indicates that a small cell deployed by the different operator B overlaps with network coverage of the present operator A at an intermediate degree. In this case, 1 is added to a quantity of small cells having an intermediate network coverage overlapping degree, that is, M=M+1, where M indicates a quantity of small cells that are deployed by the operator B and that overlap at an intermediate degree with network coverage deployed by the present operator A. In other cases, it is considered that a small cell of the different operator overlaps with network coverage of the present operator at a low degree. In this case, 1 is added to a quantity of small cells having a low overlapping degree, that is, L=L+1, where L indicates a quantity of small cells that are deployed by the operator B and that overlap at a low degree with network coverage deployed by the present operator A.
Setting of a threshold may be determined according to a reference signal received power RSRP, detected by the present operator A, of a small cell of the different operator B. For example, in a first solution, a maximum value in RSRPs, obtained by user terminals UEAs of different SeNB A through measurement, of the base station of the different operator is used as R, the threshold TH 1 is set to a large proportion (for example, ⅔) of R, and the threshold TH 2 is set to a small proportion (for example, ⅓) of R. In a second solution, a fixed threshold is set according to empirical data of the present operator A. In a third solution, the present operator A and the different operator B perform negotiation to determine a threshold in advance. In the first two solutions, the operators exchange a threshold when exchanging network-coverage-topology-based information. In the third solution, a threshold does not need to be exchanged.
Small cells of the different operator that are in a same group is processed according to the foregoing classification and counting methods, a different-operator network coverage topology of the small cells in the group can be determined, and network coverage topology information of the different operator is obtained.
Step 4. Different networks exchange network-coverage-topology-based information.
A parameter of an inter-operator coverage overlap indicator (inter-operator coverage overlap indicator) is used to indicate a degree at which coverage of different networks overlaps, and the parameter includes quantities of small cells having different network coverage overlapping degrees, that is, the quantities of small cells of the operator that are obtained according to the overlap degree indicator in step 3. After a network of the present operator A exchanges, with a network of the different operator, information of a quantity of small cells of the different operator B that overlap with the network of the present operator A at different network coverage overlapping degrees, each operator may determine, according to the exchanged information, a status of a deployed small cell that overlaps with coverage of another operator.
Operators perform exchange in two manners: First, an operation and maintenance node is used. Second, a frequency spectrum control center (spectrum controller) is used. When an operation and maintenance node is used to perform exchange, the operation and maintenance node of the operator A may send, to the operation and maintenance node of the operator B, only an inter-operator coverage overlap indicator that includes at least H and L (a case in which one threshold exists) and may include M (a case in which two thresholds exist), and details are no longer described in detail herein. When a frequency spectrum control center for making a decision on a frequency spectrum allocation solution exists in a system, an operator that needs to share a frequency spectrum sends, by using an operation and maintenance node of the operator, an inter-operator coverage overlap indicator to a frequency spectrum control center to which the operator belongs, and the frequency spectrum control center of the operator exchanges the inter-operator coverage overlap indicator.
Step 5. Negotiate, according to the network-coverage-topology-based information, a solution for sharing and allocating a frequency spectrum between operators.
An operator determines a proportion of an exclusively occupied frequency spectrum and/or a jointly used frequency spectrum of the operator according to the quantities H, M, and L, included in the exchanged information, of cells having different network coverage overlapping degrees. The operators perform negotiation to obtain an allocation proportion of a jointly used frequency band according to the proportion of an exclusively occupied frequency spectrum and/or a jointly used frequency spectrum.
In this solution, frequency bands shared by the two operators are classified into three parts, which are separately: a jointly used frequency band, a frequency band occupied by only one operator (an exclusively occupied frequency spectrum of the operator A), and a frequency band occupied by the other operator (an exclusively occupied frequency spectrum of the operator B). A structure of dividing a frequency spectrum resource is shown in FIG. 4 . A principle of allocating a frequency band resource is as follows: If a coverage overlapping degree between networks of different operators is higher (that is, H is greater), there are less frequency bands to be jointly used by the operators, and more frequency band resources need to be allocated to an operator for exclusive occupation, to reduce interference between the operators; otherwise, if a coverage overlapping degree between networks deployed by different operators is lower, more frequency bands may be allocated to operators for joint use, and there are less frequency bands independently occupied by the operators (also referred to as an exclusively occupied frequency spectrum).
That an operator determines a proportion of a frequency spectrum that the operator needs to exclusively occupy to a jointly used frequency spectrum is first introduced. Each operator evaluates an allocation proportion of an independently occupied frequency spectrum to a jointly used frequency spectrum according to quantities of small cells having different network coverage overlapping degrees. When determining the proportion between the two, the operator may use different criteria according to actual cases.
In an embodiment of the present invention, for small cells deployed by the operator B, in addition to a total quantity H B +M B +L B of small cells of the different operator B that are obtained by the operator A through measurement and that have high, intermediate, and low network coverage overlapping degrees, some small cells of the different operator B may not be obtained by the operator A through measurement, and a quantity of these small cells is marked as Z B . In this embodiment, two criteria for determining a frequency spectrum allocation proportion are provided, and are shown in FIG. 5 .
After each operator obtains quantities of small cells having different inter-network coverage overlapping degrees, the operator performs allocation according to a criterion (criterion 1) of a frequency spectrum allocation proportion, that is, an allocation proportion of an exclusively occupied frequency spectrum to frequency spectrums used by the operator is
H H + M + L + Z ,
and an allocation proportion of a jointly used frequency spectrum is
M + L + Z H + M + L + Z .
The different operator B is used as an example, an allocation proportion of an exclusively occupied frequency spectrum to frequency spectrums used by the operator is
H B H B + M B + L B + Z B ,
and an allocation proportion of a jointly used frequency spectrum is
M
B
+
L
B
+
Z
B
H
B
+
M
B
+
L
B
+
Z
B
.
Alternatively, each operator performs allocation according to another criterion (criterion 2) of a frequency spectrum allocation proportion: An allocation proportion of an exclusively occupied frequency spectrum to frequency spectrums used by the operator is
H + M H + M + L + Z ,
and an allocation proportion of a jointly used frequency spectrum to frequency spectrums used by the operator is
L + Z H + M + L + Z .
The different operator B is used as an example, an allocation proportion of an exclusively occupied frequency spectrum to frequency spectrums used by the operator is
H B + M B H B + M B + L B + Z B ,
and an allocation proportion of a jointly used frequency spectrum to frequency spectrums used by the operator is
L
B
+
Z
B
H
B
+
M
B
+
L
B
+
Z
B
.
It may be understood that if there is only one threshold, small cells of the different operator B that are obtained by the present operator A through measurement are classified into two types: high and low. An allocation proportion of an exclusively occupied frequency spectrum to frequency spectrums used by the operator B is
H B H B + L B or H B H B + L B + Z B .
Similarly, an allocation proportion of a jointly used frequency spectrum to frequency spectrums used by the operator B is
L B H B + L B or L B + Z B H B + L B + Z B .
Because a case in which there is one threshold is similar to a case in which there are multiple thresholds, no description is provided separately below.
After an operator determines a frequency spectrum allocation proportion of the operator according to a corresponding criterion, a solution for reasonably allocating a frequency spectrum between operators needs to be negotiated subsequently. FIG. 6 shows a frequency spectrum sharing and allocation proportion according to an embodiment. First, a frequency spectrum shared by two operators is defined as 1. The operator A determines that a proportion of a frequency spectrum that needs to be independently occupied by the operator A to a jointly used frequency spectrum is R A , a proportion of an independently occupied frequency spectrum of the operator B to a jointly used frequency spectrum is R B , the operators exchange the two proportions R A and R B (as network coverage topology information), and a solution for sharing and allocating a frequency spectrum between operators can be obtained according to allocation proportion solutions of the operators.
According to the allocation criterion 1,
R
A
=
H
A
M
A
+
L
A
+
Z
A
.
According to the allocation criterion 2,
R
A
=
H
A
+
M
A
L
A
+
Z
A
.
The foregoing criterion 1 or 2 may be further simplified as follows:
Criterion 1: A proportion of an exclusively occupied frequency spectrum of the operator A to a jointly used frequency spectrum is
R
A
=
H
A
T
A
-
H
A
.
Criterion 2: A proportion of an exclusively occupied frequency spectrum of the operator A to a jointly used frequency spectrum is
R
A
=
H
A
+
M
A
T
A
-
H
A
-
M
A
.
H A is a quantity of small cells that are known according to information exchanged by the operators, that are in small cells deployed by the operator A in a given area, and that have a high network overlapping degree; T A is a quantity of all small cells deployed by the operator A in a given area, or a quantity of all small cells that are detected by user terminals of the operator B and that are deployed by the operator A in a given area (that is, a case in which Z A is 0); and M A is a quantity of small cells that are known according to information exchanged by the operators, that are in small cells deployed by the operator A in a given area, and that have an intermediate network overlapping degree.
Correspondingly, the operator B may also determine the proportion R B of an exclusively occupied frequency spectrum of the operator B to a jointly used frequency spectrum according to criterion 1 or 2.
The operator A and the operator B exchange the proportions R A and R B , obtained according to criterion 1 or 2, of a respective exclusively occupied frequency spectrum to a jointly used frequency spectrum, and consequently allocation proportions of three parts, that is, two segments of exclusively occupied frequency spectrums and a jointly used frequency spectrum, are calculated as follows: a proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
R A 1 + R A + R B ,
a proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
1 1 + R A + R B ,
and a proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
R B 1 + R A + R B .
All frequency spectrums refer to a sum of a jointly used frequency spectrum of a present operator and a different operator, and exclusively occupied frequency spectrums of the present operator and the different operator.
As another implementation manner of step 5, a solution for reasonably allocating a frequency spectrum between operators may also be negotiated between operators according to exchanged network coverage topology information by using the following solution. In the following solution, an operator does not need to determine a proportion of a frequency spectrum that needs to be exclusively occupied by the operator to a jointly used frequency spectrum, the operator A and the operator B directly exchange total quantities of small cells deployed by the operator A and the operator B, and quantities of small cells of the opposite party that are obtained through measurement and that have different network coverage overlapping degrees (as network coverage topology information), and then directly allocate a frequency spectrum separately according to the quantities of small cells having different network coverage overlapping degrees. After operation and maintenance nodes of the operator A and the operator B separately obtain quantities of small cells that are deployed by different operators and that have different network coverage overlapping degrees, the operator A and the operator B exchange, as network coverage topology information, quantities of small cells of different operators that have different network coverage overlapping degrees, and quantities of small cells that are deployed by present operators. That is, the operator A notifies, to the operator B, a total quantity H A +M A +L A +Z A of small cells deployed by the operator A, and quantities H B , M B , and L B of small cells of the operator B that are obtained through measurement and that have different coverage overlapping degrees; and the operator B notifies, to the operator A, a total quantity H B +M B +L B +Z B of small cells deployed by the operator B, and quantities H A , M A , and L A of small cells of the operator A that are obtained through measurement and that have different coverage overlapping degrees. The operator A and the operator B separately allocate a frequency spectrum according to the following criterion 3. As another alternative criterion, the operator A and the operator B may also separately allocate a frequency spectrum according to the following criterion 4. Compared with criterion 1 or criterion 2, criterion 3 or criterion 4 had higher computing and exchange efficiency when criterion 3 or criterion 4 is applied.
Criterion 3:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
H
A
+
M
A
+
L
A
+
Z
A
+
H
B
+
M
B
+
L
B
+
Z
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
M
A
+
L
A
+
Z
A
+
M
B
+
L
B
+
Z
B
H
A
+
M
A
+
L
A
+
Z
A
+
H
B
+
M
B
+
L
B
+
Z
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
H
A
+
M
A
+
L
A
+
Z
A
+
H
B
+
M
B
+
L
B
+
Z
B
.
Criterion 4:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
+
M
A
H
A
+
M
A
+
L
A
+
Z
A
+
H
B
+
M
B
+
L
B
+
Z
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
L
A
+
Z
A
+
L
B
+
Z
B
H
A
+
M
A
+
L
A
+
Z
A
+
H
B
+
M
B
+
L
B
+
Z
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
+
M
B
H
A
+
M
A
+
L
A
+
Z
A
+
H
B
+
M
B
+
L
B
+
Z
B
.
For criteria 3 and 4, laws may be generalized as follows:
A proportion among an exclusively occupied frequency spectrum of the first network (A), an exclusively occupied frequency spectrum of the second network (B), and a jointly used frequency spectrum of the first network (A) and the second network (B) is: a quantity of small cells of the first network (A) that are obtained by the second network (B) through measurement and that have a high network coverage overlapping degree: a quantity of small cells of the second network (B) that are obtained by the first network (A) through measurement and that have a high network coverage overlapping degree: a quantity of remaining small cells in all small cells in the two networks. A proportion among the three may also be: a sum of quantities of small cells of the first network (A) that are obtained by the second network (B) through measurement and that have high and intermediate network coverage overlapping degrees: a sum of quantities of small cells of the second network (B) that are obtained by the first network (A) through measurement and that have high and intermediate network coverage overlapping degrees: a quantity of remaining small cells in all small cells in the two networks.
Assuming that quantities of all small cells of different operators that are detected by user terminals of present operator are T A =H A +M A +L A +Z A and T B =H B +M B +L B +Z B , the foregoing criterion 3 or 4 may be simplified as:
Criterion 3-1:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
T
A
+
T
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
1
-
H
A
+
H
B
T
A
+
T
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
T
A
+
T
B
.
Criterion 4-1:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
+
M
A
T
A
+
T
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
1
-
H
A
+
M
A
+
H
B
+
M
B
T
A
+
T
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
+
M
B
T
A
+
T
B
.
H A is a quantity of small cells that are known according to information exchanged by the operators, that are in small cells deployed by the operator A in a given area, and that have a high network overlapping degree; H B is a quantity of small cells that are known according to information exchanged by the operators, that are in small cells deployed by the operator B in a given area, and that have a high network overlapping degree; T A is a quantity of all small cells deployed by the operator A in a given area, or a quantity of all small cells that are detected by user terminals of the operator B and that are deployed by the operator A in a given area; T B is a quantity of all small cells deployed by the operator B in a given area, or a quantity of all small cells that are detected by user terminals of the operator A and that are deployed by the operator B in a given area; M A is a quantity of small cells that are known according to information exchanged by the operators, that are in small cells deployed by the operator A in a given area, and that have an intermediate network overlapping degree; and M B is a quantity of small cells that are known according to information exchanged by the operators, that are in small cells deployed by the operator B in a given area, and that have an intermediate network overlapping degree.
When the simplified criterion 3-1 is applied, network coverage topology information exchanged by the operator A and the operator B is quantities H of detected small cells of the different operators that have a high network overlapping degree, and total quantities T of small cells deployed by present operators. That is, the operator A notifies, to the operator B, a total quantity T A of small cells deployed by the operator A, and a quantity H B of small cells of the operator B that are obtained through measurement and that have a high coverage overlapping degree; and the operator B notifies, to the operator A, a total quantity T B of small cells deployed by the operator B, and a quantity H A of small cells of the operator A that are obtained through measurement and that have a high coverage overlapping degree.
Similarly, when the simplified criterion 4-1 is applied, network coverage topology information exchanged by the operator A and the operator B is quantities H and M of detected small cells of different operators that have high and intermediate network overlapping degrees, and total quantities T of small cells deployed by present operators. That is, the operator A notifies, to the operator B, a total quantity T A of small cells deployed by the operator A, and quantities H B and M B of small cells of the operator B that are obtained through measurement and that have high and intermediate coverage overlapping degrees; and the operator B notifies, to the operator A, a total quantity T B of small cells deployed by the operator B, and quantities H A and M A of small cells of the operator A that are obtained through measurement and that have high and intermediate coverage overlapping degrees.
Considering that a jointly used frequency band is multiplexed by cells of two operators, a proportion of a jointly used frequency band does not need to be as high as that in criterion 3 and criterion 4, and in the following criterion 5 and criterion 6, a jointly used frequency band is divided more reasonably and efficiently.
Criterion 5:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
H
A
+
S
1
+
H
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
S
1
H
A
+
S
1
+
H
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
H
A
+
S
1
+
H
B
.
S i =max{M A +L A +Z A , M B +L B +Z B } or S 1 =max{T A −H A , T B −H B }. Si indicates a maximum value of a quantity of small cells, which use a jointly used frequency band, of the operator A and the operator B, and a quantity of small cells of each operator that use a jointly used frequency band is a quantity of small cells, in small cells deployed by the operator, except small cells that overlap with network coverage of the different operator at a high degree.
Criterion 6:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
+
M
A
H
A
+
M
A
+
S
2
+
H
B
+
M
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
S
2
H
A
+
M
A
+
S
2
+
H
B
+
M
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
+
M
B
H
A
+
M
A
+
S
2
+
H
B
+
M
B
.
S 2 =max{L A +Z A , L B +Z B } or S 1 =max{T A −M A , T B −H B −M B }, which indicates a maximum value of a quantity of small cells, which jointly use a frequency band, of the operator A and the operator B, and which is a greater one of a sum of a quantity of small cells that are deployed by the operator A and that have a low network overlapping degree, and a quantity of small cells that are not detected by the operator B, and a sum of a quantity of small cells that are deployed by the operator B and that have a low network overlapping degree, and a quantity of small cells that are not detected by the operator A, or which may be a greater one of a quantity that is obtained by subtracting, from a quantity of small cells deployed by the operator A, quantities of small cells that have high and intermediate network overlapping degrees, and a quantity that is obtained by subtracting, from a quantity of small cells deployed by the operator B, quantities of small cells that have high and intermediate network overlapping degrees.
A proportion among an exclusively occupied frequency spectrum of the first network (A), an exclusively occupied frequency spectrum of the second network (B), and a jointly used frequency spectrum of the first network (A) and the second network (B) is: a quantity of small cells of the first network (A) that are obtained by the second network (B) through measurement and that have a high network coverage overlapping degree: a quantity of small cells of the second network (B) that are obtained by the first network (A) through measurement and that have a high network coverage overlapping degree: a maximum value of a quantity of small cells, which jointly use a frequency band, of the first network (A) and the second network (B). A proportion among the three may also be: a sum of quantities of small cells of the first network (A) that are obtained by the second network (B) through measurement and that have high and intermediate network coverage overlapping degrees: a sum of quantities of small cells of the second network (B) that are obtained by the first network (A) through measurement and that have high and intermediate network coverage overlapping degrees: a maximum value of a quantity of small cells, which jointly use a frequency band, of the first network (A) and the second network (B).
It is noteworthy that small cells deployed by each operator may further include some small cells that are not detected by a different operator (a corresponding quantity is Z), in addition to small cells (corresponding quantities are H, M, and L) that can be detected by a different operator and that have high, intermediate, and low network coverage overlapping degrees. It may be considered that these small cells that are not detected by the different operator almost do not overlap with network coverage of the different operator. In the foregoing criterion 1 to criterion 6, it is all considered that these small cells that are not detected by the different operator use a jointly used frequency band. In fact, these small cells not only can use a jointly used frequency spectrum, but also can use a dedicated frequency spectrum allocated to the different operator, while no strong interference with a network of the different operator is caused. In another aspect, the quantity X of these small cells is not very large. In comprehensive consideration of the foregoing factors, when negotiating a policy for dividing a shared frequency spectrum, operators may not consider these small cells that are not detected by the different operator, and the operators need to exchange only network coverage topology information (which includes quantities of small cells having high, intermediate, and low coverage overlapping degrees) obtained by the different operator through measurement, and do not need to know a quantity of all small cells deployed by another operator. A corresponding frequency division criterion may be described as follows:
Criterion 7: In the foregoing criterion 1 to criterion 6, regardless of actual values of Z A and Z B , when a frequency spectrum allocation proportion is calculated, Z A and Z B are set to 0. In other words, in criteria 1 to 6, T A is a quantity of all small cells that are detected by user terminals of the operator B and that are deployed by the operator A in a given area, and T B is a quantity of all small cells that are detected by user terminals of the operator A and that are deployed by the operator B in a given area, which is a case in which both Z A and Z B are 0.
Specifically, the operator A and the operator B exchange quantities of small cells, which have different network coverage overlapping degrees, of different operators. That is, the operator A notifies, to the operator B, quantities H B , M B , and L B of cells of the operator B that are obtained by the operator A through measurement, and the operator B notifies, to the operator A, quantities H A , M A , and L A of cells of the operator A that are obtained by the operator B through measurement. The following uses criteria 3 and 4 as an example to describe a case in which Z A and Z B are set to 0 (which includes a case in which Z A and Z B are not 0 at the same time). The operator A and the operator B separately allocate a frequency spectrum according to the following criterion 7-1 (which corresponds to criterion 3) or the following criterion 7-2 (which corresponds to criterion 4). In all the criteria 1, 2, 5, and 6, Z A and Z B may be set to 0 (which includes a case in which Z A and Z B are not 0 at the same time), which is similar to the case of criteria 3 and 4, and is not described in detail.
Criterion 7-1:
In a case in which both Z A and Z B are 0, the operator A calculates a proportion
H A H A + M A + L A + H B + M B + L B
of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums according to quantities H B , M B , and L B of small cells of the operator B that are detected by the operator A, and H A , M A , and L A obtained by exchanging with the operator B.
As an alternative manner, in a case in which Z A is 0 and Z B is not 0, the operator A obtains a proportion
H A H A + M A + L A + H B + M B + L B + Z B
of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums according to quantities H B , M B , and L B of small cells of the operator B that are detected by the operator A, and with reference to H A , M A , and L A obtained by exchanging with the operator B. A case in which Z B is 0 and Z A is not 0 is similar to a case in which Z A is 0 and Z B is not 0.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
M
A
+
L
A
+
M
B
+
L
B
H
A
+
M
A
+
L
A
+
H
B
+
M
B
+
L
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
H
A
+
M
A
+
L
A
+
H
B
+
M
B
+
L
B
.
Similarly, in criterion 7-1, for all the proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums, and the proportion of a jointly used frequency spectrum of the operator B to all frequency spectrums, both the case in which Z A is 0 and Z B is not 0 or the case in which Z B is 0 and Z A is not 0 may exist, and details are not described in detail herein again.
Criterion 7-2:
A proportion of an exclusively occupied frequency spectrum of the operator A to all frequency spectrums is
H
A
+
M
A
H
A
+
M
A
+
L
A
+
H
B
+
M
B
+
L
B
.
A proportion of a jointly used frequency spectrum of the operator A and the operator B to all frequency spectrums is
L
A
+
L
B
H
A
+
M
A
+
L
A
+
H
B
+
M
B
+
L
B
.
A proportion of an exclusively occupied frequency spectrum of the operator B to all frequency spectrums is
H
B
+
M
B
H
A
+
M
A
+
L
A
+
H
B
+
M
B
+
L
B
.
Similarly, in criterion 7-2, for all the proportion of an exclusively occupied frequency spectrum of the present operator A to all frequency spectrums, the proportion of an exclusively occupied frequency spectrum of the different operator B to all frequency spectrums, and the proportion of a jointly used frequency spectrum to all frequency spectrums, both the case in which Z A is 0 and Z B is not 0 or the case in which Z B is 0 and Z A is not 0 may exist, and details are not described in detail herein again.
As shown in the upper figure in FIG. 5 , according to the proportion of an exclusively occupied frequency spectrum of the present operator A to all frequency spectrums, the proportion of an exclusively occupied frequency spectrum of the different operator B to all frequency spectrums, and the proportion of a jointly used frequency spectrum to all frequency spectrums, the present operator A allocates, as a jointly used frequency spectrum, a frequency spectrum that is in frequency spectrums used by the present operator A and that is near to a frequency spectrum used by the different operator B, and allocates, as an exclusively occupied frequency spectrum, a frequency spectrum that is in frequency spectrums used by the present operator A and that is far from a frequency spectrum used by the different operator B. It may be understood that the present operator A may also not allocate a frequency spectrum in this manner, and may allocate a separated frequency band as a jointly used frequency spectrum or an exclusively occupied frequency spectrum according to a service requirement, as long as the foregoing criteria can be met.
In conclusion, in the method for sharing a frequency spectrum between networks provided in the present invention, co-primary spectrum sharing can be implemented between different operators. First, an operator classifies small cells into groups according to geographical locations and coverage areas, and allocates a group identifier; the operator performs measurement and reporting on a different operator; an operation and maintenance node to which the present operator belongs evaluates, according to a measurement report of the different operator, a degree at which a small cell of the different operator overlaps with a network of the present network, to obtain an overlap degree indicator of the small cell of the different operator; the operation and maintenance node classifies small cells of the different operator that are in a same group according to an overlapping coverage degree, and counts quantities of small cells having different overlapping coverage degrees, to form a network coverage overlapping indicator of the different operator; and the operators exchange the network coverage overlapping indicator of the different operator. An operator negotiates allocation of a frequency resource according to quantities of small cells having different network overlapping coverage degrees. By using the method for sharing a frequency spectrum between networks, different operators can fairly and reasonably share a frequency spectrum resource, improve frequency spectrum utilization of an entire communications network, and ensure communication quality of user terminals.
The method for sharing a frequency spectrum between networks provided in the present invention is described in detail above. Any obvious modification made to the present invention by a person of ordinary skill in the art without departing from the essential spirit of the present invention infringes patent rights of the present invention, and a corresponding legal responsibility is borne. | Disclosed is a network frequency spectrum sharing method, a user terminal of the present network sending a network signal strength measurement report of the different network to a home base station; an operation management node of the present network, based on the network signal strength measurement report, calculating a network overlapping level indicator of the different network, and obtaining network overlapping topology-based information of the different network; and the two networks exchanging the network overlapping topology-based information, and calculating a policy for allocating shared frequency spectrum resources therebetween. The present invention can enable different networks to fairly and reasonably share frequency spectrum resources within a specified range, thus increasing a frequency spectrum utilization rate. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 11/295,869 filed Dec. 7, 2005, now pending. The Ser. No. 11/295,869 application is incorporated by reference herein, in its entirety, for all purposes.
BACKGROUND
[0002] This invention relates to a recording system for tracking personal activities during a specified time interval on a specific day.
[0003] Modern technology has produced both devices that save time and devices that demand more of our time. The computer has increased productivity by reducing the amount time to create documents, analyze data, and to communicate work product to others via vast networks. The Internet and spread of wireless technologies has made it possible for individuals separated by vast distances to stay “connected.” Whatever time savings technology may have conferred have seemingly been lost due to the increased demands that flow from being accessible at any time from anywhere on the planet.
[0004] Managing time has thus become an import part of modern life. Time management tools may be designed to keep track of how time has been committed and/or to keep track of how time was actually used. Examples of time-commitment systems include electronic calendars and day planners. Time-spent systems can be viewed as electronic diaries or journals. What these systems have in common is that data is primarily entered in textual form. The data entry process is thus time consuming and the data in free form that is not easily analyzed or represented analytically. This raises the question of whether the data collected using the time management tool has sufficient value to justify the time spent acquiring the collected data.
[0005] To the extent that currently available time management tools capture time usage, they do not provide for goal/target setting and performance monitoring and do not server as goal and life planning/management tools.
[0006] To manage time effectively, it is important to quantify the time increments spent performing specific tasks. The quantification of time usage facilitates analysis of time usage, the evaluation of particular tasks, and the allocation of resources. Gathering these data cannot, however, become a significant task in its own right.
[0007] What would be useful, therefore, is a system for recording details of specific groups of activities in very short intervals, including interruptions or distractions. Additionally, it would be desirable to associate specific groups and categories of activities with files, text, attributes or numerical values. More over, the system for the activity details should be recorded in a form that allows for analysis, decision making, and aggregation of data.
SUMMARY
[0008] An embodiment of the present invention is an activity recording module (ARM) operated by an activity recorder. The activity recorder of this embodiment comprises a display and a user input system for interacting with the ARM. As used in this application, an “activity” relates to a “category” and a “timeframe” having a start and finish time, and a particular category belongs to a group.
[0009] In an exemplary embodiment of the present invention, the activity recorder is a personal digital assistant comprising a touchscreen display that performs the functions of the display and the user input system. However, the present invention is not so limited. Other devices may perform the functions of the activity recorder the ARM and other input systems may be used to interact with the ARM without departing from the scope of the present invention. By way of illustration and not as a limitation, the ARM functions may be integrated with or performed by a personal computer (PC), a tablet computer, a notebook computer (laptop), a personal digital assistant (PDA), an electronic organizer, a mobile phone, a smartphone, or a converged device. The user input system may, without limitation, be a keyboard, a keypad, a voice command system, a digital pen, a joystick, a jog dial, a toggle, or a pointing/click device. Further, the ARM may be used as a data capture mechanism whereby the information captured is subsequently loaded onto other applications after storage, or as a portal or gateway to other applications in which case data is captured and transferred to other applications in real time.
[0010] In the exemplary embodiment, the ARM uses a grid to record time usage as either categorized or uncategorized. A column of the grid is associated with a group identified by color and a “shortcode” or a mnemonic that appears in a header row at the top of the grid. Categories within the group may be identified by hues of the group colors or other distinguishing colors and a category shortcode. A time interval is unambiguously associated with a single category of activity. In another embodiment of the present invention, the color of the groups and categories is user selectable. In yet another embodiment of the present invention, the colors of the groups and categories is determined by a preset template that may be modified by a user.
[0011] The activity recorder is further adapted to calculate various statistical and descriptive factors relating to the proportions of time used to carry out the activities in various time intervals. The time intervals, categories, shortcodes and color codes can be changed by the user as required. Thus any indications of time intervals for recording of activity noted in the figures are not meant as a limitation. The activities may be personal or professional. The time may be recorded during any increment of an hour across the 24 hours of a day. In yet another embodiment of the present invention, targets may be set and alerts triggered. The alerts may signal, for example without limitation, when more than a preset amount of time has been given to a particular category of activity or that some “amount” has been exceeded (e.g. daily allowance of a food, exercise time, costs.)
[0012] The invention allows a wide range of different activities to be recorded using color, indicative of a group or a category within a group, and a bar length, indicative of the time spent on the activity. In the exemplary embodiment, a simple touchscreen provides a visual rather than textual or numerical representation of time usage The ARM thus provides a work-life-balance to be monitored and measured that is faster and more readily meaningful than an alphanumeric entry. The ARM is easier for dyslexic or other disadvantaged people to use and is less dependent on any language capability or symbol recognition. The screen of the ARM can be customized based on user-selectable preferences for color, display of icons, priority of task screens and the like.
[0013] In yet another embodiment of the present invention, the ARM comprises a plurality of grids that enable a user to record multiple activities. The activities may be related, in which case the group and category information in one grid has a relational connection to a group and category in another grid, or the activities may be unrelated.
[0014] In another embodiment of the present invention, a predetermined template is used to obtain data entries specific to a particular purpose. By way of illustration and not as a limitation, a template may be used to obtain information pertinent to a medical condition of a patient, information pertinent to a mental state, observations of a research project, information pertinent to providing disaster relief, and information pertinent to a law enforcement or military action. A template may be “shipped” with the ARM or may be created and imported from a spreadsheet application or via a built in wizard with picklists.
[0015] In another embodiment of the present invention, the recorded activity records are manipulated and analyzed, either alone or in conjunction with external data. The manipulation and analysis of the recorded activity records may be performed by the activity recorder on which the ARM is operated or performed by a separate analysis computer to which the recorded activity records have be sent or which accesses the ARM.
[0016] In still another embodiment of the present invention, a recorded activity record is automatically transferred to an analysis server when the activity recorder is connected to a network.
[0017] In yet another embodiment of the present invention, the activity recorder comprises a wireless network interface and transfers a recorded activity record over the wireless network to the analysis server.
[0018] In another embodiment of the present invention, an activity recorder obtains at least some elements of an activity record from another device. By way of illustration and not as a limitation, the other device may be operating an ARM or it may record activity information by other means.
[0019] It is an aspect of the present invention to provide an interface for the capture and analysis of data relating to an activities, categories, groups and timeframes as but a few examples of how data may be captured.
[0020] It is another aspect of the present invention to accept and present activity data as a dynamic bar graph presented on a grid where the size/spacing of the grid squares may be adjusted to suit user preferences.
[0021] It is yet another aspect of the present invention to operate an ARM on a touchscreen device in which the activity data is entered with a stylus or similar device or by direct contact from a user.
[0022] It is even another aspect of the present invention to record activities in time increments over a 24 hour period as determined by a template or selected by a user.
[0023] It is an aspect of the present invention to permit users to select and change the time windows displayed by the ARM and the time increments in which activity data may be collected.
[0024] It is another aspect of the present invention to present activities on the x-axis of a grid associated with columns representing categories, each of which is associated with a main group and a short-code or mnemonic.
[0025] It is yet another aspect of the present invention to permit a user of the ARM to select the activities, by group and category, as well as the color and shortcode associated with each category.
[0026] It is still another aspect of the present invention to provide templates comprising pre-determined activities, groups, categories, colors and shortcodes.
[0027] It is an aspect of the present invention to permit files, numerical values, ranges of values, and formulas to be associated with activities and time intervals.
[0028] It is another aspect of the present invention to permit activity data to be imported into an activity recorder and exported from an activity recorder.
[0029] It is another aspect of the present invention to aggregate the activity data of multiple ARM users.
[0030] It is still another aspect of the present invention to permit a user to select a variety of charts, tables or other analytical or descriptive records relating to the correlation of activities, values or files with time.
[0031] It is a further aspect of the present invention to permit notes to be added, emails to be sent and other messages uploaded to preferred programs by a user of the ARM.
[0032] It is yet another aspect of the present invention to facilitate the analysis and charting of attributes (e.g. mileage, words-per-minute, heart-rate) versus time or activity so that correlation of stimulus (e.g. eating certain foods, exercise) and response (e.g. productivity, performance measures) may be recorded and presented in various ways.
[0033] It is an aspect of the present invention to associate a user note with activity data and to permit the user note to be sent by email or posted to a BLOG.
[0034] It is still another aspect of the present invention to allow integration with other collaboration tools such as, but without limitation Wiki, instant messenger, RSS, and MS Sharepoint portal.
[0035] In an embodiment of the present invention, an activity recorder comprises a data entry system, a storage system for receiving and storing activity data, and a display system. By way of illustration and not as a limitation, the data entry system may be a touch screen and a stylus for contacting the touch screen, a cursor responsive to a keypad, a cursor responsive to joystick, and a cursor responsive to a mouse. The display system is in communication with the storage system and displays a grid comprising time cells along a first axis and group cells along a second axis. Each time cell has a same first axis coordinate representing a predetermined time segment and each group cell has a same second axis coordinate representing an activity group.
[0036] Input is accepted from the data entry system to display a graphical representation of a new time interval associated with an activity group. In an embodiment of the present invention, the activity group comprises activity categories. The new time interval comprises a start time and an end time. In an embodiment of the present invention, the graphical representation of the new time interval associated with the activity group comprises a bar extending from the start time to the end time of the new time interval.
[0037] In yet another embodiment of the present invention, the activity group is associated with a group color and the bar is displayed in the group color. In still another embodiment of the present invention, the activity group is associated with a group color and an activity category of that activity group is associated with a hue of the group color.
[0038] New activity data comprising the new time interval associated with the activity group is sent to the storage system for storage. In an embodiment of the present invention, the storage system is adapted for importing and exporting stored activity data.
[0039] In another embodiment of the present invention, the activity recorder further comprises a rules engine and the storage system comprises the new activity data and stored activity data. The rules engine determines whether the new time interval of the new activity data intersects a stored time interval of the stored activity data comprising a stored start time and a stored end time. The rules engine applies a conflicts rule if new time interval of the new activity data intersects the stored time interval of the stored activity data.
[0040] In yet another embodiment of the present invention, the conflict rule comprises the following logic:
if the start time of new time interval is after the stored start time and if the end time of the new time interval is after the stored end time, then setting the start time of the new time interval to the stored end time; if the start time of the new time interval is before the stored start time and if the end time of the new time interval is before the stored end time, setting the stop time of the new time interval to the stored start time; if the start time of the new time interval is before the stored start time and if the end time of the new time interval is after the stored end time, the deleting the stored time interval; if the start time of the new time interval is after the stored start time and if the end time of the new time interval is before the stored end time, then:
setting a first revised stored start time to the stored start time; setting a first revised stored end time to start time of the new time interval; setting a second revised stored start time to the end time of the new time interval; and setting a second revised stored end time to the stored end time.
DESCRIPTION OF THE DRAWINGS
[0049] FIG. 1 illustrates an activity recording module (ARM) implemented on an activity recorder according to an embodiment of the present invention.
[0050] FIGS. 2A and 2B illustrate a process by which an ARM is used to create an activity record according to an embodiment of the present invention.
[0051] FIG. 3 illustrates a template used by an ARM to create an activity record according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0052] An embodiment of the present invention is an activity recording module (ARM) operated by an activity recorder comprising a display and a user input system for interacting with the ARM. In an exemplary embodiment of the present invention, the activity recorder is a personal digital assistant comprising a touchscreen display that performs the functions of the display and the user input system. However, the present invention is not so limited. Other devices may perform the functions of the ARM and other input systems may be used to interact with the ARM without departing from the scope of the present invention. By way of illustration and not as a limitation, the ARM functions may be integrated with or performed by a personal computer (PC), a tablet computer, a notebook computer (laptop), a personal digital assistant (PDA), an electronic organizer, a mobile phone, a smartphone, or a converged device. The user input system may, without limitation, be a keyboard, a keypad, a voice command system, a joystick, a jog dial, a toggle, a digital pen, or a pointing/click device.
[0053] In the exemplary embodiment, the ARM uses a grid to record time usage as either categorized or uncategorized. A column of the grid is associated with a group identified by color and a “shortcode” that appears in a header row at the top of the grid. Categories within the group may be identified by hues of the group colors and a category shortcode. However, this is not meant as a limitation. The category and group colors may be assigned any distinguishing colors as desired by a user. In another embodiment of the present invention, the color of the groups and categories is user selectable. In yet another embodiment of the present invention, the colors of the groups and categories is determined by a preset template that may be modified by a user (see, FIG. 3 ). A time interval is unambiguously associated with a single category of activity.
[0054] The activity recorder is further adapted to calculate various statistical and descriptive factors relating to the proportions of time used to carry out the activities in various time intervals. By way of illustration and not as a limitation, the activity recorder may analyze the activity data for patterns or sequences of events.
[0055] The time intervals, categories, shortcodes and color codes can be changed by the user as required. The activities may be personal or professional. The time may be recorded during any increment of an hour across the 24 hours of a day. In yet another embodiment of the present invention, targets may be set and alerts triggered.
[0056] FIG. 1 illustrates an activity recording module (ARM) implemented on an activity recorder according to an embodiment of the present invention. While FIG. 1 illustrates the ARM implemented on a handheld device, as previously noted, the present invention is not so limited.
[0057] Data using a grid (C) with time intervals being displayed on the y-axis (D) and activity groups (E) and categories (F) being displayed above the grid (C) on the x-axis. A group is assigned a color and a category of a group is assigned a hue of the group color. However, this is not meant as a limitation. The category and group colors may be assigned any distinguishing colors as desired by a user. In another embodiment of the present invention, the color of the groups and categories is user selectable. In yet another embodiment of the present invention, the colors of the groups and categories is determined by a preset template that may be modified by a user (see, FIG. 3 ). A header row of grid (C) comprises a date (I) and a shortcode (G). A current time is indicated in the upper left corner of the display.
[0058] Time usage may be indicated by group (e.g. administration) and by category (e.g. filing, accounts, purchasing, correspondence). These groups and categories are normally chosen by a user, with each being assigned a shortcode (G). In another embodiment of the present invention, a predetermined template is used to obtain data entries specific to a particular purpose (see, FIG. 3 ). By way of illustration and not as a limitation, a template may be used to obtain information pertinent to a medical condition of a patient, information pertinent to a mental state, observations of a research project, information pertinent to providing disaster relief, and information pertinent to a law enforcement or military action. A template may be “shipped” with the ARM or may be created and imported from a spreadsheet application or via a built in wizard with picklists.
[0059] As illustrated in FIG. 1 , the shortcode is a pair of letters, but the present invention is not so limited. Letters, numbers, and symbols may be combined to identify the groups and categories of the present invention without departing from its scope.
[0060] The category (E) associated with each time interval (D) is allocated by drawing a bar/line (H) in the column corresponding to that activity aligned with the corresponding time interval(s) (D).
[0061] According to an embodiment of the present invention, if an activity does not correspond to a pre-defined category, the activity is assigned to a group set aside for uncategorized activities. By way of illustration, an uncategorized activity may include an interruption of a planned activity or an unexpected event within or outside a planned activity. Alternatively, a horizontal line may be drawn across the row(s) associated with the time block used for the uncategorized activity. In yet another embodiment of the present invention, a line is drawn across a row of the grid by a tap or doubleclick in the time interval box (D) associated with the uncategorized activity.
[0062] In yet another embodiment of the present invention, grid “C” may be larger than the display of the ARM. In this embodiment, the groups that are displayed may represent a consecutive block of grid squares selected by scrolling the horizontally and/or vertically. In still another embodiment of the present invention, the displayed grid is selected from the available rows and columns by the user.
[0063] At any time, a grid square or group of squares may be allocated to another activity. The latest allocation takes priority in the database with no time interval being attributed to more than one activity. A process by which this priority over-ride is achieved is illustrated in FIG. 2 . It may however be possible to allocate one time interval to both an activity or an attribute or file. Further the ARM may also have more than one activity or user able to access its capabilities with more that one screen being displayed representative of multiple applications.
[0064] In yet another embodiment of the present invention, the ARM comprises a plurality of grids that enable a user to record multiple activities. The activities may be related, in which case the group and category information in one grid has a relational connection to a group and category in another grid, or the activities may be unrelated.
[0065] In another embodiment of the present invention, groups, categories, shortcodes, colors and other attributes are defined in a library file from which a selection may be displayed and used at any time. In this way, templates for specific activities may be pre-established and call when needed. The display may be enlarged or condensed.
[0066] These selections of templates and other data representation modes may be selected via a series of icons (I) or menu lists. In an embodiment of the present invention, the icons that are not used for a particular activity are not displayed. In an alternate embodiment of the present invention, the icons that are displayed are selected by the user. The date (J) and time (K) are displayed. Date and time may be changed in a forward or backward direction, for example via date scroll bar (L) and time scroll bar (M) or via menus or other means. Entries may be deleted via the delete icon (N) or menus or other means. In an embodiment of the present invention, a user may select a day from a calendar. A date on which activity data has been collected is displayed in bold or using other well-known display attributes. Categories are listed when active (O).
[0067] FIGS. 2A and 2B illustrate a process by which an ARM is used to create an activity record according to an embodiment of the present invention. FIG. 2 illustrates this process as performed on an ARM implemented on a handheld device as illustrated in FIG. 1 . As previously noted, the process is illustrative only and the present invention is not so limited.
[0068] Referring to FIG. 2A , the process begins with the contact of a stylus on a grid displayed on a touchscreen of an activity recorder 200 . The cursor coordinates of this first contact point (X 1 , Y 1 ) are captured 204 . Time A is determined from the value of Y 1 208 . Time A is stored 210 . The category of the entry is determined from the value of X 1 212 . The category is stored.
[0069] At some subsequent time, the stylus is positioned on the touchscreen at a point having coordinates X 1 and Y 2 and the cursor values are captured 220 . A time B is determined from the value of Y 2 224 . Time B is saved 228 .
[0070] A determination is made as whether time A is less than time B 232 . If time A is less than time B, time A is deemed the start time and time B is deemed the stop time 236 . If time A is not less than time B, time B is deemed to be the start time and time A is deemed to be the end time 240 . A new activity item for the group is created for the start time to the end time 244 . In this way, the duration of the new activity is defined by the start and finish time, irrespective of which direction the stylus had moved on the touch screen.
[0071] Referring to FIG. 2B , the new activity item is compared to previously stored activity items (herein, an “old” activity item) to resolve conflicts in the recording of time entries. A determination is made whether the new activity starts after the old activity start time and ends after the old activity end time 248 . If the new activity starts after the old activity start time and ends after the old activity end time, the new activity start time is set to the old activity end time 252 . It should be noted that it is not a requirement that a user fill every time interval. Intervals may be left blank as the situation dictates.
[0072] If the new activity does not start after the old activity start time and end after the old activity end time, a determination is made whether the new activity starts before the old activity start time and ends before the old activity end time 256 . If the new activity starts before the old activity start time and ends before the old activity end time, the new activity end time is set to the old activity start time 260 . However, as noted above, there may be times when not activity is present. In these instances, a time entry is not required
[0073] If the new activity does not start before the old activity start time and end before the old activity end time, a determination is made whether the new activity starts before the old activity start time and ends after the old activity end time 264 . If the new activity starts before the old activity start time and ends after the old activity end time, the old activity is deleted 268 .
[0074] If the new activity does not start before the old activity start time and end before the old activity end time, a determination is made whether the old activity starts before the new activity start time and ends after the new activity end time 272 . If the old activity starts before the new activity start time and ends after the new activity end time, the old activity is divided into two activities as follows 276 :
[0075] an old activity first start time is set to the old activity original start time;
[0076] an old activity first end time is set to the new activity start time;
[0077] an old activity second start time is set to the new activity end time; and
[0078] an old activity second end time is set to the old activity original end time.
[0079] In an embodiment of the present invention, a new activity is checked against old activities each time an activity is defined in order to assure that the latest entries take priority.
[0080] If the old activity does not start before the new activity start time and end after the new activity end time, the process ends 280 .
[0081] In an embodiment of the present invention, the ARM made be minimized or enlarged to allow other use of the activity recorder while preserving rapid access to the ARM.
[0082] In another embodiment of the present invention, attachments are indicated with a paperclip icon and associated with a particular activity and/or time interval. This allows a user to annotate an activity record with images, video, website addresses, documents, comments, music or other sound recordings, and other types of files. This provides an enhanced e-diary capability which may be archived and restored or represented in different ways.
[0083] The activity record data may be analyzed and charted in many ways. By way of illustration and not as a limitation, these data may be used to create a table, a statistical analysis, a bar chart, a pie chart, a spider diagram, or a graph, among others. The data may be analyzed in specific time ranges and/or activity groups, for example “Monday to Friday from 9 am to 5 pm” or alternatively “weekends only”, or many other combinations.
[0084] In an embodiment of the present invention, alerts and reminders may be set according to their choice of criteria. By way of illustration and not as a limitation, an alarm may sound to indicate when a certain amount of time has been spent on a specific activity or when a certain percent of that time has been used. Alternatively, a visual but non-intrusive alert may be established to indicate when they are close to using a target amount of time on a chosen activity. The alerts may signal, for example without limitation, when more than a preset amount of time has been given to a particular category of activity or that some “amount” has been exceeded (e.g. daily allowance of a food, exercise time, costs). Such alerts may also refer to ratios of time on different activities, for example work versus entertainment, caring versus chores, or one project versus another.
[0085] In yet another embodiment of the present invention, data is be imported from other applications or exported to other applications to auto populate certain fields. Such data may be analyzed and charted in many ways, for example to compare planned/scheduled versus actual use of time.
[0086] In one embodiment of the present invention, the data acquisition aspect of the system is separated from the data analysis and charting process with data capture being on a activity recording (ideally “always on” and “always with you” with a small screen and relying to some extent on battery power) and data analysis and presentation being on a larger and less mobile device (not always on or “with you”, generally powered by an external source, larger screen and more readily connected to printers etc).
[0087] In yet another embodiment of the present invention, the activity recorder is connected to other data capture devices such as health monitors (e.g. for diabetes, glucose level measurement, multiple sclerosis), sports training monitors, exercised monitors, medication monitors, and others to automatically capture readings of specific time-dependent parameters. This may include measures of stress or other responses to external stimuli. The data may be organized using a template as previously described.
[0088] In another embodiment of the present invention, the activity recorder is connected to contact management systems, task lists, cost accounting systems (such as activity based costing) or other electronic diary/organizer facilities. In this embodiment of the present invention, the activity recorder may be further adapted to provide charts that visually represent a wide range of activities, such as pattern and frequency of contacting certain individuals by telephone or other means.
[0089] In even another embodiment of the present invention, the ARM is location sensitive such that the activity data further comprises location data (i.e. an integrated Global Positioning System). By way of illustration and not as a limitation, the location data may be used to determine the time of travel between two locations or to associate an activity with a location. An activity that does not match the location identified by the location data would prompt an alert to be issued.
[0090] In still another embodiment of the present invention, the ARM is used by consultants, coaches and other intermediaries to support and guide users on how their time is used and how that affects their goals. It may therefore be operated in combination with a phone or with website communities or collaboration tools to provide question and answer, tips or other exchange of views.
[0091] In an embodiment of the present invention, data may be imported from a application. By way of illustration and not as a limitation, imported data may comprise a appointment data or a task. Imported data may also comprise data of past activities or template data for a current activity. Activity data may also be exported to applications via wired or wireless network connections or direct connection to the ARM.
[0092] In another embodiment, the ARM can be used in a monitoring and analysis mode. In this case, information that has been stored in the ASRM can be analyzed to determine how time was used and on what tasks. In a similar fashion, the ARM can be sued to analyze what resources and tasks are to be engaged in (i.e. forward-looking) so that resources can be appropriately allocated and conflicts found. In this mode, goal setting and performance monitoring can be achieved by analyzing the tasks noted and obtaining feedback on the execution of those tasks.
[0093] Using the ARM in conjunction with other activities would potentially allow a user to note dietary, medical, sports and other information in conjunction with the noted time entries thus allowing analysis of other factors along with the time entries themselves.
[0094] It will be apparent to those skilled in the art that the ARM may also comprise other feature now becoming available on other wireless devices such as email, web surfing, physical navigation and other tasks.
[0095] An activity recorder has been described. It will be understood by those skilled in the art that the present invention may be embodied in other specific forms without departing from the scope of the invention disclosed and that the examples and embodiments described herein are in all respects illustrative and not restrictive. Those skilled in the art of the present invention will recognize that other embodiments using the concepts described herein are also possible. Further, any reference to claim elements in the singular, for example, using the articles “a,” “an,” or “the” is not to be construed as limiting the element to the singular. Moreover, a reference to a specific time, time interval, and instantiation of scripts or code segments is in all respects illustrative and not limiting. | The invention refers to a system of recording the activities carried out by an individual person during specific time intervals. This system will normally be on an electronic device, but the initial method of recording may be paper-based. This system involves recording activity and associated attributes as a function of time on a grid, using lines to define the activity recorded in each grid interval. The invention is an intuitive data entry system, principally but not exclusively via touchscreen. The system will preferably be deployed on a handheld digital device with touchscreen entry capability. The activity recording system may also record values, attributes or files associated with specific time intervals. It may generate charts, tables, alerts and reminders. It may synchronize with other devices and applications and may import or export data from them. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates in general to a stabilizer pad for use with earthmoving apparatus. More particularly, the present invention concerned with a stabilizer pad that is reversible so that it may be usable on either concrete, for example or a more yielding surface such as gravel. Even more particularly, the present invention relates to a reversible stabilizer pad of improved construction having improved resilient pad construction that is very durable and long-lasting in use.
Reference is now made herein to U.S. Pat. Nos. 3,897,079 and 3,913,942 both relating to stabilizer pads relating to earthmoving apparatus. These prior art patents, in which I am a co-inventor, illustrate a reversible stabilizer pad having a generally flanged surface for engagement with gravel, for example, and a somewhat resilient surface for engagement with concrete or asphalt, for example. U.S. Pat. No. 3,897,079, for example describes the use of rubber pads or stops 38 on one side of the stabilizer member such as illustrated in FIG. 2 of this patent.
In the past these have been constructed of a molded rubber and although operation therewith has been satisfactory, for some applications the service life of the molded pad is too short particularly when these pads are used on larger machines. The molded rubber pad can be destroyed particularly if the surface upon which the pad is used is somewhat abrasive. It was common for a small tear to develop in the molded rubber pad and after use thereof the pad might come apart in chunks.
Accordingly, it is an object of the present invention to provide an improved reversible stabilizer pad for use with earthmoving apparatus and in particular one that employs a laminated pad.
Another object of the present invention is to provide an improved stabilizer pad construction that is of laminated form and that is more durable and has a longer operable life than with the use of a molded rubber pad.
Another object of the present invention is to provide an improved stabilizer pad construction that is of laminated form and that can be assembled to the overall pad construction quite easily.
Another object of the present invention is to provide an improved stabilizer pad that is more compact in construction without sacrificing the strength and durability of the pad.
SUMMARY OF THE INVENTION
To accomplish the forgoing and other objects features and advantages of the invention, there is provided an improved stabilizer pad construction for use with earthmoving apparatus or for other related applications. The improved pad construction of the present invention is preferably for use with a reversible stabilizer pad but may also find use in connection with other stabilizer pad applications. In connection with the reversible stabilizer pad construction, each pad is formed with opposed surfaces, one of the surfaces having flange means extending therefrom and the other of the surfaces having resilient means associated therewith. The pad is supported by means which permit reversal of the pads so that either of the surfaces may be the downwardly facing surface.
In accordance with the invention the resilient means is in the form of a laminated pad and constructed of a separate synthetic rubber pieces that are preferably formed from truck tire side walls so that each of the pieces is comprised of a synthetic rubber supported on a base cord. Angle iron means forms a pocket for receiving the laminated pad and means are provided for securing the rubber/cord laminate pieces within the angle iron pocket. The angle iron pocket then in turn is supported from the stabilizer member.
BRIEF DESCRIPTION OF THE DRAWINGS
Numerous other objects features and advantages of the invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a fragmentary view of a typical loader/backhoe that may embody the stabilizer pads of this invention;
FIG. 2 is an exploded view illustrating the flanged side of the stabilizer pad with the associated support arm;
FIG. 3 is a view of the reverse side of the showing the improved resilient laminate construction;
FIG. 4 is a perspective view illustrating a portion of the pad of the invention in particular illustrating the angle irons and securing pin;
FIG. 5 is a perspective view illustrating the multiple rubber/cord pieces that comprise the laminate;
FIG. 6 is a cross-sectional view through the pad construction in an early step of assembly;
FIG. 7 is a similar cross-section view in a later step of construction in which the laminate has been compressed and the pins secured as well as the securing of the angle iron together;
FIG. 8 is a fragmentary view illustrating the means by which the pads are secured to the stabilizer member;
FIG. 9 is a fragmentary view illustrating one form of angle iron and laminate;
FIG. 10 shows a different form of angle iron in particular at the end thereof.
DETAILED DESCRIPTION
FIG. 1 is a fragmentary view of a typical loader/backhoe 10 showing a shovel mechanism 12, stabilizer arms 14 and 16, and associated stabilizer pads 18 and 20. A hydraulic piston 15 may operate each of the stabilizer arms 14 and 16 independently. When the equipment is being moved the pistons associated with each cylinder are withdrawn so that the support arms are elevated above ground level. Alternatively, when the support arms are to be used the pistons associated with each of the cylinders are extended to the position as substantially shown in FIG. 1.
The stabilizer pad 18 generally includes a flat plate 22 having extending normal to the surface thereof the flanges 24 and 26 extending from one surface of the plate 22. The support member is also provided with supporting ribs 25, two such ribs being provided for providing additional support for each of the flanges 24 and 26 in the embodiment of FIG. 1.
In connection with the embodiment of FIG. 1, it is noted that the stabilizer member construction is substantially identical to that described in U.S. Pat. No. 3,897,079. However, in a preferred embodiment of the present invention the stabilizer member construction is substantially as illustrated in FIGS. 2 and 3 which is a slightly different configuration than that illustrated in FIG. 1. In the embodiment FIGS. 2 and 3 there is likewise provided a flat plate 22 having flanges 24 and 26 extending therefrom. In the embodiment illustrated in FIG.2 it is noted that there is one rib 28 on either side of the stabilizer member.
The plate 22 is notched at 30 between flanges 24 and 26 so as to accommodate arm 14. Arm 14 includes a journal end for accommodating pin 34. Pin 34 also fits within holes 35 and 36 of flanges 24 and 26, respectively. The pin 34 may be secured in place by means of a typical cotter pin, or the pin 34 may be threaded to accommodate a bolt.
FIG. 3 shows the resilient side of the stabilizer member which comprises resilient means in the form of laminated pads 40.
Reference is now made to FIGS. 4 and 5 that together illustrate the basic components comprising the stabilizer member resilient pad structure. FIG. 4 illustrates the angle irons 44 and 48. The angle iron 44 includes a base leg 44A and an upright leg 44B. Similarly, the angle 48 contains a base leg 48A and an upright leg 48B. The upright legs 44B and 48B each have holes therein illustrated in FIG. 4 for receiving the elongated pins 50.
FIG. 5 illustrates the laminate structure 52 which generally comprises a plurality of separate pieces 54 shown arranged in a sandwich or laminate construction. Each of the pieces may be pre-drilled with a hole such as illustrated at 56 in FIG. 5 to receive the corresponding pins 50.
Each of the pieces 54 is preferably made from sidewall segments of a truck-tire carcasses. In this connection it is preferred not to use a steel belted tire for forming these simply because it is more difficult to cut a steel belted tire into such pieces. Each of the pieces 54 may have a thickness as illustrated by the dimension W in FIG. 5 that is preferably on the order of 1/2 inch in its uncompressed state, and preferably in the range of 1/4 to 3/4 inch thickness. In a typical installation 8 to 10 pieces 54 may be employed in the laminate. Of course, for larger pads than the number of pieces would be increased.
It is preferred to use segments from a truck tire so that each of the individual pieces are of proper thickness to provide proper durability and stiffness. Typically, truck tires are of 10 ply or greater. It is preferred to use a multiple ply truck tire because this provides a relatively high ratio of cord to rubber relative thickness. The thickness of the cord that provides the primary stability is preferably 4 times that of the thickness of the rubber. The greater the ply number of the tire the greater the stability of the laminate.
Reference is now made to FIGS. 6-8 showing certain sequences in the method of assembly. In this connection it is noted that in FIG. 6 the angle irons 44 and 48 are disposed on some suitable support table 53. The pieces 54 of the laminate 52 are disposed in position and are considered in FIG. 6 as in their initial uncompressed state. The holes in each of the pieces 54 may be aligned so as to receive the pins 50. In FIG. 6 one of the pins 50 is illustrated exploded to the right of the structure. It is also noted in FIG. 6 that the bases of the angle irons 44 and 46 are spaced from each other as illustrated by the gap 49 in FIG. 6.
The next step in the method of assembly is to compress the laminate by moving one or both of the angle irons so that the angle irons are brought together. This compresses the pieces 54 of the laminate 52. In this connection note in FIG. 7 the arrows 51 indicating the relative direction of movement for compression of laminate. With the angle iron compressed by use of some type of a conventional press arrangement, then the angle irons are welded at 56 longitudinally along the seam between the angle irons. In this connection also refer to FIG. 4 where, at 56, the place is illustrated where the weld would occur. At the same time the ends of each of the pins are also welded at 58. This is illustrated in FIG. 7. The pin ends are welded to the respective angle iron upright legs. The compression forces as indicated by the arrows 51 may then be released and then the laminate is then maintained in somewhat of a compressed state. The compression of the pieces 54 of the laminate 52 provide for a sturdy laminate that is relatively rugged and rigid.
FIGS. 7 and 8 also illustrate the means by which the improved resilient pad means of the present invention is secured to the stabilizer member. In this connection note in FIGS. 7 and 8 the flat plate 22 of the stabilizer member with there being provided bolts 60 and associated nut 62 that are used for this purpose. These are preferably carriage bolts and have a relatively small head. The carriage bolts, as illustrated in FIG. 8, are tack welded to the angle iron at 64.
After the angle irons have been welded and the pins 50 have also been welded to the angle irons, the carriage bolts 60 that have been previously tack welded may then be inserted into holes pre-drilled in the stabilizer member. The nuts 62 preferably with the use of a associated lock washers then secure the resilient pad means to the stabilizer member.
The angle irons themselves are preferably constructed so as to have a thickness that is sufficiently rugged to provided good support but that is not too thick it is preferred that this thickness, illustrated in FIG. 6 by the dimension T be about 3/16 inch. If the angle iron thickness is smaller than that it will not have sufficient strength. On the other hand if the angle iron thickness is substantially greater than that the angle iron itself, as the laminate wears, will tend to tear into the pavement particularly at the corners of the upright legs of the angle irons. The preferred 3/16 inch thickness provides sufficient flexibility so that if the angle iron does engage a hard surface such as asphalt or concrete surface it will tend to deflect rather than gouge the surface.
Reference is now made to FIGS. 9 and 10 which show two preferred ways of arranging the components as far as the angle iron and the laminate are concerned. It is of course preferred that the laminate extend above the angle iron as illustrated in FIGS. 9 and 10 and at the corners of the angle iron it is preferred that the laminate also extend beyond as illustrated at 68 in FIG. 9. This leaves sufficient room at the corner of the laminate so that even if the corners thereof wear there still will be sufficient room before the angle iron is exposed.
In this connection FIG. 10 shows an alternate construction in which the end of the angle iron; that is the upright wall of the angle iron is angled as illustrated at 70 in FIG. 10. This leaves a relatively large exposed area of laminate at 72 at the corners. With either of the arrangements of FIGS. 9 and 10, this prevents tearing of the pavement upon which the pad is used particularly at the corners thereof.
With regard to securing the resilient pad means to the stabilizer member itself, in one embodiment, such as illustrated in FIG. 2, three bolts 60 may be employed per pad. In the embodiment of FIG. 2 three such pads are illustrated. In another embodiment of the invention in which the overall stabilizer member is larger then a greater number of bolts may be employed. For example one version employs five bolts for securing purposes.
Having now described a limited number of embodiments of the present invention, it should now be apparent to those skilled in the art that numerous other embodiments and modifications thereof are contemplated as falling within the scope of the present invention as defined by the appended claims. | Earthmoving equipment especially of the loader/backhoe type is provided with hydraulically operated stabilizer arms having stabilizer members associated therewith. Each member or pad is of reversible type having a flanged surface for engagement with gravel, for example, in a somewhat resilient surface for engagement with concrete or asphalt for example. The resilient surface is formed by a laminate constructed of separate pieces each of synthetic rubber cord construction. | 4 |
FIELD OF THE INVENTION
The invention relates in general to guiding a printing medium that is being conveyed along a travel path in a printing machine, whereby the printing medium is not making contact along at least one edge.
BACKGROUND OF THE INVENTION
In printing machines, especially in electrophotographic printing machines, printing media such as paper, for example, are conveyed along a path of travel with the aid of conveyor belts, traction systems, or the like.
Printing media can be conveyed such that only certain areas of the printing media come into contact with the appropriate conveying elements. For example, the printing medium can lie midway on an electrostatic conveyor belt and be conveyed thereby while one edge or even both edges of the printing medium make no contact.
This freedom of contact of the edges can, for example, be necessary when microwave fuser mechanisms are used, as is proposed in DE 101 45 005 A1. In such case, for example, toner can initially be fused on the edges of the printing medium by microwaves. Because contacts made by the printing medium directly downstream of the microwave applicators can lead to smeared print images, it is desirable that the printing medium be conveyed in such a way that no contact is made with the edges. To achieve this purpose, the use of an electrostatic conveyor belt for conveying the printing medium is preferred, whereby the conveyor belt is set up such that the middle section of printing medium lies on the conveyor belt.
If the printing medium is conveyed such that the edges do not make contact, undesirable movements of the edges can occur. The edge can begin to flutter or become bent in an undesirable way; it can, in particular, hang down or roll up, or the like.
The undesirable movements can cause reductions in print quality. The layer of toner can be adversely affected or, inside a lithographic or ink jet printing machine, ink that has not yet dried can run. If the path of travel runs through another mechanism, the movements of the edges of the printing medium can result in the medium making contact with or bumping into feed-in slots that are present. This can damage the printing medium, or cause a paper jam.
SUMMARY OF THE INVENTION
The object of the subject invention is, therefore, to introduce a process and a way of guiding printing media which help to prevent undesirable movements of the edges of a printing medium that is being conveyed along a travel path, whereby at least one of its edges does not make contact.
The object of the invention is achieved with respect to process by using a stream of sucked air that is directed at least partially outward with respect to at least one edge of the printing medium. The sucking of air in the vicinity of the printing medium essentially prevents turbulent air currents in these areas, and the edges of the printing medium are either guided with greater stability or actively stabilized. Parts of this air stream that are directed in the direction of the path of travel can additionally support the travel movement of the printing medium.
In a particularly beneficial embodiment, provision is made with respect to the process for the air stream to flow above and/or below the printing medium. By layers of air streams above and/or below the printing medium, the edges become more stably guided. In particular, it is possible by regulating these air streams to generate or to improve desirable curving of the printing medium edges. If the air stream is, for example, reduced on one side of the printing medium (if reduced to zero then the printing medium will be guided only on one side) then the printing medium edge will be curved in the opposite direction.
The object that underlies the invention is additionally achieved by guiding the printed medium by at least one air suction mechanism that is used for suctioning the air out of the area of the printing medium's travel path, thereby creating an air stream that is at least partially directed outwards. The advantages of such an air stream have already been described.
In a beneficial embodiment of the printing media guide, the air suction mechanism generates an air stream that supports the printing medium from above and/or below. In this way the printing medium edge can, as described, be curved in a desired manner. A particularly rigid shape of the printing medium edge can be created, in which practically no warping exists. Conveyance of the printing medium through slots, for example in a microwave mechanism, is then easily achieved without the risk of making contact. An adverse affect on the quality of a printed image on the printing medium caused by undesired movement can thus be precluded with even greater certainty.
In a particularly beneficial further development of the printing media guide, the air suction mechanism incorporates a wall that has air vents and borders laterally on the printing medium's travel path. By the use of air vents it is beneficially possible to create a more even air stream, whereby a more stable guidance of the printing medium edges is made possible. In particular, it can be possible by an array of air vents distributed differently in the wall to vary the location of the air stream. For example, a faster moving stream of air can be generated above the printing material in this way. Thus, when necessary, a curving of the printing medium edge resulting from its own weight can be beneficially compensated.
By skillful distribution of the air vents, it can also be made possible to better adjust the printing medium to changes within the printing medium's travel path. To generate a more even air stream, the air suction mechanism has at least one antechamber. In this way an even negative pressure, which then creates the air stream, can be created across a wider area parallel to the travel path.
In a beneficial further development of the printing media guide at least one air guide element that acts upon the air stream is provided. This air guide element conducts an air stream such that it also beneficially acts in places that are not directly in the vicinity of the area in which the air stream is created. Thus, the sphere of influence of the printing media guide becomes more flexible. In addition, the air stream can, by this guide, be better directed so that air currents that influence the printing medium can be created more precisely.
In order to maintain the printing medium edge in a more rigid alignment or to create a desired curving, it is necessary that the air stream be able to act upon the upper and/or the lower side of the printing medium. Consequently provision has been made according to the invention that at least one, but preferably two, air guide elements located above and/or below the printing medium extend into the area of the travel path, essentially in a plane parallel to the printing medium.
The plane of the air guide elements need not necessarily be parallel to the printing medium. Deviations from such a parallel plane within the range of several degrees are certainly tolerable, because in such case stable guidance of the printing medium edge would nevertheless continue.
Often, different types of paper or printing media with varying widths are processed inside the printing machine. The printing media guide must, therefore, be so flexible that it can (1) guide printing media with maximum width, as well as with minimal width, and/or (2) stabilize the edges of the printing media. Thus, with respect to the apparatus, provision is made for the air guide elements to border on the air suction mechanism and to extend into the area of the travel path of the narrowest conceivable printing medium, and thus provide an expanded sphere of influence for the printing media guide. The air suction mechanism delimits the sides of the travel path and thus limits the maximum width that a printing medium may have. By the air guide elements according to the invention the air stream is directed even into the areas of the edge of the narrowest conceivable printing medium. This edge can thereby be advantageously guided or stabilized. In this way, great flexibility with respect to the guidance of printing media of various widths can be achieved.
In a beneficial embodiment of the printing media guide according to the invention, provision is made for the air suction mechanism and the air guide elements to follow the course of the conveyor travel path. This allows the printing media guide to beneficially assure for stability and guidance of the printing medium edges along various courses of the conveyor travel path. In this embodiment, the printing media guide is located essentially always in the same plane as the conveyor path, even when the plane of the conveyor path curves or changes in some other way. In this way, the printing media guide can, for example, even follow a helix-shaped conveyor path, such as is introduced for the turnover mechanism in DE 100 59 913C2.
Inside a printing machine, printing media can be guided onto different planes. For a turnover mechanism, for example, the conveyor path can, for example, have a commensurate curve radius. The surface of the printing medium is then proportionately curved. By the printing media guide, according to the invention, the edges of the printing media can be stably guided even as this curving takes place.
The invention, and its objects and advantages, will become more apparent in the detailed description of the preferred embodiment presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
In the detailed description of the preferred embodiment of the invention presented below, reference is made to the accompanying drawings, to which, however, the scope of the invention is not limited, in which:
FIG. 1 is an overhead view of a printing media guide;
FIG. 2 is a cross section through an air suction mechanism;
FIG. 3 is a sketched course of the printing media guide; and
FIG. 4 is an overhead view of a printing media guide showing possible printing media widths.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a printing media guide according to the invention. The view is from overhead. A printing medium 1 is being conveyed on a conveyor path in the direction of arrow 2 . Impetus for the movement is transferred to the printing medium 1 via a conveyor belt 3 . In principle, the printing medium 1 can be held on the conveyor belt 3 in various ways, for example, by electrostatic energy. With respect to the conveyor belt 3 shown here, the printing medium 1 is held to the conveyor belt 3 by vacuum induced through suction holes 4 .
An edge area 5 of the printing medium shown by the dashed lines, also referred to hereinafter as edge 5 or printing medium edge 5 , is located in the vicinity of air guide elements 6 and 7 . In the overhead view shown here, only the upper air guide element 6 is visible. In FIG. 2 , both air guide elements 6 and 7 can be seen. The air guide elements 6 and 7 connect to an air suction mechanism 8 . A cross section of the air suction mechanism 8 is shown in FIG. 2 .
The printing medium 1 is guided on the conveyor belt 3 , such that the edge area 5 of the printing medium 1 lies midway between the two air guide elements 6 and 7 . In a conventional arrangement of a printing media guide, the printing medium 1 would simply lie on the conveyor belt 3 . The edge areas 5 would, for one thing, hang down because of their own weight and/or be so affected by turbulent air currents that undesirable waving or other bending would occur. The edges 5 of the printing medium 1 could also begin to flutter.
With the use of the printing media guide shown here, undesirable bending and/or fluttering of the printing medium edges 5 can be successfully avoided. Between the air guide elements 6 and 7 , a suction-induced air stream 9 , is symbolically represented by arrows. The suction induced air stream 9 has a stabilizing and guiding effect on the printing medium edges 5 so that, depending upon the need, either curving or straightening out can occur, whereby the suction induced air stream 9 is preferably used to stabilize the edges 5 . In the case shown here, at least one printing medium edge 5 lies even with and parallel to the air guide elements 6 and 7 . The air guide elements 6 and 7 border on a wall 10 that delimits the travel path of the printing medium 1 . This wall 10 has air vents 11 . The wall 10 is part of the air suction mechanism 8 .
Behind the wall 10 , the air suction mechanism 8 has an antechamber 12 . In this antechamber 12 an even negative pressure can build up. Then, air can be sucked commensurately evenly through the air vents 11 in the wall 10 , and out of the area between the air guide elements 6 and 7 , so that an even stream of suction air 9 can arise therein and assure that the printing medium edges 5 are stably guided. The printing medium edges 5 are prevented by the constant stream of suction air 9 above and below the printing medium from deviating from their flat, midway position.
In order for the antechamber 12 to build up a negative pressure, air is pumped out of this antechamber 12 by fans or pump mechanism 13 . As shown in FIG. 1 , several pump mechanisms 13 can be used in order to create the appropriate negative pressure. However, configurations with only one pump mechanism 13 are conceivable.
A desired bending of the edge of a printing medium 5 can be achieved by the printing media guide according to the invention. For this to happen, it is sufficient to direct the suction air stream 9 above and/or below the printing medium 1 , such that, through relative differences in pressure that are created via different steam velocities, a force impacts upon the printing medium edge 5 that bends it in the desired manner. To achieve this result, the locational array of air vent holes 11 in the wall 10 can, for example, be varied commensurately.
FIG. 3 shows a sketched course of a printing media guide. The printing medium 1 follows the travel path of printing medium 1 . The printing medium 1 is conveyed by the above-described conveying elements in the direction shown by the arrow 2 . The travel path shown in the example as a curved course. Such a course can, for example, be found in a turnover mechanism.
Air guide elements are located above and below the printing medium 1 , and they are shown in FIG. 3 by dashed lines. They follow the curved travel path of the printing medium 1 . In this way, a stable, well-guided printing medium edge 5 can be continuously assured. During its curved course, the travel path is bordered by at least one wall 10 on which air guide elements 6 and 7 border. Of course, for the sake of a better view, the wall 10 is not shown in FIG. 3 ; it is located between the air guide elements 6 and 7 . The air guide elements 6 and 7 extend into the drawing plan and over the edge 5 of the printing medium 1 .
Such an arrangement can be useful, for instance, in turnover mechanisms. It is particularly useful in a turnover mechanism, pursuant to DE 100 59 913C2. Therein, it is proposed that the printing medium 1 be turned over between belts. The travel path, in such a case, has a helix-shaped course, which can be followed by the printing media guide, according to the invention. In general, it is possible for the printing media guide to follow every conceivable change in the travel path. In this way, especially in the areas in which the travel direction of the printing medium 1 is changed, a stable guidance of the printing media edge can be achieved.
The printing media guide described here, and the use of the suction air stream 9 that it generates in order to guide and stabilize a printing medium edge 5 , are intended to act mainly on both edges 5 of a printing medium 1 . Action upon only one edge 5 , can however, also be feasible if the remaining area of the printing medium 1 can be guided and/or held in place by other elements.
FIG. 4 shows an overhead view of a printing media guide, in which one can see the range of width over which a printing medium can vary, and still have its edges 5 guided by the suction air stream 9 . The travel path of the printing medium 1 , is laterally delimited by the walls 10 . Consequently, the maximal width b of a printing medium 1 is delimited by the fact that the printing medium 1 must not bump against a wall 10 . Thus, a safety clearance in the range of millimeters should be maintained.
As long as edge area 5 of a printing medium 1 remains in the area of air guide elements 6 and 7 , the suction air stream 9 can stabilize and/or guide the edge 5 . A minimal width a of the printing medium 1 is consequently derived from the distance l, which represents how far the air guide elements extend into the travel path of the printing medium. In this regard the air guide elements 6 and 7 should preferably extend over the printing medium 1 . A safety area in the range of millimeters, by which the air guide elements 6 and 7 extend over the narrowest conceivable printing medium 1 , is also recommended here.
As can be seen, the printing media guide can readily accommodate various widths of the printing medium 1 . Of course, the distance l, by which the air guide elements 6 and 7 should extend into the area of the travel path, should be selected such that even the narrowest expectable printing medium 1 can be guided by the suction air stream 9 . The distance between the walls 10 should be great enough so that a printing medium 1 with the maximum expectable width can fit between the walls 10 .
Aside from these considerations, no adjustments during the operation of the printing media guide are necessary. In general, different gram weights, i.e., weights of the printing media in use, do not require readjustment of the printing media guide during operation.
Thus, being introduced here, is a printing media guide that can readily accommodate different printing media 1 , and that makes possible in a very simple way, stabilization and/or guidance of printing media 1 that are being conveyed in such a way that at least one edge 5 is contact-free. Undesirable movements of edges 5 can thus be ideally avoided. Other difficulties can also be quickly corrected. As soon as the printing medium edge 5 moves away from its position midway between the air guide elements 6 and 7 , the suction air stream 9 guides it quickly back to a central position. Undesirable bending of the edges 5 can be avoided and desired bending, for example, during operation within a turnover mechanism, can be precisely achieved. However, it is not absolutely necessary that the printing medium edge 5 lies midway between the air guide elements 6 and 7 . An array of air vent holes in the wall 10 allows the printing medium edges 5 to assume other than midway positions between the air guide elements 6 and 7 , but the midway position is preferred.
In addition, the printing media guide is very sturdy and is not subjected to being adversely affected in the face of other undesirable effects. For example, changes in the alignment of the air guide elements 6 and 7 do not substantially adversely affect the operation of the printed media guide. A position of the air guide elements 6 and 7 , that is, exactly parallel to the plane of the travel path, is not necessary for the printing media guide to operate. To a large extent, changes in the alignment of the air guide elements 6 and 7 across a broad range of degrees can be tolerated.
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. | Guiding a printing medium that is being conveyed along a travel path in a printing machine, whereby the printing medium is not making contact along at least one edge. A stream of sucked air ( 9 ) is directed at least partially outward, with respect to at least one edge ( 5 ) of the printing medium. A printing media guide with at least one air suction mechanism ( 8 ) for sucking air out of the area of the travel path of the printing medium ( 1 ) in order to create a suction air stream ( 9 ) is directed at least partially outwards. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a washbasin drain assembly.
Design of subsystems of a commercial passenger aircraft is a continuing pursuit of a favorable balance between functionality and weight.
For several years, the lavatory washbasins in commercial passenger aircraft were generally made from stainless steel. Although stainless steel has many desirable properties with respect to this use, a basin made of stainless steel is heavier than a basin of comparable size and made of a material having a higher strength-to-weight ratio than stainless steel, such as a glass fiber reinforced synthetic polymer material.
In order to provide a basin of sufficient strength made from non-metallic material, the thickness of the basin must generally be greater than the thickness of a basin made of stainless steel.
The drain body that is connected to the outlet opening of the lavatory washbasin in a commercial passenger aircraft is connected to a waste line which supplies the gray water from the basin either to a pressure responsive valve which feeds the gray water to a drain mast for discharge from the aircraft or to a vacuum interface valve for supplying the water to a vacuum sewer through which the water is delivered to a collecting tank aboard the aircraft. In certain applications, there may be other devices downstream of the drain body.
A solid contaminant in the gray water may interfere with operation of the interface valve or other downstream device, and may lead to a flooding condition.
It is known to include a strainer in the outlet of a washbasin to prevent solid objects from entering the drain line. Depending on the installation of the basin, the purpose of the strainer may be either to protect against loss, e.g. of small items of jewelry, or to protect against blockage of the drain line, e.g. by kitchen waste. In either case, however, the strainer openings are fairly large, typically hiving a minimum linear dimension of at least 5 mm.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved washbasin drain assembly for a commercial passenger aircraft, wherein the drain assembly is provided with a filter to protect a downstream device, such as a vacuum interface valve, from contamination by objects that might otherwise enter the gray water collection and disposal system through the washbasin, and wherein the filter is positively retained in normal use yet can be selectively removed during routine maintenance for cleaning.
It is also an object of the invention to provide such a washbasin drain assembly in which the filter allows use of either a stopper attached to a chain or other cord-like element or a stopper assembly including a lift rod operated by a draw bar, such that the stopper assembly remains partially within the drain assembly in the open condition.
It is a further object of the invention to provide an improved washbasin drain assembly which can accommodate use in a commercial passenger aircraft of a lavatory washbasin made either of metal, such as stainless steel, or a non-metallic material, such as fiber reinforced synthetic polymer material.
In accordance with a first aspect of the invention there is provided an improved washbasin drain assembly, for fitting in an outlet opening of a washbasin and connecting to a waste line, comprising a drain body which defines a drain passage connecting the interior space of the washbasin to the waste line and a drain plug in cooperative engagement with the drain body for selectively sealing the drain passage, wherein the improvement resides in a sieve fitted removably in the drain body downstream of the plug relative to the direction of flow of liquid from the basin to the waste line.
In accordance with a second aspect of the invention there is provided an improved washbasin drain assembly, for fitting in an outlet opening of a washbasin and connecting to a waste line, comprising a seat which fits in the outlet opening and defines a drain passage surrounded by a flange, a drain body attached to the seat and positioned below the washbasin, a lift member fitted in the drain body and displaceable between an upper position and a lower position, a plug fitted in the drain passage and supported by the lift member, such that when the lift member is in its lower position, the plug engages the seat and seals the washbasin and when the lift member is in its upper position the plug is clear of the seat, and a pivot engaged with the lift member, wherein the improvement resides in that the lift member is adapted to be engaged by the pivot rod selectively in one of at least two locations spaced apart along the lift member, to accommodate possible variation in height of the flange relative to the pivot rod.
In accordance with a third aspect of the invention there is provided an improved washbasin drain assembly, for fitting in a outlet opening of a washbasin and connecting to a waste line, comprising a drain body subassembly which fits in the outlet opening and defines a drain passage connecting the interior space of the washbasin to the waste line, a stopper subassembly fitted in the drain passage and including a plug for sealing the drain passage and a lift member for selectively raising and lowering the plug, and an actuator coupled to the lift member, wherein the improvement resides in that the plug is releasably attached to the lift member, whereby the plug can be disengaged from the lift member to allow removal of the plug without disengaging the lift member from the actuator.
In accordance with a fourth aspect of the invention there is provided an improved washbasin drain assembly for a washbasin mounted in a deck, the drain assembly comprising a drain body for fitting in an outlet opening of a washbasin and connecting to a waste line, a stopper subassembly fitted in the drain body subassembly and movable selectively therein for releasing and preventing flow of liquid from the basin, a pivot rod mounted in the drain body and having an inner end engaged with the stopper subassembly and also having an outer end, a draw bar guide mounted in the deck, a draw bar slidable within the draw bar guide, and a link rod connecting the draw bar to the outer end of the pivot rod, the link rod including a upper vertical segment extending adjacent the draw bar, a lower vertical segment extending toward the pivot rod, and a horizontal segment extending between a lower end of the upper vertical segment and an upper end of the lower vertical segment, to limit encroachment of the link rod on the space below the draw bar.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which
FIG. 1 is a part sectional schematic view of an aircraft washbasin drain assembly in accordance with the invention,
FIG. 2 is a part sectional view of a second aircraft washbasin drain assembly in accordance with the invention,
FIGS. 3A-3F are enlarged partial views of a subassembly of the drain assembly shown in FIG. 2, and illustrate the manner in which two components of the subassembly are coupled,
FIGS. 4A and 4B show the washbasin drain assembly of FIG. 2 in open and closed conditions respectively,
FIGS. 5A and 5B illustrate the drain assembly of FIG. 2 when modified to fit in a thicker washbasin, in open and closed conditions respectively; and
FIG. 6 is an enlarged partial view of the drain assembly taken along line 6--6 of FIG. 1.
DETAILED DESCRIPTION
FIG. 1 illustrates a relatively thin washbasin 4 made of a metallic material such as stainless steel and having an inner rim surrounding an outlet opening 8. A drain body 12, which has an external flange 14 and is internally threaded at 16, is positioned below the outlet opening of the washbasin. A seat 20 has a flange 22 above the outlet opening of the basin and an extension sleeve extending through the outlet opening and in threaded engagement with the drain body 12. The annular margin surrounding the outlet opening of the basin is clamped between the flanges 14 and 22, and a gasket is provided to prevent leakage of water between the flange 14 and the underside of the basin. The seat 20 defines a drain passage connecting the interior space of the washbasin to the drain body. At its lower end, the drain body has a connection nipple 24 over which a hose 28, serving as a drain line, is fitted. The nipple defines an outlet conduit which is divided into sectors by four webs 32 projecting inward toward the central axis of the conduit. The four webs 32 do not meet at the center of the outlet conduit, but leave a narrow guideway 34 clear. The hose 28 is connected to a downstream flow control device 36, such as a vacuum interface valve.
A stopper 40, of the kind that is typically attached to a chain so that it can be freely moved relative to the basin within the limits imposed by the length of the chain yet is positively retained, can be fitted in the drain passage defined by the seat 20. When the stopper 40 is fitted in this drain passage, it blocks flow of water from the washbasin whereas when the stopper is removed from the drain passage water can flow from the basin.
The seat 20 has an internal flange or shoulder 44 at the lower end of its extension sleeve. A filter subassembly 48 includes a mesh cup 52 with a circular opening 53 (illustrated in FIG. 6) at its bottom end and an annular rim 56 at its top end, and a tube 60 attached to the cup 52 and extending upward from the circular opening at the bottom of the cup. The filter subassembly 48 is located in the drain body with the annular rim 56 resting on the shoulder 44 so that the tube 60 is coaxial with the drain body 12.
A cap subassembly 64 includes a cap 66 which is attached by an annular web formed with holes 68 to an annular mounting ring 72, carrying an O-ring 76 at its outer periphery. The cap subassembly 64 is releasably secured to the seat 20 by engagement of the O-ring 76 in a V-shaped groove at the interior of the seat. In this position, the cap 66 extends over the opening at the upper end of the tube 60. The cap 66 is configured so that it is awkward for the simply curious to grasp the cap and remove the cap subassembly, but service personnel can readily grasp the cap subassembly and remove it.
The aperture size of the mesh cup 52 depends on the nature and structure of the downstream device to be protected and the nature of the contaminants against which the downstream device is to be protected. Research has shown that the type of debris that is deposited in the lavatory washbasin of a commercial passenger aircraft depends on the route served by the aircraft. Therefore the actual mesh size may depend on the route. If the service of a particular aircraft is changed, the mesh size of the filter to be installed in that aircraft can also be changed. The size may be in the range from 40 μm to 5 mm, preferably 100 μm to 2 mm.
When the stopper 40 is removed, water in the basin can flow out through the drain body and outlet conduit and is filtered so that even relatively small particles are trapped in the cup 52. The mounting ring 72 serves as a coarse filter, blocking large objects. During routine servicing, the cap subassembly 64 is removed and the service person can then remove the filter subassembly 48 and either clean it on the spot and reinstall it or can replace it with a clean filter subassembly and take the one removed from the drain body away for cleaning. In this way, the downstream device 36 is protected from contamination with solids in the basin, reducing the likelihood of a malfunction of the downstream device.
The tube 60 is constructed with a solid wall in order to afford sufficient rigidity to allow it to be gripped by service personnel without collapsing the tube.
The drain body has a lateral stub 80 just above the connection nipple 24. The purpose of the lateral stub 80 will be described with reference to FIG. 2. In the case of the drain assembly shown in FIG. 1, the lateral stub is not used and it is sealed by a cap nut 84.
Referring to FIG. 2, the stopper subassembly 40' includes a circular plug 88 having an annular flange formed with a peripheral groove containing an O-ring. A guide sleeve 92 formed with openings 96 is attached to the plug 88 and extends downward from the annular flange. Inward of the guide sleeve 92, a cylindrical socket 100 formed with inverted J-shaped slots 102 (FIG. 3) projects downward from the plug and is removably coupled to a lift rod 104 which extends axially within the drain body, passing through the tube 60, and has a stem 108 fitted in the guideway 34 and restrained against lateral movement by the guide webs 32.
FIG. 3 shows several views of the stopper subassembly 40' in order to illustrate the manner in which the plug 88 is attached to the lift rod 104. The sleeve 92 is not shown in FIG. 3, in order to avoid concealing the socket 100. As shown in FIG. 3, the lift rod 104 is formed with lower and upper transverse bores through which respective pins 106, 107 extend. The upper pin 107 functions as a bayonet pin for coupling the plug 88 to the lift rod 104 by engagement in the J-shaped slots. A spring 112 is captive on the lift rod between the two pins. When the plug 88 is engaged with the lift rod 104, the spring 112 is held in compression between the lower pin 106 and the lower end of the socket 100. In order to remove the filter subassembly, the circular plug 88 is disengaged from the lift rod 104 by pressing down on the plug and rotating it clockwise through 90° in order to align the upper pin 107 with the slots 102. The plug can then be removed from the seat, exposing the filter subassembly.
Just above the guide stem 108, the lift rod 104 is formed with two transverse openings 116. A pivot rod 120 extends through a ball journalled in the lateral stub 80, the ball being held captive by a cap nut 84', the pivot rod 120 having an inner end which threads the upper opening 116. Angular movement of the pivot rod 120 about a horizontal axis is transmitted through the lift rod to the plug 88, which can be raised toward an open position, in which it is clear of the seat 20 and water can flow from the basin into the drain body, and lowered toward a closed position in which it seals the drain passage. The guide sleeve 92 serves to guide movement of the plug 88 relative to the seat 20 and the openings 96 prevent large particles from entering the drain body 12.
The coupling of the lift rod 104 to the pivot rod 120 and the coupling of the plug 88 to the lift rod 104 provide positive retention of the plug 88 and lift rod 104.
The filter is designed to maximize the filter area within the space available in the drain body 12. The available space is limited by the lift rod and the connection, to the pivot rod. In a practical implementation, the cup is about 5.5 cm long and about 2.3 cm in diameter.
The basin 4 is mounted in a deck 124 (FIG. 2). Spaced somewhat from the rim of the basin 4 is a circular opening 128 in the deck and a draw bar guide 132 is fitted in this opening and is held in position by a nut. The draw bar guide 132 defines a circular bore through which a draw bar 136, provided at its upper end with an actuator knob, is fitted slidably. A detent mechanism cooperating with peripheral grooves in the draw bar establishes two principal operating positions (open and closed) for the draw bar.
A linkage rod 140 has upper and lower vertical segments and inner and outer (with respect to the drain body 12) horizontal segments. At its lower end, the draw bar L36 is provided with a clamp 144 having a first jaw which grips the lower end of the draw bar 136 and a second jaw which grips the upper vertical segment of the linkage rod 140. The upper clamp 144 holds the upper vertical segment of the linkage rod substantially parallel to the draw bar. The upper clamp can be attached to the draw bar at any angular position about the axis of the draw bar and it can also be attached to the upper vertical segment of the linkage rod at any angular position about a vertical axis. Further, the vertical position at which the upper clamp grips the upper segment of the linkage rod is adjustable. The inner horizontal segment of the linkage rod is attached to the pivot rod 120 by a lower clamp 148, which can be attached to the pivot rod and the inner horizontal segment of the linkage rod at any horizontal position. The lower clamp includes a swivel allowing the angular position of the inner horizontal segment relative to the pivot rod to vary about a vertical axis. Play in the connection between the linkage rod and the pivot rod allows limited angular relative movement of the inner horizontal segment and the pivot rod about a horizontal axis perpendicular to the lift rod. This arrangement of the linkage rod and the upper and lower clamps provides wide flexibility in location of the draw bar guide 132 relative to the basin 4. Because the lower vertical segment connects the inner and outer horizontal segments, the linkage rod does not encroach substantially on the space immediately below the draw bar, leaving this space available for other equipment.
FIGS. 4A and 4B illustrate the drain assembly of FIG. 2 in the open and closed conditions respectively.
In a conventional domestic washbasin, the drain body is attached to the basin by a mounting nut in threaded engagement with the drain body. In the case of the drain assembly shown in FIGS. 1 and 2, the annular margin of the basin is clamped between the flanges of the seat 20 and the drain body 12. This is advantageous in an aircraft application because it avoids the need for the mounting nut, which adds weight and is a potential source of failure due to the possibility of loosening through vibration. However, because the annular margin of the basin 4 is clamped between the flanges of the seat 20 and the drain body 12, the vertical position of the lateral stub 80 relative to the seat 20 depends on the thickness of the basin.
Referring to FIGS. 5A and 5B, the thickness of the basin 4' is significantly greater than the thickness of the basin 4 shown in FIGS. 4A and 4B and so the flange 22 of the seat 20 is higher relative to the drain body 12. The vertical distance between the flange 22 of the seat 20 and the lateral stub 80 is significantly greater in the case of FIGS. 5A and 5B than in the case of FIGS. 4A and 4B. Accordingly, the range of movement through which the stopper subassembly 40' must move in order to lift the plug is shifted upward relative to the arrangement shown in FIGS. 4A and 4B. In order to elevate the lift rod and accommodate the greater thickness of the basin 4', the inner end of the pivot rod is fitted in the lower opening 116, as shown in FIGS. 5A and 5B. It will therefore be seen that use of two openings 116 in the lift rod allows the same drain assembly to be used not only with a thin basin made of metal but also with a thicker basin, such as one made of a glass fiber reinforced synthetic polymer material.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims and equivalents thereof. For example, although the invention has been described with reference to a washbasin installed in a passenger aircraft, it is also applicable to other installations, particularly mobile installations such as trains, buses and ships. | A washbasin drain assembly comprises a drain body which defines a drain passage connecting the interior space of the washbasin to the waste line and a drain plug in cooperative engagement with the drain body for selectively sealing the drain passage. A sieve is fitted removably in the drain body downstream of the plug relative to the direction of flow from the basin to the waste line. | 4 |
BACKGROUND
[0001] In the process for electrolytic production of aluminium, such as the Hall-Heroult process where aluminium is produced by reducing alumina (aluminium oxide, Al 2 O 3 ) in a melted electrolyte in the form of a fluorine-containing mineral to which alumina is fed, the process gases are loaded with fluorine-containing substances, such as hydrogen fluoride and fluorine-containing dust. Being extremely damaging to the environment, these substances have to be separated before the process gases can be discharged into the surrounding atmosphere. At the same time the fluorine-containing melt is essential to the electrolytic process.
[0002] Dry scrubbing is often used to clean gas and dust emitted from electrolysis cells in the production of aluminium. By utilising smelter grade alumina (primary alumina) as scrubbing medium (adsorbent), fluorine-containing gases, as well as fumes and dust are collected in the dry scrubber filter. The collected material (secondary alumina) is then used in the production of aluminium, hence the emitted gaseous fluorine and particulate fluorine compounds are recycled.
[0003] The recovery of fluorine-containing compounds from gases generated during aluminium production suffers from the inconvenience that the process gas is usually loaded also with other substances considered as unwanted impurities. These impurities have limited solubility in the aluminium metal and hence accumulate in the cell and dry scrubber system during collection and recycling. The impurities enter the dry scrubber as condensed cell volatiles and entrained bath particles, and become a fraction of the secondary alumina, which is fed back to the electrolytic process. Compounds of transition metals, phosphorous, carbon and some other elements are among the substances considered as unwanted impurities due to their negative effect on the electrolytic process and on metal quality. Accumulation of sodium will shift the composition of the electrolysis bath. In order to regenerate the desired composition, some electrolysis bath must be removed and replaced with bath components with less sodium. This removed bath is called “excess bath”, and represents a material which has to be disposed off. Sodium may thus also be considered as unwanted, since more sodium implies more “excess bath”.
[0004] The impurities originate from the consumption of anodes but also from impurities found in the raw material, and should be removed from the secondary alumina before this is recycled to the process.
[0005] It is possible to reduce the amount of impurities in this recirculation loop by removing fumes and dust with dust collecting devices in the pot gas duct upstream the dry scrubber as described by Boehm et al. “Removal of Impurities in Aluminium Smelter Dry Gas using the VAW/Lurgi Process”, Light Metals (1976) Vol 2 pp 509-521 and L. C. B Martins “Use of Dry Scrubber Cyclone to improve the purity of Al” Light Metals (1987) pp 315-317.
[0006] Another option is to remove impurities from the secondary alumina stream on its way to the cell. The latter can be done by capture of the fine particulate fraction from the bulk alumina stream, since the impurities are highly enriched in the finest fraction of secondary alumina (secondary alumina fines).
[0007] A process for separation of the finest fraction from the bulk secondary alumina stream is disclosed by Beckman in U.S. Pat. No. 4,525,181. This patent discloses a process for separation of fine dust containing impurities from alumina, consisting of
(a) a disintegrating step, where the secondary alumina is blown against a substantially transverse impinging surface to disintegrate the fines containing the impurities from the alumina crystals, (b) a separating step, where the dust or finely divided sublimate particles are selectively separated from the alumina crystals.
[0010] An alternative process for separation of the finest fraction from the bulk secondary alumina stream is disclosed by Schuh and Jansen in WO 96/20131 (DE 195 44 887 A1). In this process, the alumina powder is projected at a predetermined speed and frequency against at least one surface in order to separate therefrom particles of impurities that adhere to the surface of the powders. The powders are then sorted according to size.
[0011] The capture of this fine particulate material, either from the pot gas stream or from the secondary alumina stream, yields a waste product of secondary alumina enriched in impurities and fluorine-compounds. In practical applications, the loss of alumina and fluorine-compounds may be considerable. A fines fraction of 2 wt % amounts to 40 kg per ton aluminium produced. If purified, alumina and/or fluorine-compounds could be recovered economically from the fines, this would make the simple fines separation (according to U.S. Pat. No. 4,525,181 and WO 96/20131) more attractive proposals.
[0012] With the intention to recover valuable fractions, thermal treatment, physical separation techniques and different wet chemical methods have been studied and are reported in the literature.
[0013] Thermal treatment: GB 1479924 by Winkhaus et al, recovers HF from a separated fine fraction of used adsorbent, e.g. fluorine and impurity enriched alumina, by pyrohydrolysis at T>500° C. This is a well known method for HF formation. The produced HF can be guided back to the dry scrubber plant or reacted to valuable fluorine-containing products such as AlF 3 .
[0014] Generally it is well known that carbon in contaminated samples may be oxidised in air or an oxygen rich atmosphere at elevated temperatures, typically above 500° C. Since impurities such as phosphorous and iron compounds have low volatility, these compounds remain in the solid fraction and hence recovery of pure alumina is rather difficult with the thermal method.
[0015] Physical separation: Lossius and Øye present in “Removing Impurities from Secondary Alumina Fines”, Light Metals (1992) pp 249-258, that the app. 2 wt % finest fraction of secondary alumina contains 10% of the fluorine compounds and 50% of the contaminants. Physical separation techniques include ultrasonic vibration of water slurries, wet and dry magnetic separation, flotation and stratification by settling. The aim is to separate a valuable fraction of the fluorine enriched alumina fines. Lossius and Øye concluded that wet magnetic separation of these partly deagglomerated fines is an efficient way of separating the impurities P, S, Ti, V, Fe and Ni from the process stream without sacrificing F reclamation or loss of Al 2 O 3 . However this process has not proven to be valuable on industrial scale.
[0016] Wet chemical methods: Wet chemical methods include dissolution of fluorine-compounds in both basic and acidic solutions. The dissolved fluorine-compounds may then be recovered as AlF 3 or cryolite. According to Lossius and Øye in “Removing Impurities from Secondary Alumina Fines”, Light Metals (1992) pp 249-258, some of the impurities are only slightly soluble in water, basic or acidic solutions.
[0017] Accordingly, the remaining undissolved residue (e.g. the alumina fraction in the case of alumina fines treatment) will still be contaminated. U.S. Pat. No. 5,558,847 by Kaaber et al discloses a process for recovering aluminium and fluorine from “Fluorine Containing Waste Materials” (FCWM). FCWM is leached with dilute sulphuric acid, at pH 0-3, if necessary with aluminium in acid soluble form. pH is adjusted to 3,7-4,1 by aqueous NaOH to precipitate silica at T<60° C. The mixture is separated to a solid phase containing precipitated silica and non-soluble residues and a purified solution. The precipitate of AlF 2 OH hydrate is calcined at 500-600° C. to give AlF 3 and Al 2 O 3 , which are recycled back to the electrolysis cells.
[0018] U.S. Pat. No. 6,187,275 by Barnett and Mezner, discloses a method for recovering AlF 3 from spent potliner (SPL) by using an acid digest to form gaseous HF which is converted to hydrofluoric acid and reacted with alumina trihydrate to form AlF 3 . In the process, spent potliner material is introduced onto an acid digester containing, for example, sulphuric acid. As a result, a gas component is produced which includes hydrogen fluoride and hydrogen cyanide. Also, a slurry component is produced which includes carbon, silica, alumina, sodium compounds such as sodium sulphate, aluminium compounds such as aluminium sulphate, iron compound such as iron sulphate, magnesium and calcium compounds such as magnesium and calcium sulphate. The slurry component remains in the digester after the gas component is removed. The gas component is recovered and heated an effective amount to convert or decompose the hydrogen cyanide to a remaining gas component including CO 2 , H 2 O, nitrogen oxides as well as HF. The remaining gas component is directed through a water scrubber in which HF is converted to liquid hydrofluoric acid, which is further reacted to useful end products. The slurry is rinsed and may be used as fuel in cement or glass manufacturing, or may be subjected to elevated temperature in an oxygen-rich atmosphere, which causes carbon to oxidise to carbon dioxide, leaving a refractory material such as mullite formed from silica and alumina which has commercial utility in forming bricks.
[0019] It is one object of the present invention to provide a process for treating secondary alumina fines from fume treatment systems in aluminium production facilities, in order to remove contaminants from said alumina.
[0020] It is another object of the present invention to recover valuables from the alumina, that is alumina and fluorides, while the impurities are deposited.
[0021] The process is described mainly with reference to treating alumina fines, however, it is assumed that the process may be used on material collected in pot gas dust collecting devices, “excess bath” and/or any other fluorine or alumina containing material occurring in aluminium production.
SUMMARY OF THE INVENTION
[0022] The present invention relates to a combined chemical and thermal process for purification of contaminated secondary alumina fines or any other sodium-alumina-fluorine containing material related to aluminium production. Alumina and aluminium fluoride are to a high extent recovered, while impurities such as compounds of phosphorous, iron, titanium, vanadium, nickel, carbon, sulphur, sodium, etc. to a high extent are removed.
[0023] The invention is disclosed with basis in the non-limiting detailed description and examples. However, the patent is intended to cover all possible variations and adjustments within the scope and spirit of the invention as disclosed in the appended claims.
[0024] The present invention relates to a process for removal of impurities from secondary alumina fines and alumina and/or fluorine containing material wherein the process comprises:
(a) acidification of the material to be purified ( 1 , 11 , 31 ) by adding an acid ( 2 , 12 , 32 ); (b) heating the acidified mixture ( 3 , 13 , 35 ); (c) leaching the mixture in a solution of an acid ( 6 , 16 , 39 ); (d) separating the solid and liquid.
[0029] In one embodiment of the invention, the gas evolved in step (a) and (b) is collected and guided to a dry scrubber, in order to recover the fluorine-compounds.
[0030] The acid utilized in the process may be neat or aqueous. The process may be conducted in a batchwise or continuous mode.
[0031] In another embodiment, the material to be purified is mixed with the aqueous acid between the steps (a) and (b).
[0032] In a further embodiment, the acidified material is pre-dried before the heat treatment (b).
[0033] The material separated in step (d) may be dried in a conventional dryer.
[0034] The acid in step (a) may be a strong acid, preferably a strong inorganic acid, most preferably sulphuric acid. The molar ratio of H + from the acid to F-content in the material may be from 0,2 to 10 more preferably 0,4 to 4, most preferably 0,6 to 2. The volume of acid or aqueous acid ( 2 , 12 , 32 ) in step (a) may in total be from 10 to 1000 ml per 100 g alumina, preferably from 20 to 200 ml per 100 g alumina, most preferably from 30 to 100 ml per 100 g alumina.
[0035] In another embodiment the material before the acid leaching step ( 38 ) is crushed in a crusher (D 3 ).
[0036] The solids before the drying step ( 23 , 46 ) may be washed in order to remove rest acid. The washing liquor ( 20 , 43 ) is water, lower alcohol e.g. methanol, ethanol, or an alkali solution, e.g. ammonia.
[0037] In a further embodiment, the residence time in the heat treatment (B 1 , B 2 , C 3 ) is at least 2 minutes, preferably at least 5 minutes, most preferably at least 10 minutes. The temperature in the heat treatment (B 1 , B 2 , C 3 ) may be from 100 to 1000° C., preferably from 300 to 800° C., most preferably 400 to 700° C.
[0038] In a further embodiment, the residence time in the acid leaching step (C 1 , C 2 , E 3 ) is at least 5 minutes, preferably at least 15 minutes, most preferably at least 30 minutes.
[0039] In an even further embodiment the residence time in the washing step (E 2 , G 3 ) for removal of rest acid is at least 2 minutes, preferably at least 5 minutes, most preferably at least 10 minutes. The temperature in the acid leach (C 1 , C 2 , E 3 ) and washing step (E 2 , G 3 ) for removal of rest acid may be in the range 20-150° C., preferably 60-95° C.
[0040] The scope of the invention shall be considered to be covered by the appended independent claim.
BRIEF DESCRIPTION OF THE FIGURES
[0041] Some non-limiting embodiments of the invention are shown in the figures wherein:
[0042] FIG. 1 shows a schematic flow diagram of the simplest embodiment of the process according to the invention.
[0043] FIG. 2 shows a schematic flow diagram of one preferred embodiment of the process according to the invention.
[0044] FIG. 3 shows a schematic flow diagram of another preferred embodiment of the process according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The present invention relates to a combined chemical and thermal process for purification of contaminated secondary alumina or other sodium-aluminium-fluorine containing materials. Alumina and aluminium fluoride are to a high extent recovered, while impurities such as compounds of phosphorous, iron, titanium, vanadium, nickel, carbon, sulphur, sodium, etc. to a high extent are removed.
[0046] As mentioned above, heat treatment of fluorine-enriched alumina fines in air to above 500° C. releases carbon as CO 2 . Depending on temperature and residence time, parts of the fluorine compounds may be released as HF gas.
[0047] It was observed that addition of an aqueous acid solution ( 2 , 12 , 32 ) to the fluorine-enriched alumina fines prior to heat treatment in air caused release of C and some F (i.e. more than 25 wt-%) ( 4 , 14 , 36 ) during the heat treatment step (B 1 , B 2 , C 3 ); this is similar to heating in air only. The volume of aqueous acid is not necessarily large, moistening of the material to be purified is sufficient.
[0048] The acid- and heat-treated sample ( 5 , 15 , 38 ) is then brought to an acid leaching step (C 1 , C 2 , E 3 ) containing a concentrated solution of a strong acid ( 6 , 16 , 39 ), preferably a strong inorganic acid, e.g. hydrochloric acid or sulphuric acid, preferably sulphuric acid. Surprisingly, it was observed that the phosphorous, sodium and transition metals such as Fe, Ni, Ti and V to a high extent were leached into the solution, while only a small leach of F was detected. The solid material recovered from the acid leaching step ( 19 , 42 ) was washed with a washing solution ( 20 , 43 ) and dried (G 2 , 13 ). Analysis showed that a substantial part of all elements other than Al, O, F and S were removed, compared with the initial concentrations. When using sulphuric acid, sulphur in the sample is mainly remaining sulphuric acid, and its concentration is depending on the duration of the washing step to remove remaining acid. Since sodium is removed, the former cryolite and chiolite must have reacted to acid-insoluble aluminium fluoride compounds.
[0049] This observation is unexpected, since similar leaching experiments of non acid- and heat treated samples yields a solution with dissolved fluorides, where the solid alumina fines are still contaminated with impurities, e.g. P and transition metals.
[0050] The novelty of the process is the reaction of insoluble impurities (Fe, P, V, Ni, Ti, etc.) to acid soluble species, while the F-compounds which previously were acid soluble, are reacted to non-soluble aluminium-fluoride complexes. The process, consisting of acidification, heat treatment and leaching with acid solution, represents a new method for treating of contaminated fluorine-enriched alumina fines and other alumina containing materials. The result of the combination of these steps could not be expected on the basis of known technology.
[0051] The simplest embodiment of the invention is disclosed in FIG. 1 wherein an aqueous acid solution ( 2 ) is added to the material to be purified ( 1 ) before this enters the heat treatment, from where it is passed to an acid leaching and separation step (C 1 ) to achieve purified material ( 8 ).
[0052] In this most basic form, the process according to the invention consists of the following main steps as shown in FIG. 1 .
[0053] i. Acidification (Al): The material which is to be purified ( 1 ), is wetted with an aqueous solution of a strong acid ( 2 ), most preferably sulphuric acid.
[0054] The material is wetted to a clay-like paste ( 3 ). The molar ratio of acid to F-content in the material is, when sulphuric acid is utilized, in the range from 0,1 to 5, more preferably 0,2 to 2, most preferably 0,3 to 1. If a monoprotic acid is utilized, all the figures given above must be doubled. The amount of aqueous acid solution is from 10 to 1000 ml per 100 g material, preferably from 20 to 200 ml per 100 g material, most preferably from 30 to 100 ml per 100 g material. As an alternative, it may be possible to use a neat acid, which is not in aqueous solution.
[0055] ii. Heat treatment (B 1 ): The wetted material ( 3 ) is heated to a high temperature in a furnace (B 1 ), preferably in the range 100-1000° C., more preferably 300-800° C., most preferably 400-700° C. The reaction time is typically at least 2 minutes, more preferably at least 5 minutes, most preferably at least 10 minutes. Carbon is preferably oxidised to CO 2 , and some of the fluorides in the sample are emitted as HF gas ( 4 ) which is guided back to the dry scrubber. The amount of HF released in this step is not critical.
[0056] iii. Acid leaching and separation step (C 1 ): The heat-treated material ( 5 ) is treated with a solution of a strong acid ( 6 ), preferably a strong inorganic acid, e.g. hydrochloric acid or sulphuric acid, most preferably sulphuric acid, for at least 5 minutes, more preferably at least 15 minutes, most preferably at least 30 minutes at elevated temperature in the range 20 to 150° C. The impurities, consisting of elements of e.g. phosphorous, sodium and transition metals, are leached into solution, while alumina and aluminium fluorides mainly remain as a solid fraction. The liquid ( 7 ) and solid ( 8 ) phases are separated by a conventional separation method, e.g. gravity, centrifugation or filtration.
[0057] Alternative embodiments are disclosed in the FIGS. 2 and 3 wherein
[0058] FIG. 2 shows a schematic flow diagram of one preferred embodiment of the process according to the invention. The material to be purified ( 11 ) is mixed with an aqueous acid solution ( 12 ) prior to passing into the heat treatment (B 2 ), from where it is passed to an acid leaching step (C 2 ) followed by separation of purified material ( 19 ) which is washed to remove remaining acid, separated and dried.
[0059] FIG. 3 shows a schematic flow diagram of another preferred embodiment of the process according to the invention. The material to be purified ( 31 ) is mixed with an aqueous acid solution ( 32 ) prior to pre-drying and passing into the heat treatment (C 3 ), upon leaving the heat treatment, it is crushed (D 3 ) and passed to an acid leaching step (E 3 ) followed by separation of purified material ( 42 ) which is washed to remove remaining acid, separated and dried.
[0060] The alternative embodiements as seen in the FIGS. 2 and 3 , comprise the following additional steps, the numerals refer to FIG. 3 :
[0061] ia. Mixing (A 3 ): The acidification may take place in a mixer.
[0062] iia. Pre-drying (B 3 ): The acidified material ( 33 ) may be pre-dried by heating in a conventional heating device (B 3 ) prior to the heat treating ii in order to remove some of the water ( 34 ).
[0063] iiia. Crushing (D 3 ): The heated paste ( 37 ) turns into a hard material which may be crushed in a conventional crushing device (D 3 ) prior to the acid leaching step. The crusher may be integrated in the heat treatment (C 3 ) or between pre-drying and heat treatment.
[0064] iv. Washing (G 3 ): The solid material ( 42 ) may be washed in a polar liquid ( 43 ), e.g. water, alcohol e.g. methanol, ethanol, or an alkali solution, e.g. an ammonia solution in order to remove remaining acid from the acid leaching step. The residence time in the washing step (G 3 ) is at least 2 minutes, preferably more than 10 minutes.
[0065] v. Separation (H 3 ): The liquid ( 45 ) and solid ( 46 ) phases are separated in a conventional separation device (H 3 ), e.g. by gravity, centrifugation or filtration.
[0066] vi. Drying of the purified material ( 13 ): The purified material ( 46 ) is dried in a conventional dryer ( 13 ) or by utilising heat present in the dry scrubber system, before the material is returned to the electrolytic cell for aluminium production.
[0067] The waste product ( 7 , 18 , 41 ) is a bleed-off consisting of an impurity containing acid solution used for the leaching step, which has to be neutralised and deposited of.
[0068] The process may be conducted in a batchwise or in a continues mode. The process according to the invention is mainly developed for treating contaminated secondary alumina fines or pot fumes and dust captured from the pot gas, but is also suitable for treating of bath material skimmed off during anode change, “excess bath” and any other fluorine and/or alumina containing material occurring in aluminium production.
EXAMPLES
[0069] Embodiments of the invention will be further described by way of the following illustrating but non-limiting examples.
Example 1
Treatment of Alumina Fines
[0070] 100 g Secondary alumina fines from the process described in WO 96/20131 (DE 195 44 887 A1) was wetted with an aqueous solution of 50 ml 40 wt % H 2 SO 4 . The resulting “paste” was heated to 600° C. for 15 minutes in air in a furnace. The sample was then crushed and suspended in a 30 wt % sulphuric acid solution for one hour at 90° C. After this leaching step, the solids were separated from the liquor by using a centrifuge. The sample was then washed in pure hot water (90° C.) for another 15 minutes, and finally dried.
[0071] The following Tables 1 and 2 show the elemental composition (in % and g) of the alumina fines sample as received, the sample after the pre-acidification and heat treatment step, and of the final purified material
TABLE 1 Elemental composition (in wt %) of the alumina fines sample as received, of the sample after the acidification and heat treatment step, and of the purified alumina produced: weight Al O C F Na S Ca K Fe Si P Ni Cu V Pb Ti Ga As (g) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) alumina 100 46 35 2 10.2 4.2 1.17 0.14 0.33 0.45 0.03 0.04 0.21 0.022 0.017 0.032 0.006 0.04 0.009 fines as received after 102 42 41 0 5.5 3.4 7.5 0.13 0.34 0.44 0.11 0.037 0.2 0.02 0.017 0.026 0.006 0.04 0.01 acidifi- cation and heat treatment after acid 73 51 40 0 6.3 0.58 1.6 0.017 0.024 0.09 0.08 0.009 0.042 0.003 0.006 0.02 0.002 N.D. 0.016 leach and water wash
[0072]
TABLE 2
Elemental composition (in total weight) of the alumina fines sample as received, of the sample
after the acidification and heat treatment step, and of the purified alumina produced:
weight
Al
O
C
F
Na
S
Ca
K
Fe
Si
P
Ni
Cu
V
Pb
Ti
Ga
As
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
(g)
alumina fines
100
46
35
2
10.2
4.2
1.17
0.14
0.33
0.45
0.03
0.04
0.21
0.022
0.017
0.032
0.006
0.04
0.009
as received
after
102
43
42
0
5.6
3.5
7.7
0.13
0.35
0.45
0.11
0.037
0.2
0.02
0.017
0.027
0.006
0.04
0.01
acidification and
heat treatment
after acid leach
73
37
29
0
4.6
0.42
1.2
0.012
0.018
0.07
0.06
0.007
0.03
0.002
0.004
0.015
0.001
N.D.
0.012
and water wash
[0073] As can been seen from the 2 . column in Table 1, the recovered solid fraction constitutes 73% of the initial mass. Approximately 45% of the initial amount of fluorides is released through the heat treatment, while another approximately 45% is recovered with the purified alumina fines. The silicon content in the material during processing is increased due to carry over from the porcelain crucible used in the experiment.
[0074] Similar experiments have been performed on the pot fumes removed from Søderberg cell gas by electrostatic precipitators. Results from these experiments show much of the same tendencies as illustrated in the example above, but the release of fluorine in the heating step is higher.
Example 2
Treatment of Fumes from Søderberg Pot Gas Separated by Electrostatic Precipitators
[0075] 100 g fumes separated by electrostatic precipitators from pot gas on a typical Søderberg plant in Norway was moistened with an aqueous solution of 50 ml 15 wt % H 2 SO 4 . The resulting “paste” was heated to 600° C. for 15 minutes in air in a furnace. The sample was then crushed and suspended in a 30 wt % sulphuric acid solution for one hour at 90° C. After this leaching step, the solid sample was separated from the liquor by using a centrifuge. The sample was then washed in pure hot water (90° C.) for another 15 minutes, and finally dried.
[0076] The following Table 3 shows the elemental composition of the pot fumes as received, the sample after the acidification and heat treatment step, and of the final purified material.
Example 3
Treatment of Alumina Fines; Comparison with Treatment without Acidification Step
[0077] 100 g Secondary alumina fines from the process described in WO 96/20131 (DE 195 44 887 A1) was heated to 600° C. for 30 minutes in air in a furnace. The sample was then suspended in a 30 wt % sulphuric acid solution for one hour at 90° C. After this leaching step, the solid sample was separated from the liquor by using a centrifuge. The sample was then washed in pure hot water (90° C.) for another 15 minutes, and finally dried.
[0078] The following Table 4 shows the elemental composition (in % and g) of the alumina fines sample as received, the sample after heat treatment, and of the final material produced.
[0079] As can be seen from table 4, this method, i.e. without acidification of the material prior to heat treatment, gave only limited reduction in impurity content in the final product, while the fluorine-compounds are almost completely dissolved during the acid leaching step.
[0080] The patent is intended to cover all possible variations and adjustments which may appear obvious for a person skilled in the art after reading this specification.
TABLE 3 Elemental composition (in wt %) of the pot fumes sample as received, of the sample after the acidification and heat treatment step, and of the purified pot fumes produced: weight Al O C F Na S Ca K Fe Si P Ni V Pb Ti Ga Zn (g) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%) pot 100 48 40 4 4.2 2.0 0.90 0.063 0.028 0.30 0.07 0.009 0.014 0.010 0.014 0.011 0.036 0.005 fumes as received after 103 52 42 0 1.6 1.1 3.3 0.068 0.018 0.27 0.07 0.009 0.014 0.010 0.013 0.013 0.032 0.005 acidifi- cation and heat treatment after acid 72 52 46 0 1.3 0.20 0.90 0.004 0.002 0.093 0.06 0.002 0.007 0.004 0.005 0.007 0.019 0.003 leach and water wash
[0081]
TABLE 4
Elemental composition (in wt %) of the initial alumina fines sample as received, of the sample after the heat
treatment step, and of the purified alumina produced:
weight
Al
O
C
F
Na
S
Ca
K
Fe
Si
P
Ni
Cu
V
Pb
Ti
Ga
As
(g)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
(%)
alumina
100
46
35
2
10.2
4.2
1.17
0.14
0.33
0.45
0.03
0.04
0.21
0.022
0.017
0.032
0.006
0.04
0.009
fines as
received
after heat
95
49
38
0
7.0
3.5
1.0
0.14
0.34
0.45
0.2
0.040
0.23
0.025
0.018
0.03
0.007
0.038
0.01
treatment
after acid
62
51
46
0
0.4
0.20
0.65
0.04
0.06
0.50
0.19
0.021
0.25
0.023
0.017
0.027
0.007
0.046
0.007
leach and
water
wash | The invention relates to a process for removal of impurities from secondary aluminia fines and alumina and or fluorine containing material comprising. (a) acidification by adding an acid ( 2,12,32 ) to the material to be purified ( 1,11,31 ); (b) heading the acidified mixture ( 3,13,35 ); (c) leaching the mixture in a solution of an acid ( 6,16,39 ); (d) separating the solid and liquid. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 60/553,800 filed Mar. 16, 2004, the content of which is herein incorporated by reference in its entirety.
GOVERNMENT SUPPORT
[0002] This invention was made in part with U.S. Government support under grant number 5 RO1 HL39150-15 awarded by the National Institutes of Health. The U.S. Government has certain rights in this application.
FIELD OF INVENTION
[0003] The present invention is directed to a method of treating or preventing abnormal cellular proliferation.
BACKGROUND OF THE-INVENTION
[0004] Atherosclerosis, a common form of arteriosclerosis, results from the deposition of fatty substances, primarily cholesterol, and subsequent fibrosis in the inner layer (intima) of an artery, resulting in plaque deposition on the inner surface of the arterial wall and degenerative changes within it. The ubiquitous arterial fatty plaque is the earliest lesion of atherosclerosis and is a grossly flat, lipid-rich atheroma consisting of macrophages (white blood cells) and smooth muscle fibers. The fibrous plaque of the various forms of advanced atherosclerosis has increased intimal smooth muscle cells surrounded by a connective tissue matrix and variable amounts of intracellular and extracellular lipid. At the luminal surface of the artery, a dense fibrous cap of smooth muscle or connective tissue usually covers this plaque or lesion. Beneath the fibrous cap, the lesions are highly cellular consisting of macrophages, other leukocytes and smooth muscle cells. As the lesions increase in size, they reduce the diameter of the arteries and impede blood circulation resulting in coronary heart disease, myocardial infarction (MI) and other serious complications.
[0005] Many therapies have been considered for the treatment of atherosclerosis, including surgery and medical treatment. One potential therapy is percutaneous transluminal angioplasty (balloon angioplasty). More than 400,000 such procedures are performed each year in the United States. In balloon angioplasty, a catheter equipped with an inflatable balloon is threaded intravascularly to the site of the atherosclerotic narrowing of the vessel. Inflation of the balloon compresses the plaque enlarging the vessel.
[0006] While such angioplasty has gained wider acceptance, it suffers from two major problems, i.e., abrupt closure and restenosis. Abrupt closure refers to the acute occlusion of a vessel immediately after or within the initial hours following a dilation procedure. Abrupt closure occurs in approximately one in twenty cases and frequently results in myocardial infarction and death if blood flow is not restored in a timely manner.
[0007] As many as 50% of the patients who are treated by balloon angioplasty require a repeat procedure within six months to correct a re-narrowing of the artery. Restenosis refers to such re-narrowing of an artery after an initially successful angioplasty. Restenosis of the blood vessel is thought to be due to injury to the endothelial cells of the blood vessel during angioplasty, or during inflation of the balloon catheter. During healing of the blood vessel after surgery, smooth muscle cells proliferate faster than endothelial cells resulting in a narrowing of the lumen of the blood vessel and starting the atherosclerotic process anew. In recent years, smooth muscle cell proliferation has been recognized as a major clinical problem limiting the long-term efficacy of coronary angioplasty.
[0008] In an effort to prevent restenosis of the treated blood vessel, the search for agents that can reduce or prevent excessive proliferation of smooth muscle cells have been the object of much research. (The occurrence and effects of smooth muscle cell proliferation after these types of surgery have been reviewed, for example, in Ip, et al., (June 1990) J. Am. College of Cardiology 15:1667-1687, and Faxon, et al. (1987) Am. J. of Cardiology 60: 5B-9B.). Such compounds have found little if any practical success. There therefore exists a need to identify and successfully administer compounds that inhibit smooth muscle cell proliferation.
[0009] An alternative to angioplasty is the placement of endovascular stents in the occluded blood vessel. Placement of a stent at such a site, should mechanically block abrupt closure and delay restenosis (Harrison's Principles of Internal Medicine, 14 th Edition, 1998). Of the various procedures used to overcome restenosis, stents have proven to be the most effective. Stents are metal scaffolds that are positioned in the diseased vessel segment to create a normal vessel lumen. Placement of the stent in the affected arterial segment prevents recoil and subsequent closing of the artery. By maintaining a larger lumen than that created using balloon angioplasty alone, stents reduce restenosis by as much as 30%. Despite their success, stents have not eliminated restenosis entirely. (Suryapranata et al. 1998. Randomized comparison of coronary stenting with balloon angioplasty in selected patients with acute myocardial infarction. Circulation 97:2502-2502).
[0010] Unfortunately, the use of such stents are limited by direct (subacute thrombosis) or indirect (bleeding, peripheral vascular complications) complications. After stent implantation the patients are threatened with stent thrombosis until the struts of the stent are covered by endothelium. Thus, an aggressive therapy using anticoagulation and/or antiplatelet agents is necessary during this period of time. While these therapies are able to decrease the rate of stent thrombosis, they are the main source of indirect complications.
[0011] In addition to coronary artery occlusion, narrowing of the arteries can occur in other vessels. Examples include the aortoiliac, infrainguinal, distal profunda femoris, distal popliteal, tibial, subclavian and mesenteric arteries. The prevalence of peripheral artery atherosclerosis disease (PAD) depends on the particular anatomic site affected as well as the criteria used for diagnosis of the occlusion. Rates of PAD appear to vary with age, with an increasing incidence of PAD in older individuals. Data from the National Hospital Discharge Survey estimate that every year, 55,000 men and 44,000 women had a first-listed diagnosis of chronic PAD and 60,000 men and 50,000 women had a first-listed diagnosis of acute PAD. Ninety-one percent of the acute PAD cases involved the lower extremity. The prevalence of comorbid coronary artery disease (CAD) in patients with PAD can exceed 50%. In addition, there is an increased prevalence of cerebrovascular disease among patients with PAD.
[0012] PAD can be treated using percutaneous transluminal balloon angioplasty (PTA). The use of stents in conjunction with PTA decreases the incidence of restenosis. However, the post-operative results obtained with medical devices such as stents do not match the results obtained using standard operative revascularization procedures, i.e., those using a venous or prosthetic bypass material. (Principles of Surgery, Schwartz et al. eds., Chapter 20, Arterial Disease, 7th Edition, McGraw-Hill Health Professions Division, New York 1999).
[0013] Preferably, PAD is treated using bypass procedures where the blocked section of the artery is bypassed using a graft. (Principles of Surgery, Schwartz et al. eds., Chapter 20, Arterial Disease, 7th Edition, McGraw-Hill Health Professions Division, New York 1999). The graft can consist of an autologous venous segment such as the saphenous vein or a synthetic graft such as one made of polyester, polytetrafluoroethylene (PTFE), or expanded polytetrafluoroethylene (ePTFE). Restenosis and thrombosis, however, remain significant problems even with the use of bypass grafts. For example, the patency of infrainguinal bypass procedures at 3 years using an ePTFE bypass graft is 54% for a femoral-popliteal bypass and only 12% for a femoral-tibial bypass.
[0014] Consequently, there is a significant need to improve the performance of both stents and synthetic bypass grafts in order to further reduce the morbidity and mortality of CAD and PAD.
[0015] With stents, the approach has been to coat the stents with various anti-thrombotic or anti-restenotic agents in order to reduce thrombosis and restenosis. For example, impregnating stents with radioactive material appears to inhibit restenosis by inhibiting migration and proliferation of myofibroblasts. (U.S. Pat. Nos. 5,059,166, 5,199,939 and 5,302,168). Irradiation of the treated vessel can pose safety problems for the physician and the patient. In addition, irradiation does not permit uniform treatment of the affected vessel.
[0016] Numerous attempts to develop stents with a local drug-distribution function have been made, most of which are variances of the so called stent graft, a metal stent covered with polymer envelope, containing a medicament. It would be of benefit to coat a stent with a compound capable of diminishing or eliminating restenosis.
[0017] Unlike the unwanted smooth muscle cell proliferation seen in restenosis, cellular proliferation is a normal ongoing process in all living organisms and is one that involves numerous factors and signals that are delicately balanced to maintain regular cellular cycles.
[0018] When normal cellular proliferation is disturbed or somehow disrupted, the results can be inconsequential or they can be the manifestation of an array of biological disorders. Disruption of proliferation could be due to a myriad of factors such as the absence or overabundance of various signaling chemicals or presence of altered environments. Some disorders characterized by abnormal cellular proliferation include cancer, abnormal development of embryos, improper formation of the corpus luteum, difficulty in wound healing as well as malfunctioning of inflammatory and immune responses.
[0019] Cancer is characterized by abnormal cellular proliferation. Cancer cells exhibit a number of properties that make them dangerous to the host, often including an ability to invade other tissues and to induce capillary ingrowth, which assures that the proliferating cancer cells have an adequate supply of blood. One of the defining features of cancer cells is that they respond abnormally to control mechanisms that regulate the division of normal cells and continue to divide in a relatively uncontrolled fashion until they kill the host.
[0020] It is clear that aberrant cellular proliferation plays a major role in the formation and progression of a cancer. If this abnormal or undesirable proliferative activity could be repressed, inhibited, or eliminated, then the tumor, although present, would not grow. In the disease state, prevention of abnormal or undesirable cellular proliferation could slow or abate the progression of cancer. Additionally, compounds that could induce apoptosis of abnormally proliferating cells would be especially beneficial for complete removal or elimination of malignant cells, helping to reduce relapses. Therapies directed at control of the cellular proliferative processes could lead to the abrogation or mitigation of such malignancies.
[0021] Pulmonary hypertension is caused largely by an increase in pulmonary vascular resistance and is classified clinically as either primary or secondary. Secondary pulmonary hypertension, the more common form, is generally a result of (1) chronic obstructive or interstitial lung disease; (2) recurrent pulmonary emboli; (3) liver disease; or (4) antecedent heart disease. Primary pulmonary hypertension is diagnosed only after all known causes of increased pulmonary pressure are excluded.
[0022] At the moment there is no successful cure for pulmonary hypertension. Administration of vasodilatating drugs has not proved to be useful in patients suffering from pulmonary hypertension. The prognosis is poor, with a median survival time of about 3 years.
[0023] Pulmonary fibrosis can occur in response to known stresses such as asbestos or silica but most is idiopathic. There is a spectrum of idiopathic fibrosis but most kinds are fatal in 3-5 years. At present, there is no effective therapy for most cases.
[0024] What is needed therefore is a composition and method which can inhibit abnormal or undesirable cellular proliferation, especially the growth of smooth muscle cells after angioplasty, stent placement, pulmonary hypertension, pulmonary fibrosis or the proliferation of malignant cells. The composition should be able to overcome the activity of endogenous growth factors in premetastatic tumors and inhibit smooth muscle cell proliferation during restenosis. Finally, the composition and method for inhibiting cellular proliferation should preferably be non-toxic and produce few side effects.
[0025] Heparin is a glycosaminoglycan that was first described by McLean in 1916 and has been used clinically as an anticoagulant for more than 50 years [McLean, Circulation 19, 75-78 (1959)]. Members of the glycosaminoglycan family include hyaluronan, heparan sulfate, dermatan sulfate, and chondroitin sulfate. Beyond its well-recognized anticoagulant activity, heparin has other activities. The antimetastatic activity of heparin has been known for some time (see, for example, Drago, J. R. et al., Anticancer Res., 4(3), 171-2, 1984).
[0026] Unfortunately, native and currently described modified heparins are extremely anticoagulant. Their anticoagulant properties are such that doses effective in the treatment of malignancies and anti-proliferative disorders are not attainable. It has therefore been suggested that altering the chemical structure of heparin might decrease the anticoagulant properties of heparin while maintaining its other important biological activities, such as its antimetastatic activity (Barzu et al., J. Med. Chem, 1993, 36, pg. 3546-3555).
[0027] Low molecular weight heparins have shown promise in reducing anticoagulation while maintaining their antimetastatic activity. For example, when compared to unmodified heparin, 2-O-desulfated and 3-O-desulfated heparins had reduced anticoagulant activities, but preserved their angiostatic, anti-tumor and anti-metastatic properties (Masayuki et al., U.S. Pat. No. 5,795,875 (1997); Lapierre et al., Glycobiology 6, 355-366 (1996)]. Nevertheless, the use of currently available heparins and heparin derivitives for the treatment of abnormal cellular proliferative disorders is not practical due to their marked anticoagulant and antithrombotic activities.
[0028] O-acylated heparins have been described. These molecules have very low anticoagulative effects in vitro, yet retain activity against HIV-1 and 2 induced cytopathicity (Barzu et al., J. Med. Chem, 1993, 36, pg. 3546-3555).
[0029] A chemically modified heparin that can be used to treat and/or prevent abnormal cellular proliferative disorders is needed. Such a compound should have minimal anticoagulant properties while maintaining antiproliferative properties. The anticoagulative properties of the compound must not limit its use in the clinical setting.
SUMMARY
[0030] This invention provides a method for inhibiting or preventing the abnormal growth of cells, including transformed cells, by administering an effective amount of O-acylated heparin derivative. Abnormal growth of cells refers to cell growth independent of normal regulatory mechanism (e.g. loss of contact inhibition). This includes the abnormal growth of: (1) tumor cells (tumors); (2) benign and malignant cells of other proliferative disease in which aberrant cellular proliferation occurs; (3) aberrant smooth muscle cell proliferation, such as might occur following treatment for coronary atherosclerosis such as angioplasty or the insertion of a stent into an occluded vessel. The O-acylated heparin derivative is preferably an O-hexanoylated heparin derivative or an O-butanoylated heparin derivative. In a preferred embodiment, the o-acylated heparin is weakly anticoagulant as compared to non-chemically modified heparins.
[0031] One embodiment of the present invention provides a method for inhibiting or preventing tumor growth by administering an effective amount of an o-acylated heparin, to a subject, e.g. a mammal (and more particularly a human) in need of such treatment. In particular, this invention provides a method for inhibiting the growth of malignant cells by the administration of an effective amount of an O-acylated heparin. In a preferred embodiment, the methods are directed toward the treatment or prevention of lung and colon cancer. Preferably, the O-acylated heparin derivative is an O-hexanoylated or an O-butanoylated heparin derivative
[0032] In another embodiment, the invention provides a method of preventing abnormal smooth muscle cell proliferation. The method comprises presenting an O-acylated heparin near or into a site of abnormal smooth muscle cell proliferation. In a preferred embodiment, the methods are directed toward the prevention of smooth muscle cell proliferation as occurs in restenosis. The methods are used to prevent restenosis that occurs following angioplasty or vascular stent placement. Alternatively, the methods of the current invention are used to prevent restenosis following coronary artery stent placement, peripheral artery stent placement, or cerebral artery stent placement.
[0033] In yet another embodiment, the invention provides a medical device coated with the heparin composition, e.g., a stent for implantation in a blood vessel. The stent of the invention comprises a coating containing an O-acylated heparin and preferably, an O-hexanoylated or O-butanoylated heparin derivative. In one embodiment, the stent is coated with an O-acylated heparin and one or more compounds selected from the group consisting of a polymer, fiber polymer, polyurethane, silicone rubber elastomer, drug, hydrogel, or other acceptable compound or carrier known to those of skill in the art. Other medical devices such as catheters may also be coated with the O-acylated heparin.
[0034] Finally, the invention provides a method of treating pulmonary hypertension and pulmonary fibrosis. The methods of the present invention provide treating a subject with a therapeutic amount of an o-acylated heparin, preferably a O-hexanoylated or O-butanoylated heparin derivative. In one embodiment, the invention provides for the treatment of primary pulmonary hypertension. In another embodiment, the invention provides for the treatment of secondary pulmonary hypertension. In a final embodiment, the invention provides for the treatment of pulmonary fibrosis.
DESCRIPTION OF FIGURES
[0035] FIG. 1 shows the preparation of O-acylated heparin derivatives.
[0036] FIG. 2 shows the results of 1 H NMR spectroscopy, where approximately 10 mg of each sample was exchanged by lyophilization three times from 0.5 ml portions of 99.9% 2 H 2 O before being redissolved in 2 H 2 O for NMR analysis. Chemical shifts are reported relative to TMS at 0.00 ppm. The degree of substitution (O-acylation) was determined from the ratio of the integrated area of the peaks assigned to the aliphatic methyl protons of the hexanoyl group (0.753 ppm) to the anomeric proton of IdoA2S (5.092 ppm).
[0037] FIG. 3 shows the structures of O-hexanoylated heparin and O-butanoylated heparin.
[0038] FIG. 4 shows that hexanoylated heparin (HHP) significantly inhibited pulmonary artery smooth muscle cell proliferation in vivo.
[0039] FIG. 5 shows that hexanoylated heparin (HHP) significantly inhibited the development of pulmonary hypertension induced by hypoxia in the pig lung.
[0040] FIG. 6 shows a comparison of tumor growth in SCID mice treated with various doses of native heparin (UHP) and butanoylated heparin (BHP). Butanoylated heparin significantly inhibited A549 (non-small cell lung carcinoma) cell tumor growth in a dose dependent manner.
[0041] FIG. 7 shows a comparison of tumor weights from SCID mice treated with native heparin and butanoylated heparin. Butanoylated heparin (BHP) significantly decreased A549 (non-small cell lung carcinoma) cell tumor weight in a dose dependent manner.
[0042] FIG. 8 shows percent inhibition of tumor growth in SCID mice treated with native heparin and butanoylated heparin. Butanoylated heparin (BHP) significantly inhibited A549 (non-small cell lung carcinoma) cell tumor growth in a dose dependent manner.
[0043] FIG. 9 shows tumor growth in SCID mice treated with native heparin and butanoylated heparin. Butanoylated heparin (BHP) significantly inhibited DMS79 (small cell lung carcinoma) cell tumor growth in a dose dependent manner.
[0044] FIG. 10 shows tumor weight from SCID mice treated with native heparin and butanoylated heparin. Butanoylated heparin (BHP) significantly decreased DMS79 (small cell lung carcinoma) cell tumor weight in a dose dependent manner.
[0045] FIG. 11 shows tumor growth in SCID mice treated with native heparin and butanoylated heparin. Butanoylated heparin (BHP) significantly inhibited HCT116 (colon cancer) cell tumor growth in a dose dependent manner.
[0046] FIG. 12 shows tumor growth in SCID mice treated with native heparin and butanoylated heparin. Butanoylated heparin (BHP) significantly inhibited HCT116 (colon cancer) cell tumor growth in a dose dependent manner.
[0047] FIG. 13 shows coagulation time for various heparin compounds. Native heparin (UPJ HP) increased coagulation time in a dose dependent manner. Butanoylated heparin had no significant effect on coagulation time.
[0048] FIG. 14 shows histology of A549 cell tumor tissue grown in SCID mice. Hemorrhage was detected in mice treated with 100 mg/kg native, unfractionated heparin only.
[0049] FIG. 15 shows histology of heart from SCID mice bearing A549 cell tumor. No significant pathological change was observed in any group.
[0050] FIG. 16 shows histology of kidney from SCID mice bearing A549 cell tumor. No significant pathological change was observed in any group.
[0051] FIG. 17 shows histology of liver from SCID mice bearing A549 cell tumor. No significant pathological change was observed in any group.
[0052] FIG. 18 shows histology of lung from SCID mice bearing A549 cell tumor. No significant pathological change was observed in any group.
[0053] FIG. 19 shows apoptosis index in different treatment groups. Heparin significantly induces apoptosis in tumor grown in SCID mice.
[0054] FIG. 20 shows expression of p27/KIP1 gene product in the A549 cell tumor tissue grown in SCID mice treated with heparins. BHP significantly inhibited p27/KIP1 in a dose dependent manner.
[0055] FIG. 21 shows expression of Rb gene product in the A549 cell tumor tissue grown in SCID mice treated with heparins. BHP decreased Rb gene expression in a dose dependent manner although to a lesser effect than on p27/KIP1.
[0056] FIG. 22 shows expression of E2F1 protein in A549 cell tumor tissue grown in SCID mice treated with heparins. BHP significantly inhibited E2F1 protein expression in a dose dependent manner.
[0057] FIGS. 23A and 23B show diagrams of a stent. FIG. 23A , a stent; FIG. 23B , an end view of the stent of FIG. 23A
[0058] FIG. 24 shows a diagram of a stent having a second coating formed on the outer surface.
DETAILED DESCRIPTION
[0059] The present invention is directed generally to compositions and their use in the therapy and prevention of abnormal cellular proliferative disorders, such as cancer, (i.e. lung and colon cancer), restenosis (following angioplasy, vascular stent placement, coronary artery stent placement, periphaeral artery stent placement, or cerebral artery stent placement), pulmonary hypertension (primary or secondary), and pulmonary fibrosis. The administration of therapeutic levels of the O-acylated heparin derivatives result in a decrease, cessation, or prevention of the abnormal cellular proliferation.
[0000] O-Acylated Heparin
[0060] As described further below, compositions useful in the present invention include, but are not restricted to, O-acylated heparins, particularly O-hexanoylated heparin derivatives and O-butanoylated heparin derivatives.
[0061] O-acylated heparins are prepared using any of a variety of well known synthetic and/or recombinant techniques, an example of which is further described below. Furthermore, O-acylated heparins, useful in the present invention, have been described in Barzu et al., J. Med. Chem, 1993, 36, 3546-3555 and U.S. Pat. No. 4,990,502 (Lormeau et al.). The structure of the O-acylated heparin derivatives used in the present invention are shown in FIG. 3 . Preferably, the major disaccharide units (m) vary from about 4 to about 14. Most preferably the major disaccharide units (m) vary from about 7 to about 9. In the O-hexanoylated derivative, R═CH 3 (CH 2 ) 4 in the O-butanoylated derivative, R═CH 3 (CH 2 ) 2- .
[0062] Low-molecular weight heparins (LMWHs) are fragments of conventional heparin. LMWHs were developed to provide more selective inhibition of enzyme function and reduce adverse effects. Heparin fragmentation produces products which maintain activity against factor Xa and release antithrombotic factors, but have significantly less activity against factor II a . As a result, treatment with LMWHs provides antithrombotic effects with less anticoagulant effect, lessening the risk of hemorrhage. However, in the generic sense, LMWHs have not proven beneficial in the treatment of cancer due to their high anticoagulant activity.
[0000] Administration of Compounds
[0063] The heparins of the present invention can be administered via any medically acceptable means which is suitable for the compound to be administered, including oral, rectal, topical, parenteral (including inhaled, subcutaneous, intramuscular and intravenous) administration, or by coated stent, coated graft, or coated catheter.
[0064] Effective doses for heparin-like substances are well known to those of skill in the art. Generally, for heparin-like substances, an effective dose is that which maintains the anti-X a level between 0.5 and 1.0 units/ml. This range has been shown to optimize antithrombotic activity while avoiding adverse effects.
[0065] The total daily dose may be given as a single dose, multiple doses, e.g., two to six times per day, or by intravenous infusion for a selected duration. Dosages above or below the range cited above are within the scope of the present invention and may be administered to the individual patient if desired and necessary. If discrete multiple doses are indicated, treatment might typically be 4-6,000 units of a compound given 4 times per day or if given continuously, as is more often the case, then a loading dose of 80 units/kg followed by 18 units/kg/hr (Rascke R A, Reilly B M, Guidry J R, et al. The weigh based heparin dosing nomogram compared with a “standard care” nomogram: A randomized control trial. Ann Int Med 119:874-81, 1993).
[0066] Formulations
[0067] The compounds described above are preferably administered in a formulation including an O-acylated heparin and/or an O-acylated heparin-together with an acceptable carrier for the mode of administration. Any formulation or drug delivery system containing the active ingredients, which is suitable for the intended use, as are generally known to those of skill in the art, can be used. Suitable pharmaceutically acceptable carriers for oral, rectal, topical or parenteral (including inhaled, subcutaneous, intraperitoneal, intramuscular and intravenous) administration are known to those of skill in the art. The carrier must be pharmaceutically acceptable in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0068] Formulations suitable for parenteral administration conveniently include sterile aqueous preparation of the active compound which is preferably isotonic with the blood of the recipient. Thus, such formulations may conveniently contain distilled water, 5% dextrose in distilled water or saline. Useful formulations also include concentrated solutions or solids containing the compound which upon dilution with an appropriate solvent give a solution suitable for parental administration above.
[0069] For enteral administration, a compound can be incorporated into an inert carrier in discrete units such as capsules, cachets, tablets or lozenges, each containing a predetermined amount of the active compound; as a powder or granules; or a suspension or solution in an aqueous liquid or non-aqueous liquid, e.g., a syrup, an elixir, an emulsion or a draught. Suitable carriers may be starches or sugars and include lubricants, flavorings, binders, and other materials of the same nature.
[0070] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active compound in a free-flowing form, e.g., a powder or granules, optionally mixed with accessory ingredients, e.g., binders, lubricants, inert diluents, surface active or dispersing agents. Molded tablets may be made by molding in a suitable machine, a mixture of the powdered active compound with any suitable carrier.
[0071] A syrup or suspension may be made by adding the active compound to a concentrated, aqueous solution of a sugar, e.g., sucrose, to which may also be added any accessory ingredients. Such accessory ingredients may include flavoring, an agent to retard crystallization of the sugar or an agent to increase the solubility of any other ingredient, e.g., as a polyhydric alcohol, for example, glycerol or sorbitol.
[0072] Formulations for rectal administration may be presented as a suppository with a conventional carrier, e.g., cocoa butter or Witepsol S55 (trademark of Dynamite Nobel Chemical, Germany), for a suppository base.
[0073] Alternatively, the compound may be administered in liposomes or microspheres (or microparticles). Methods for preparing liposomes and microspheres for administration to a patient are well known to those of skill in the art. U.S. Pat. No. 4,789,734, the contents of which are hereby incorporated by reference, describes methods for encapsulating biological materials in liposomes. Essentially, the material is dissolved in an aqueous solution, the appropriate phospholipids and lipids added, along with surfactants if required, and the material dialyzed or sonicated, as necessary. A review of known methods is provided by G. Gregoriadis, Chapter 14, “Liposomes,” Drug Carriers in Biology and Medicine, pp. 287-341 (Academic Press, 1979).
[0074] Microspheres formed of polymers or proteins are well known to those skilled in the art, and can be tailored for passage through the gastrointestinal tract directly into the blood stream. Alternatively, the compound can be incorporated and the microspheres, or composite of microspheres, implanted for slow release over a period of time ranging from days to months. See, for example, U.S. Pat. Nos. 4,906,474, 4,925,673 and 3,625,214, and Jein, TIPS 19:155-157 (1998), the contents of which are hereby incorporated by reference.
[0075] In one embodiment, the O-acylated heparin can be formulated into a liposome or microparticle which is suitably sized to lodge in capillary beds following intravenous administration. When the liposome or microparticle is lodged in the capillary beds surrounding ischemic tissue, the agents can be administered locally to the site at which they can be most effective. Suitable liposomes for targeting ischemic tissue are generally less than about 200 nanometers and are also typically unilamellar vesicles, as disclosed, for example, in U.S. Pat. No. 5,593,688 to Baldeschweiler, entitled “Liposomal targeting of ischemic tissue,” the contents of which are hereby incorporated by reference.
[0076] Preferred microparticles are those prepared from biodegradable polymers, such as polyglycolide, polylactide and copolymers thereof. Those of skill in the art can readily determine an appropriate carrier system depending on various factors, including the desired rate of drug release and the desired dosage.
[0077] In one embodiment, the formulations are administered via catheter directly to the inside of blood vessels. The administration can occur, for example, through holes in the catheter. In those embodiments wherein the active compounds have a relatively long half life (on the order of 1 day to a week or more), the formulations can be included in biodegradable polymeric hydrogels, such as those disclosed in U.S. Pat. No. 5,410,016 to Hubbell et al. These polymeric hydrogels can be delivered to the inside of a tissue lumen and the active compounds released over time as the polymer degrades. If desirable, the polymeric hydrogels can have microparticles or liposomes which include the active compound dispersed therein, providing another mechanism for the controlled release of the active compounds.
[0078] The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of bringing the active compound into association with a carrier which constitutes one or more accessory ingredients. In general, the formulations are prepared by uniformly and intimately bringing the active compound into association with a liquid carrier or a finely divided solid carrier and then, if necessary, shaping the product into desired unit dosage form.
[0079] The formulations can optionally include additional components, such as various biologically active substances such as growth factors (including TGFβ, basic fibroblast growth factor (bFGF), epithelial growth factor (EGF), transforming growth factors alpha and beta (TGFα and TGFβ), nerve growth factor (NGF), platelet-derived growth factor (PDGF), and vascular endothelial growth factor/vascular permeability factor (VEGF/VPF), antivirals, antibacterials, antiinflammatories, immunosuppressants, analgesics, vascularizing agents, cell adhesion molecules (CAM's), and anticoagulants other than heparin or heparin-like substances.
[0080] In addition to the aforementioned ingredients, the formulations may further include one or more optional accessory ingredient(s) utilized in the art of pharmaceutical formulations, e.g., diluents, buffers, flavoring agents, binders, surface active agents, thickeners, lubricants, suspending agents, preservatives (including antioxidants) and the like.
[0081] Finally, compositions of the compound are presented for administration to the respiratory tract as a snuff or an aerosol or solution for a nebulizer, or as a microfine powder for insufflation, alone or in combination with an inert carrier such as lactose. In such a case the particles of active compound suitably have diameters of less than 50 microns, preferably less than 10 microns, more preferably between 2 and 5 microns.
[0000] Stents, Grafts and Implants
[0082] The present invention further provides an intravascular implant coating. The coating includes a therapeutically effective amount of an O-acylated heparin. The coating can be used in any type of implant. These include balloon catheters, stents, stent graphs, drug delivery catheters, atherectomy devices, filters, scaffolding devices, anastomothic clips, anastomotic bridges and suture materials.
[0083] The coating can also include a polymer matrix, with the polymer being a resorbable polymer selected from the group consisting of poly-α hydroxyl acids, polyglycols, polytyrosine carbonates, starch, gelatins, cellulose, and blends and copolymers thereof. Examples of suitable poly-α hydroxyl acids include polylactides, polyglycol acids, and blends and co-polymers thereof.
[0084] According to the present invention, a coating for an intravascular implant is provided. The coating can be applied either alone, or within a polymeric matrix, which can be biostable or bioabsorbable, to the surface of an intravascular device. The coating can be applied directed to the implant or on top of a polymeric substrate, i.e. a primer. If desired, a top coat can be applied to the therapeutic coating.
[0085] It should be noted that the present invention relates to a combinatorial therapy for delivery of more than one agent through a coating on any intravascular implant. As used herein, implant means any type of medical or surgical implement, whether temporary or permanent. Delivery can be either during or after an interventional procedure. Non-limiting examples of intravascular implants now follow.
[0086] The outside surface of a balloon catheter may be coated with the coating according to the present invention and could be released immediately or in a time dependent fashion. When the balloon expands and the wall of the vessel is in contact with the balloon, the release of the o-acylated heparin can begin.
[0087] The surface of a stent may be coated with the combination of agents and the stent is implanted inside the body. The stent struts could be loaded with several layers of the agents or with just a single layer. A transporter or a vehicle to load the agents on to the surface can also be applied to the stent. The graft material of the stent graft can also be coated (in addition to the stent or as an alternative) so that the material is transported intravascularly at the site of the location of the injury.
[0088] The drug delivery catheters that are used to inject drugs and other agents intravascularly can also be used to deliver the o-acylated heparins. Other intravascular devices through which the transport can happen include atherectomy devices, filters, scaffolding devices, anastomotic clips, anastomotic bridges, suture materials etc.
[0089] The present invention envisions applying the coating directly to the intravascular implant. However, the coating can be applied to a primer, i.e. a layer or film of material upon which another coating is applied. Furthermore, the o-acylated heparins can be incorporated in a polymer matrix. Polymeric matrices (resorbable and biostable) can be used for delivery of the therapeutic agents. In some situations, when the agents are loaded on to the implant, there is a risk of quick erosion of the therapeutic agents either during the expansion process or during the phase during which the blood flow is at high shear rates at the time of implantation. In order to ensure that the therapeutic window of the agents is prolonged over-extended periods of time, polymer matrices can be used.
[0090] These polymers could be any one of the following: semitelechelic polymers for drug delivery, thermo responsive polymeric micelles for targeted drug delivery, pH or temperature sensitive polymers for drug delivery, peptide and protein based drug delivery, water insoluble drug complex drug delivery matrices polychelating amphiphilic polymers for drug delivery, bioconjugation of biodegradable poly lactic/glycolic acid for delivery, elastin mimetic protein networks for delivery, generically engineered protein domains for drug delivery, superporbus hydrogel composites for drug delivery, interpenetrating polymeric networks for drug delivery, hyaluronic acid based delivery of drugs, photocrosslinked polyanhydrides with controlled hydrolytic delivery, cytokine-incuding macromolecular glycolipids based delivery, cationic polysaccharides for topical delivery, n-halamine polymer coatings for drug delivery, dextran based coatings for drug delivery, fluorescent molecules for drug delivery, self-etching polymerization initiating primes for drug delivery, and bioactive composites based drug delivery.
[0091] One embodiment of the present invention discloses an implant, e.g., a stent for implantation into a body, e.g., blood vessel. The implant comprises a coating of O-acylated heparin or o-acylated heparin in combination with one or more compounds selected from the group consisting of (but not limited to) a polymer, fiber polymer, polyurethane, silicone rubber elastomer, drug, hydrogel, or other acceptable compound or carrier known to those of skill in the art. Methods of coating an implant such as a stent with heparin or heparin in combination with one or more of the compounds listed above, are known to those of skill in the art and are further described below and in the examples. Alternatively, O-acylated heparins of the present invention may be coated alone or in combination with the above polymer, fiber polymer, polyurethane, silicone rubber elastomer, drug, hydrogel, or other acceptable compound or carrier known to those of skill in the art onto a bypass graft. The implant, e.g., graft or stent may be used in the treatment of peripheral artery atherosclerosis disease (PAD).
[0092] Whereas the polymer of the coating may be any compatible biostable material capable of being adhered to the stent material as a thin layer, hydrophobic materials are preferred because it has been found that the release of the biologically active species can generally be more predictably controlled with such materials. Preferred materials include silicone rubber elastomers and biostable polyurethanes.
[0093] Heparin-loaded polymer can be applied by spraying or by dipping the stent graft into a solution or melt, as disclosed, for example, in U.S. Pat. Nos. 5,383,922, 5,824,048, 5,624,411 and 5,733,327. Additional methods for providing a drug-loaded polymer are disclosed in U.S. Pat. Nos. 5,637,113 and 5,766,710, where a pre-fabricated film is attached to the stent. Other methods, such as deposition via photo polymerization, plasma polymerization and the like, are also known in the art and are described in, e.g., U.S. Pat. Nos. 3,525,745, 5,609,629 and 5,824,049 and in the below examples.
[0094] U.S. Pat. No. 5,549,663 discloses a stent graft having a coating made of polyurethane fibers which are applied using conventional wet spinning techniques. Prior to the covering process, a medication is introduced into the polymer. Alternatively, a metallic stent cam be coated with a polymeric material and load the polymeric material with a drug.
[0095] The Figures have not been drawn to scale, and the dimensions such as depth and thickness of the various regions and layers have been over or under emphasized for illustrative purposes. Referring to FIGS. 23A and 23B , a stent 10 is formed from a plurality of struts 12 . Struts 12 are separated by gaps 14 and may be interconnected by connecting elements 16 . Struts 12 can be connected in any suitable configuration and pattern to form an a tubular body. While a strut configuration is illustrated, any known stent configuration may be used. Stent 10 is illustrated having an outer surface or sidewall 18 (tissue-contacting surface) and an inner surface 20 (blood-contacting surface). A hollow, central bore 22 extends longitudinally from a first open end 24 to a second end 26 of stent 10 .
[0096] FIG. 24 illustrates stent 10 coated in accordance with the present invention. The stent may have a first coating 28 containing an O-acylated heparin on inner surface 20 and/or a second coating 32 containing an O-acylated heparin formed on outer surface 18 of stent 10 . The coatings can be of any suitable thickness. The thickness of second coating 32 can be from about 0.1-15 microns, more narrowly from about 3 microns to about 8 microns. By way of example, second coating 32 can have a thickness of about 4 microns.
[0000] Cancer
[0097] In another embodiment of the present invention, methods are disclosed for the treatment and or prevention of cancer. Therapeutic amounts of O-acylated heparin, particularly O-hexanoylated heparin derivatives and O-butanoylated heparin derivatives are given to a patient alone or in combination with other cancer therapies, known to those of skill in the art. Compounds may be administered before, at the same time as, or after the administration of other conventional cancer therapies. O-acylated heparins of the present invention may be given prior to the diagnosis of cancer, such as in the case of a patient having a high-risk of developing cancer, or after the successful treatment of cancer (ie. remission). The compounds of the present invention may also be administered with the goal of reducing metastases.
[0098] Examples of tumors which may be inhibited, but are not limited to, lung cancer (e.g. adenocarcinoma, small cell, and including non-small cell lung cancer), pancreatic cancers (e.g. pancreatic carcinoma such as, for example exocrine pancreatic carcinoma), colon cancers (e.g. colorectal carcinomas, such as, for example, colon adenocarcinoma and colon adenoma), prostate cancer including the advanced disease, hematopoietic tumors of lymphoid lineage (e.g. acute lymphocytic leukemia, B-cell lymphoma, Burkitt's lymphoma), myeloid leukemias (for example, acute myelogenous leukemia (AML)), thyroid follicular cancer, myelodysplastic syndrome (MDS), tumors of mesenchymal origin (e.g. fibrosarcomas and rhabdomyosarcomas), melanomas, teratocarcinomas, neuroblastomas, gliomas, benign tumor of the skin (e.g. keratoacanthomas), breast carcinoma (e.g. advanced breast cancer), kidney carcinoma, ovary carcinoma, bladder carcinoma and epidermal carcinoma.
[0099] For the treatment of the above conditions, the compound of the invention may be advantageously employed in combination with one or more other medicinal agents such as anti-cancer agents.
[0100] For example, O-acylated heparins of the invention may be given in combination with one or more compounds selected from platinum coordination compounds for example cisplatin or carboplatin, taxane compounds for example paclitaxel or docetaxel, camptothecin compounds for example irinotecan or topotecan, anti-tumor vinca alkaloids for example vinblastine, vincristine or vinorelbine, anti-tumor nucleoside derivatives for example 5-fluorouracil, gemcitabine or capecitabine, nitrogen mustard or nitrosourea alkylating agents for example cyclophosphamide, chlorambucil, carmustine or lomustine, anti-tumor anthracycline derivatives for example daunorubicin, doxorubicin or idarubicin; HER2 antibodies for example trastzumab; and antitumor podophyllotoxin derivatives for example etoposide or teniposide; and antiestrogen agents including estrogen receptor antagonists or selective estrogen receptor modulators preferably tamoxifen, or alternatively toremifene, droloxifene, faslodex and raloxifene, or aromatase inhibitors such as exemestane, anastrozole, letrazole and vorozole.
[0000] Aberrant Smooth Muscle Cell Proliferation
[0101] The methods of the present invention can be used to treat disorders wherein smooth muscle cells abnormally proliferate. Such conditions include, but are not limited to, restenosis (following angioplasy, vascular stent placement, coronary artery stent placement, peripheral artery stent placement, or cerebral artery stent placement), pulmonary hypertension, and pulmonary fibrosis. We have shown that heparin can inhibit fibroblast proliferation (Dahlberg et al. Am Rev. Respir. Dis. 143:A357, 1993) and can inhibit pulmonary fibrosis in the rat in response to bleomycin. We also have unpublished data showing hexanoylated and butanoylated heparins, which have virtually no anticoagulant property, can also inhibit fibroblast proliferation and thus may offer a potent therapeutic agent for human pulmonary fibrosis.
[0102] The methods of the invention provide for the treatment (reduction or cessation) or prevention of disorders wherein smooth muscle cells are abnormally proliferating. These methods include the administration of O-acylated heparin compounds, preferably O-hexanoylated or O-butanoylated heparin derivatives.
[0103] Administration of the compounds of the invention to treat and/or prevent aberrant smooth muscle cell proliferation are known to those skilled in the art and are presented above. Preferably, O-acylated heparin is coated on an implantable stent, wherein the delivery of the heparin is controlled and sufficient to reduce or ablate aberrant smooth muscle cell proliferation.
[0000] Pulmonary Hypertension and Pulmonary Fibrosis
[0104] In yet another embodiment, the present invention is directed to the treatment and/or prevention of pulmonary hypertension and pulmonary fibrosis. Preferably, O-acylated heparins of the invention are presented for administration to the respiratory tract as a snuff or an aerosol or solution for a nebulizer, or as a microfine powder for insufflation, alone or in combination with an inert carrier such as lactose. In such a case the particles of the active compound suitably have diameters of less than 50 microns, preferably less than 10 microns, more preferably between 2 and 5 microns. The methods of the present invention are directed to the treatment of both primary and secondary pulmonary hypertension and pulmonary fibrosis.
EXAMPLES
[0000] Preparation of O-Acylated Heparins
[0105] In this example, we describe the synthesis of Low Molecular Weight (LMW) heparin by periodate oxidation, its characterization, and its O-acylation.
[0106] Heparin was fragmented by periodate oxidation based on a modification of an earlier procedure (described in U.S. Pat. No. 4,990,502), wherein heparin sodium salt (20 g, 1.43 mmol) was dissolved in 175 mL distilled water. The pH was adjusted to 5.0 using 1 N HCl. NaIO 4 (15 g, 0.070 mol), dissolved in 500 ML water, was added in a single portion with stirring. The pH was readjusted to 5.0 using 1 N HCl and left for 24 hours at 4° C. in the dark. The solution was dialyzed against 4 volumes of water (with one change of water) for 15 h at 4° C.
[0107] To the approximately 1.5 L solution obtained after dialysis, 32 mL of 10 N NaOH was added. The solution was stirred at room temperature for 3 h. To prevent the development of colored products, this step was done in the dark.
[0108] NaBH 4 (1 g, 0.026 mol) was added in one portion and the approximately 1.5 L of solution was stirred for 4 hours. The pH was then adjusted to 4.0 using 37% HCl and the solution was stirred for an additional 15 min. The solution was neutralized to pH 7.0 using 1 N NaOH, NaCl (32.8 g, 0.56 mol) followed by 2.54 μL of ethanol. The solution was left for 3 h without stirring and the precipitate was recovered by centrifugation at 15000 rpm (22,000×g) for 20 min. The precipitate was recovered by decantation and suspended in 400 mL absolute ethanol. The solution was filtered using a Buchner funnel and left to dry for 5 hours under vacuum affording 14.2 g of product.
[0109] The product was dissolved in 190 mL of water. NaCl (2.8 g, 0.05 mol) was added and the pH was adjusted to 3.5 using 1 N HCl. The volume was adjusted to 280 mL using water. Absolute ethanol (240 mL) was added with stirring. The solution was stirred 15 min and then left without stirring for 10 hours at room temperature. After decanting, the precipitate was recovered and dissolved in water. The ethanol was removed by rotary evaporation under reduced pressure and freeze-dried affording ˜10 g of LMW heparin fragments ( FIG. 1 ).
[0000] NMR Sample Preparation
[0110] For 1 H NMR spectroscopy, approximately 10 mg of each sample was exchanged by lyophilization three times from 0.5 ml portions of 99.9% 2 H 2 O before being redissolved in 2 H 2 O for NMR analysis. Chemical shifts are reported relative to TMS at 0.00 ppm. The degree of substitution (O-acylation) was determined from the ratio of the integrated area of the peaks assigned to the aliphatic methyl protons of the hexanoyl group (0.753 ppm) to the anomeric proton of IdoA2S (5.092 ppm) (Table 1, FIG. 2 ).
[0000] Gradient PAGE Analysis
[0111] Gradient polyacrylamide gel electrophoresis (PAGE) was performed on a 32 cm vertical slab gel unit PROTEAN II equipped with Model 1000 power source from Bio-Rad IRichmond, Calif.). Polyacrylamide linear gradient resolving gels (14×28 cm), 12-22%) total acrylamide) were prepared and run as previously described (Edens et al., 1992, J. Pharm. Sci. 81, 823-827). The molecular sizes of the oligosaccharide samples were determined by comparing with a banding ladder of heparin oligosaccharide standards prepared from bovine lung heparin. Oligosaccharides were visualized by Alcian blue staining. The average MW of the product was determined to be 6,000.
[0000] Anti-factor Xa and anti-factor IIa activities
[0112] LMW heparin and heparin standard were in diluted normal human plasma. Chromogenic Xa substract S-2732 (Suc-Ilc-Glu(gamma-piperidyl)-Gly-Arg-pNA) 2.9 MM in 50 mM Tris, 7.5 μM EDTA, pH 8.4 buffer (200 μL), was added to 25 μL of plasma containing sample and 200 μL of bovine Factor Xa (1.25/mL). After mixing, the reaction was incubated for 8 min. at 37 degrees Celsius and 200 μL of 20% aqueous acetic was added. Residual Factor Xa was then determined by measuring absorbance at 405 nm. Anti-factor IIa activity was determined by incubating 50 ML of LMW heparin in NHP diluted 4-fold with water with 50 mL of human thrombin (12 NIH units/mL) at 37° C. for 30 s. then 50 mL of (2.5 mmol/mL of Chromogenic TH (ethylmalonyl-Pro-Aeg-p-nitroanilide hydrochloride) was added, and the amidolytic thrombin activity was measured at 405 nm. Measurements were performed on an ACL 300 plus from Instrumentation (Lexington, Mass.) and calculated in comparison with USP Heparin Reference Standard (K-3) supplied by U.S. Pharmacopeial Convention (Rockville, Md.). The product exhibited no measurable anti-factor Xa or anti-factor IIa activity.
[0000] O-acylated LMW Heparin Derivatives
[0113] (1) O-Hexanoyl derivative of periodate-oxidized heparin fragments. These were obtained by treating the tributylaminmonium salt of periodate oxidized heparin fragments with hexanoic anhydride as described previously (Gohda et al., 2001, Biomacromolecules, 2(4):1178-83)(Lormeau U.S. Pat. No. 4,990,502). Briefly, the tributylammonium salt (11.9 g) was dissolved in dry DMF (114 mL), kept under Ar and cooled to 0 degrees Celsius. 4-Dimethylaminopyridine (0.695 g, 5.69 mmol), hexanoic anhydride (26.2 mL, 0.113 mol), and tributylamine (227 mL, 0.113 mol) were successively added in single portions, and the reaction was allowed to proceed under argon at room temperature for 24 hours. After cooling to 0° C., 5% NaHCO3 in water (227 mL) was gradually added and the solution was stirred at room temperature for 48 h. Excess NaHCO3 was eliminated by slow, dropwise addition of 1 N HCL (˜200 mL) until pH4 was reached and then readjusted to pH 7 with 1 N NaOH (˜150 mL). Cold denatured (95%) ethanol (5L, 5 vol) was added with stirring. The sample was allowed to sit overnight at 4 degrees Celsius to afford precipitate. The precipitate was recovered by by decanting and dissolved in 0.2 M NaCl (114 mL), and the precipitation procedure was repeated by adding absolute ethanol (570 mL). The precipitate was recovered by centrifugation at 15000 rpm for 20 minutes, dissolved in water (114 mL), and passed through a column (300 mL) of Dowez 50WX8(H + ) cation-exchange resine and 600 ml was recovered. The acid was neutralized to pH 7 with 10 N NaOH and the solution was filtered through a 0.22 μm Millipore filter. After lyophilization, O-hexanoyl heparin oligosaccharides (7.12 g) was obtained as an off-white powder ( FIG. 3 ).
[0000] O-butanoylated LMW Heparin
[0114] This derivative was prepared from the tributylaminmonium salt of LMW heparin by treatment with butyric anhydride under the same condition as described for hexanoyl derivative (see above).
[0000] Application of Heparin to Stent
[0115] O-acylated heparin derivatives can be coated on stents using the methods set forth in U.S. Pat. No. 6,620,194. The method is generally as follows.
[0116] The application of the coating material to the stent is quite similar for all of the materials and the same for the heparin and one or more additional suspensions prepared as in the above Examples. The suspension to be applied is transferred to an application device, typically a paint jar attached to an air brush, such as a Badger Model 150, supplied with a source of pressurized air through a regulator (Norgren, 0-160 psi). Once the brush hose is attached to the source of compressed air downstream of the regulator, the air is applied. The pressure is adjusted to approximately 15-25 psi and the nozzle condition checked by depressing the trigger.
[0117] Any appropriate method can be used to secure the stent for spraying and rotating fixtures. Both ends of the relaxed stent can be fastened to the fixture by two resilient retainers, commonly alligator clips, with the distance between the clips adjusted so that the stent remains in a relaxed, unstretched condition. The rotor is then energized and the spin speed adjusted to the desired coating speed, nominally about 40 rpm.
[0118] With the stent rotating in a substantially horizontal plane, the spray nozzle is adjusted so that the distance from the nozzle to the stent is about 2-4 inches and the composition is sprayed substantially horizontally with the brush being directed along the stent from the distal end of the stent to the proximal end and then from the proximal end to the distal end in a sweeping motion at a speed such that one spray cycle occurs in about three stent rotations. Typically a pause of less than one minute, normally about one-half minute, elapses between layers. Of course, the number of coating layers will vary with the particular application. For example, for a coating level of 3-4 mg of heparin per cm.sup.2 of projected area, 20 cycles of coating application should be required and about 30 ml of solution will be consumed for a 3.5 mm diameter by 14.5 cm long stent.
[0119] The rotation speed of the motor, of course, can be adjusted as can the viscosity of the composition and the flow rate of the spray nozzle as desired to modify the layered structure. Generally, with the above mixes, the best results will be obtained at rotational speeds in the range of 30-50 rpm and with a spray nozzle flow rate in the range of 4-10 ml of coating composition per minute, depending on the stent size. It is contemplated that a more sophisticated, computer-controlled coating apparatus will successfully automate the process demonstrated as feasible in the laboratory.
[0120] The coated stent can be thereafter subjected to a curing step in which the pre-polymer and crosslinking agents cooperate to produce a cured polymer matrix containing the biologically active species. The curing process involves evaporation of the solvent xylene, THF, etc. and the curing and crosslinking of the polymer. Certain silicone materials can be cured at relatively low temperatures, (i.e. RT-50° C.) in what is known as a room temperature vulcanization (RTV) process. More typically, however, the curing process involves higher temperature curing materials and the coated stents are put into an oven at approximately 90° C. or higher for approximately 16 hours. The temperature may be raised to as high as 150° C. for dexamethasone containing coated stents. Of course, the time and temperature may vary with particular silicones, crosslinkers, and biologically active species.
[0121] Stents coated and cured in the manner described need to be sterilized prior to packaging for future implantation. For sterilization, gamma radiation is a preferred method particularly for heparin containing coatings; however, it is possible that stents coated and cured according to the process of the invention subjected to gamma sterilization may be too slow to recover their original posture when delivered to a vascular or other lumen site using a catheter unless a pretreatment step as at 24 is first applied to the coated, cured stent.
[0122] The pretreatment step can involve an argon plasma treatment of the coated, cured stent in the unconstrained configuration. In accordance with this procedure, the stents are placed in a chamber of a plasma surface treatment system such as a Plasma Science 350 (Himont/Plasma Science, Foster City, Calif.). The system is equipped with a reactor chamber and RF solid-state generator operating at 13.56 mHz and from 0-500 watts power output and being equipped with a microprocessor controlled system and a complete vacuum pump package. The reaction chamber contains an unimpeded work volume of 16.75 inches (42.55 cm) by 13.5 inches (34.3 cm) by 17.5 inches (44.45 cm) in depth.
[0123] In the plasma process, unconstrained coated stents are placed in a reactor chamber and the system is purged with nitrogen and a vacuum applied to 20-50 mTorr. Thereafter, inert gas (argon, helium or mixture of them) is admitted to the reaction chamber for the plasma treatment. A highly preferred method of operation consists of using argon gas, operating at a power range from 200 to 400 watts, a flow rate of 150-650 standard ml per minute, which is equivalent to 100-450 mTorr, and an exposure time from 30 seconds to about 5 minutes. The stents can be removed immediately after the plasma treatment or remain in the argon atmosphere for an additional period of time, typically five minutes.
[0124] After this, the stents can be exposed to gamma sterilization at 2.5-3.5 Mrad. The radiation may be carried out with the stent in either the radially non-constrained status—or in the radially constrained status.
[0125] With respect to the anticoagulant material heparin, the percentage in the tie layer is nominally from about 20-50% and that of the top layer from about 0-30% active material. The coating thickness ratio of the top layer to the tie layer varies from about 1:10 to 1:2 and is preferably in the range of from about 1:6 to 1:3.
[0126] Suppressing the burst effect also enables a reduction in the drug loading or in other words, allows a reduction in the coating thickness, since the physician will give a bolus injection of antiplatelet/anticoagulation drugs to the patient during the stenting process. As a result, the drug imbedded in the stent can be fully used without waste. Tailoring the first day release, but maximizing second day and third day release at the thinnest possible coating configuration will reduce the acute or subacute thrombosis.
[0000] Results
[0127] Effect on smooth muscle cell proliferation in vitro and in vivo. Hexanoylated LMW heparin significantly inhibited pulmonary artery smooth muscle cell proliferation in vivo ( FIG. 4 ) and the development of pulmonary hypertension induced by hypoxia in pig lung ( FIG. 5 )
[0128] In comparison to non-acylated heparin fragments, hexanoylated LMW heparin significantly enhanced the antiproliferative effect of bovine pulmonary artery smooth muscle cells in vitro.
[0129] Effect of O-acylation of heparin on tumor growth in vivo. As seen in FIGS. 6-10 , butanoylated heparin significantly inhibited the growth of both A549 non-small cell lung carcinoma and DMS79 small cell lung carcinoma in SCID mice ( FIG. 6-10 ). In addition, FIGS. 11 and 12 demonstrate that butanoylated heparin significantly inhibited the growth of HCT116 colonic carcinoma in SCID mice.
[0130] FIGS. 13 and 14 demonstrate that the above butanoylated heparin compounds exhibit very low anticoagulant effects (compared to non-acylated controls). Butanoylated heparin had no toxic effect on heart, liver, kidney, and lung of the animals tested ( FIG. 15-18 ). Furthermore, the anti-tumor effect of butanoylated heparin is associated with the induction of apoptosis ( FIG. 19 ). The mechanism by which butanoylated heparin inhibits tumor growth of lung cancer and coloncancer may involve p27- and p21-RB-E2F pahthway ( FIG. 20-22 ). Similar antiproliferative effects were seen with O-hexanoylated LMW heparin on anti-tumor cell growth in vitro.
TABLE 1 Assignment of selected signals in the 1 H NMR spectrum of the O- hexanoyl heparin derivative. Chemical (ppm) shift Residue H-1 H-2 H-3 H-4 H-5 GlcNS6S 5.302 3.093 3.539 3.629 3.892 IdoA2S 5.092 4.218 4.008 3.920 4.709 | This invention provides a method for inhibiting or preventing the abnormal growth of cells, including transformed cells, by administering an effective amount of O-acylated heparin derivative. Abnormal growth of cells refers to cell growth independent of normal regulatory mechanism (e.g. loss of contact inhibition). This includes the abnormal growth of: (1) tumor cells (tumors); (2) benign and malignant cells of other proliferative disease in which aberrant cellular proliferation occurs; (3) aberrant smooth muscle cell proliferation, such as might occur following treatment for coronary atherosclerosis such as angioplasty or the insertion of a stent into an occluded vessel. | 2 |
This is a continuation of application Ser. No. 07/970,121, filed Nov. 2, 1992 now abandoned.
FIELD OF THE INVENTION
The invention relates to an improved subunit vaccine preparation and method for manufacturing such improved vaccine preparation for immunizing animals against Tritrichomonas foetus. The vaccine preparation is effective to treat animals infected with T. foetus and immunize animals against T. foetus infection.
BACKGROUND OF THE INVENTION
Trichomoniasis is a venereal disease caused by the protozoan parasite, Tritrichomonas foetus. The infection is confined to the lower reproductive tract of the female; i.e., the uterus, cervix and vaginal vestibule. In the male, T. foetus is found in the preputial cavity and less commonly in the urethral orifice. Transmission is almost exclusively by coitus.
Trichomoniasis is a worldwide disease of cattle. In infected cows, clinical manifestations of the disease are: early embryonic death, abortion, pyometra, and infertility, all of which result in reduced calf production. Prevalence increases with the age of the bull, possibly due to deepening of crypts in the preputial epithelium. Therefore, older bulls tend to remain long-term carriers. Infection rates are similar in both Bos taurus and Bos indicus cattle Yule et al., Parasitol. Today, 5(12), 373-377 (1989)!. A suggestion that there is a breed difference is susceptibility to T. foetus has not been substantiated.
The prevalence of trichomoniasis in bulls within a herd reported from around the world varies from 5.8-38.5% in California and 26.4% in South Africa, to 30.6-50% in Australia Kimsey et al., J. Am. Vet. Med. Assoc., 177, 616-619 (1980)!. Losses due to reduced milk and calf production in a California dairy were calculated at U.S. $665.00 per infected cow Goodger et al., J. Am. Vet. Med. Assoc., 189, 772-776 (1986)!.
Although trichomoniasis is purely a localized infection, the parasite does come into close contact with epithelial tissue at the site of colonization. The presence of circulating anti-T. foetus antibodies has been established by several assay systems. Naturally infected cattle have low circulating antibody levels. Highest titers have been seen in animals experiencing abortion and pyometra. However, serological tests, including agglutination, complement fixation, and gel precipitation, have failed to detect naturally infected cattle. Adequate antibody levels have been induced in cattle by inoculation of live parasites as well as various killed preparations of T. foetus. Live parasites generally stimulate production of antibody at higher levels than killed preparations. The circulating antibodies, however, reportedly do not come into contact with the parasite and supposedly play no protective role B. M. Honigberg, "Trichomonads of Veterinary Importance, Trichomonads of Importance in Human Medicine", in Parasitic Protozoa, Vol. II, J. P. Kreier, ed. (1978)!.
A number of T. foetus vaccines have been described Yule et al., supra (1989); Clark et al., Aus. Vet. J., 60(6), 178-179 (1983); and Clark et al., Aus. Vet. J., 61(2), 65-66 (1984)!. However, a reliable and highly effective vaccine has not been produced. There is a need for a vaccine preparation that can effectively eliminate T. foetus infection from animals and immunize uninfected animals.
SUMMARY OF THE INVENTION
The invention is directed to a vaccine preparation and a method for manufacturing an improved vaccine preparation for use in immunizing animals against mucosal pathogens, such as equine influenza virus, Streptococcus equi, Campylobacter foetus, Tritrichomonas foetus, and the like. The vaccine can also be used to effectively treat animals infected with such agents.
A preferred vaccine comprises an effective amount of an immuno-stimulating complex having a subunit fraction of T. foetus membrane antigens of molecular weights between 45 kD and 300 kD and a saponin. More particularly, the subunit fraction of T. foetus membrane antigens corresponds to a supernate fraction of a T. foetus cell suspension that has been centrifuged for at least 10 minutes at least at 40×g. More preferably, the antigens of the T. foetus subunit correspond to the antigens contained in the supernate of T. foetus cells obtained by centrifugation for at least 10 minutes at about 50×g and/or 830×g. Most preferably, the antigens present in the supernate after centrifugation at 830×g for at least about 15 minutes.
The method of the invention comprises providing an antigen suspension obtained from T. foetus organisms, including a physiologic saline solution (or a buffer solution), separating the antigen to be used in the vaccine from cell fragments, including structural cell components, nucleii, and the like, and forming an immuno-stimulating complex of selected antigens with saponin. In a preferred embodiment, providing the antigen suspension includes homogenizing the Tritrichomonas foetus cells to release the antigens.
The antigens are separated from the cell fragments by centrifugation, preferably for at least 10 minutes at least at 40×g, more preferably for 15 minutes at 50×g, more preferably for 15 minutes at least at 830×g, and most preferably for 15 minutes at 830×g. The antigens thus separated from the cell fragments form the basis for the subunit vaccine.
A nonionic detergent in sufficient quantity is then added and mixed with the dialyzed supernatant for a period of time effective for solubilizing the antigens, ie. to release from the cell membrane. Preferably, the nonionic detergent is N-octyl-β-D-glucopyranoside (OBDG) or octyl phenol ethylene oxide (NP-40) or the like.
Sufficient quantity of a saponin is then added and mixed with the solubilized antigens for a sufficient length of time to form an immuno-stimulating complex (ISCOM). Excess detergent and saponin are removed by dialysis. The dialysis steps can also be done by means of an ultrafiltration system. The ISCOM is suitable for use in immunization through the subcutaneous route.
The vaccine preparation of the invention can be used for treating and immunizing animals, preferably mammals, and most preferably cattle, against T. foetus. Administration of the vaccine preparation can be used topically, such as intravaginally or intrapretutially. Preferably, subcutaneous administration is done in conjunction with topical administration.
For intravaginal/preputial immunization or treatment, preferably an adjuvant, such as retinol palmitate (RP), is added to the ISCOM. For intrapretutial/intravaginal administration of the vaccine preparation, preferably, ISCOM with RP and glycerol is used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the results of SDS-PAGE Western immunoblot antigen analysis using rabbit anti-T. foetus hyperimmune serum. Lane A, B and C are the SDS-page result of an 830×g membrane lysate preparation, 50×g membrane lysate preparation and whole cell lysate preparation, respectively.
FIG. 2 shows the results of SDS-PAGE Western immunoblot antigen analysis using bovine anti-T. foetus hyperimmune serum. Lanes A and B are the SDS-page result of an 830×g and 50×g membrane lysate preparation, respectively.
FIG. 3 shows the inhibition of T. foetus by vaginal mucus from two immunized heifers: heifer #3628 immunized with flagellar fraction immunogen and heifer #3798 immunized with membrane lysate immunogen.
DETAILED DESCRIPTION OF THE INVENTION
A. Protective Immunity and Vaccine Composition
The major host defense mechanism on mucosal surfaces such a those of the vagina, cervix and uterus, which are target sites for T. foetus, is provided by antibodies produced locally by plasma cells in the secretory mucosal tissues. Secretory IgA is the principal immunoglobulin on mucosal surfaces and in colostrum. It is a heterodimer of MW of approximately 400 kD consisting of two subunits of the basic four-chain structure with a single J chain, and as the molecule passes across the mucosal epithelium, it acquires an additional "secretory piece".
All natural mucosal infections are known to induce the production of secretory IgA antibodies and there is clear evidence that these antibodies constitute the primary line of defense against these mucosal pathogens Mims, The Pathogenesis of Infectious Disease, Academic Press, London - New York (1976); Lamm, "Mucosal Responses to Viruses" in Mucosal Immunity and Infections at Mucosal Surfaces, W. Strober et al., eds., Oxford University Press, New York, pp. 277-278 (1988)!. In natural infection, however, IgA antibody response is slow to develop Lamm, supra (1988)!. Accordingly, in order to protect the host against a mucosal infection such as T. foetus, specific IgA antibodies must be available prior to the onset of the infection. This can only be accomplished by prophylactic immunization designed to stimulate the production of anti-T. foetus secretory IgA antibodies. Even though a scientific theory may help to explain the effectiveness of the invention, the adoption of any particular theory is not to be understood as limiting the scope and claims of this invention.
As used herein, the term Tritrichomonas foetus refers to the species of parasitic flagellated protozoan that infects the genital tract of animals, particularly cattle. Generally, the organism is characterized by a pear-shaped morphology with multiple flagella in the front, typically three; an undulating membrane; and a trailing flagellum.
The vaccine of the present invention includes a subunit of T. foetus to induce the production of anti-T. foetus IgA antibodies. As used herein, "subunit" refers to a composition including one or more major membrane surface antigens of T. foetus. The immunoactive major surface antigens can be glycoproteins and/or other cell surface components that induce the production of anti-T. foetus IgA antibodies. In one preferred embodiment, the vaccine subunit is a membrane surface antigen fraction having a molecular weight between about 45 kD and 300 kD. The subunit is preferably obtained by centrifuging a homogenized cell suspension of T. foetus cells for at least 10 minutes at least 40×g to produce the effective antigen fraction.
As described herein, the antigen fraction is separated from the cell debris and employed as the T. foetus surface membrane subunit of the vaccine. Preferably, the antigens present in the membrane fractions obtained at about 50×g and/or about 830×g are employed in the vaccine preparation.
The preferred vaccine includes the T. foetus subunit fraction, and a saponin. The saponin is exemplified by Quil-A or the like. The amount of saponin employed to create the immuno-stimulating complex will vary from about 0.15 to about 0.20 percent with respect to the amount of antigen to be complexed and will be readily adjusted to effective amounts by one of skill in the art based on the description herein.
The vaccine preparation is administered in a dose of about 0.2 to about 0.3 mg/ml of the immuno-stimulating complex of antigens and saponin. To treat or clear an infected animal of T. foetus infection, from about 0.08 to about 0.12 mg/ml of the complex is preferably administered.
Preferably, the vaccine is administered topically, intravaginally, or intrapretutially. We have also found that a combination of topical and parenteral administration is most effective to treat T. foetus infection. Similarly, immunization to prevent T. foetus infection can be accomplished by topical vaccine delivery alone or, preferably, in combination with parenteral vaccine administration.
One of skill in the art will understand that the antigen/saponin complex (ISCOM) can be combined with other adjuvants, such as an acceptable pharmaceutical carrier such as water, saline, glycerol, retinol palmitate, or the like in amounts that form an effective vaccine composition that can clear up or prevent T. foetus infection in animals, preferably female and male bovines. Useful adjuvants include retinol palmitate, sodium fluoride, cholera toxin B, or the like.
We have determined that there unexpectedly appears to be a synergistic protective effect exerted by IgA antibodies in the mucosal secretions and IgG antibodies in animal's serum in response to a vaccine, such as the vaccine described herein. Specifically, the vaccine of the present invention is effective to promote production of anti-T. foetus IgA antibodies in amounts sufficient to clear or prevent T. foetus infection.
B. Isolates and Culture
Isolates
The two isolates of Tritrichomonas foetus used to exemplify this invention were isolates T. foetus D1, received from the University of California Davis, and T. foetus IDOWY41492 (internal designation), obtained from the Bureau of Animal Health Laboratories in Boise, Id. The antigenic profile of these isolates are representative of T. foetus. Analysis of protein and antigen profiles of T. foetus from cattle from different geographic locations has shown that no significant difference in composition of total proteins or antigenic proteins was detected and that there are strong antigenic cross-reaction among diverse isolates of T. foetus Huang et al., Am. J. Vet. Res., 50(7), 1064-1068 (1989), incorporated by reference herein!
The first isolate of the organism, designated T. foetus D1, originated from a cow with pyometra and had been propagated in vitro at U. C., Davis, before a sample was acquired. The second isolate, T. foetus IDOWY41492, was obtained from an infected bull in Owyee County, Id. This isolate was collected from a naturally infected bull, and supplied in 3.0 ml of transport medium in collection pouch. The field sample was propagated in vitro and a stabilate was prepared from the expanded cultures and frozen down for cryopreservation in liquid nitrogen (LN 2 ). Later, a portion of the frozen stabilate was expanded in T-flasks (T-25→T-75) and then scaled up in 1.0-liter bottles from which a master seed stock (MSS), designated #IDOWY41492, was established as follows:
Two 1.0-ml vials of the stabilate prepared from the Idaho isolate of the organism (T. foetus IDOWY41492) were used to propagate the organism to a quantity sufficient to prepare a MSS stabilate for cryopreservation. In this regard, the pooled suspension of T. foetus was centrifuged at 1500×g for 35 minutes. The pelleted organisms were resuspended in a total of 82 ml of fresh culture medium and a sample was taken to determine their viability and parasite count. Using the standard trypan blue dye exclusion method, the viability and count of this suspension of the parasite was determined to be 93% and 2.69×10 8 organisms/ml, respectively. A total of approximately five hundred (500) 1.0-ml vials of T. foetus stabilate were frozen in T. foetus culture medium containing 10% (v/v) dimethylsulfoxide (DMSO). Each vial contained 2.0×10 7 organisms/ml of parasite suspension.
The antigenic protein profiles of the D1 and IDOWY41492 isolates were typical of T. foetus. Researchers have found that there are strong antigenic cross-reaction and noticed no significant differences in the composition of total proteins or antigenic proteins of parasite isolates obtained from cattle in different geographic locations.
Tritrichomonas foetus was cultured in T. foetus culture medium supplemented with 5% (v/v) donor calf serum (Sigma). Each LN 2 stored vial of T. foetus stabilate, containing 2.0×10 7 organisms/ml, was rapidly thawed in a 37° C. water bath, and the contents were aseptically transferred to a T-75 tissue culture flask containing 50 ml of culture medium. The flask was incubated at 37° C. and observed daily for parasite density and fresh medium was added as needed to a maximum of 220 ml per T-75 flask. As soon as the parasite density increased to 5.0×10 6 -1.0×10 7 /ml, the organisms were transferred to a 40-liter spinner flask to which more medium was added to an initial volume of 2.0 liters. The volume of medium in the spinner flask was gradually increased to 40 liters as the organism increased in number and depleted the nutrients. When the culture reached a parasite density of 8.0×10 6 -1.0×10 7 /ml, the organisms were harvested for antigen processing.
Three preparations of T. foetus were used in characterizing the parasite's antigens by immunochemical analysis using the Western immunoblot technique: (i) whole cell lysate (1.11 mg of protein/ml), (ii) 50×g membrane lysate (1.07 mg of protein/ml) and (iii) 830×g membrane lysate (0.88 mg of protein/ml).
The antigens detected in the 50×g and the 830×g membrane lysates were similar. A total of 18 antigenic bands were detected on the blots by both the rabbit and bovine immune sera. There were at least 6 high molecular weight polypetides (>200 kD), 1 polypeptide at 180 kD, 5 polypeptides between 55 and 100 kD, 4 polypeptides in the 42-50 kD region, and 2 weak bands in the 28-30 kD region. There were no significant differences in the antigenic makeup of the two isolates (T. foetus D1 and T. foetus IDOWY41492) used in the development of the vaccine. FIGS. 1 and 2 show the antigen bands of SDS-PAGE Western immunoblot antigen analysis.
Referring to FIG. 1, A is the SDS-PAGE result 830×g membrane lysate preparation, while B and C are the SDS-PAGE result of the 50×g membrane lysate preparation and the whole-cell lysate preparation, respectively. All major antigens present in the whole-cell lysate are apparently retained in the 50×g and 830×g membrane lysates.
Referring to FIG. 2, A and B are the SDS-PAGE result of the 830×g and 50×g membrane lysates, respectively.
C. Immunogen Preparations and Immunizations
The D1 isolate of T. foetus was used to produce an exemplary immunogen preparation. It will be appreciated by those skilled in the art that other T. foetus isolates can be employed to prepare effective immunogens based on the disclosure herein.
The parasite suspension was washed three times in phosphate buffered saline (PBS), pH 7.2, using a MINI-TAN (Millipore) tangential flow ultrafiltration system equipped with a 70 kD filter, then centrifuged at 8000×g for 30 minutes and resuspended in PBS containing 0.02% (w/v) sodium azide and 1.0 mM phenyl-methylsulfonyl fluoride (PMSF) as preservatives. This suspension was freeze-thawed once then passed through a MICROFLUIDIZER homogenizer (Microfluidics) twice to homogenize the organisms. To produce the antigen component for use in the described vaccine, the homogenate is centrifuged in a centrifuge such as a Heraeus Christ, cryofuge 8000, or the like. The suspension is centrifuged for at least about 10 minutes, preferably at least about 15 minutes, at least at 40×g, more preferably at least about 50×g. Effective membrane subunit fractions are best obtained from the supernate of a suspension centrifuged at about at least 50×g or 830×g for about 10 minutes, more preferably about 15 minutes. By way of example, the above homogenate was centrifuged at 830×g for 15 minutes, and the resulting supernatant was the "830×g membrane lysate". Similarly, a `50×g membrane lysate` was obtained by centrifuging at 50×g for 15 minutes. The 830×g membrane lysate was again centrifuged at 3400×g for another 15 minutes. The latter supernatant was designated the "3400×g membrane lysate". The cell debris containing pellet from the last centrifugation step was resuspended in PBS and designated the "flagellar fraction", as it consisted predominantly of flagella. Both factions were concentrated by lyophilization (freeze-drying) and subsequently reconstituted to the desired protein concentration with deionized water before use. The third antigen preparation consisted of whole T. foetus D1 organisms which were frozen and thawed once and then sonicated. This preparation was designated the "whole-cell lysate".
Each antigen preparation was dialyzed overnight against 10 mM Tris-140 mM sodium chloride (TN) buffer, pH 7.4, at 4° C., following which 136 mM of N-octyl-beta-D-gluco-pyraanoside (OBDG) was added and the mixture was stirred for 1 hour at room temperature to solubilize the antigen. Saponin (Quil-A brand, Superfos) was then added at a concentration of 1.5 mg/ml and the mixture was stirred for 10 minutes at room temperature. It is to be understood that the amount of saponin to be added will depend on the concentration of antigen in the mixture and can be accordingly adjusted to form the immuno-complex. Excess OBDG and saponin was removed by overnight dialysis against 3 changes of TN buffer. The dialysis can be accomplished by dilution and filtration using an ultrafiltration system for retaining molecules larger than 10 kD. The resulting antigen-saponin complex, referred to as the "Immuno-Stimulating Complex" (ISCOM), was used to immunize animals as described herein, including two heifers via the s.c. route in the Example section A2. For intravaginal immunization, retinol palmitate (RP) (Sigma) was added to the ISCOM at a concentration of 41.66667 mg/ml (i.e., 1.0 g RP in 24 ml of ISCOM, equivalent to 12 doses). The amount of RP employed as a vaccine adjuvant can range from about 10 to about 50 mg/ml and can be further adjusted by one of skill in the art based on this disclosure.
D. Tests and Assays for Measuring Immune Responses
Samples
To demonstrate the effectiveness of the ISCOM of the present invention, blood for serum was collected pre- and post-vaccination, at varying time intervals, by jugular venipuncture and the serum was aliquoted into small volumes for storage at -20° C. until use.
Samples of vaginal mucus secretions were also collected pre- and post-vaccination at varying time intervals and treated in three different ways. The first sample was collected by flushing the vaginal vestibule with a sufficient volume of PBS, pH 7.2. The sample was then passed through a 0.22 mm filter, dialyzed against PBS, pH 7.2, and concentrated by lyophilization. It was then reconstituted to the desired dilution with deionized water before use. The second sample was collected and treated similarly, except that it was concentrated by placing the dialysis bag(s) containing the sample in a tray filled with polyvinylpyrrolidone (PVP) powder and letting the bag(s) sit in the PVP powder for a given period of time until the volume was reduced to the desired level. The third sample was collected with a tampon from which the vaginal mucus was subsequently washed into a volume of PBS,pH 7.2, dialyzed against the same buffer and concentrated by lyophilization. It was then reconstituted to the desired concentration with deionized water before use.
Analysis of Samples by Dot-Enzyme-Linked Immunosorbent Assay (Dot-ELISA)
Whole cell T. foetus homogenates were prepared as described before, pooled and standardized to an optimal concentration for Dot-ELISA by checker-board titration of the antigen against T. foetus-specific serum IgG and vaginal mucus IgG 1 and secretory IgA. Commercially obtained alkaline phosphatase-labelled, heavy chain-specific goat anti-bovine IgG conjugate (Kirkegaard and Perry Laboratories, Inc., Gaithersburg, Md.), and alkaline phosphatase-labelled, heavy and light chain-specific sheep anti-bovine IgG 1 and anti-bovine IgA conjugates (Bethel Laboratories, Inc., Montgomery, Tex.) were used. 5-bromo-4-chloro-3-indolyl phosphate/nitroblue tetrazolium (BCIP/NBT) was used as the substrate-chromogen system.
The antigen was passively adsorbed, in spots or dots, to nitrocellulose discs (approximately 5 mm in diameter) in 1.0-2.0 ml volumes and let dry at room temperature for at least an hour. The discs were then blocked with 5% (w/v) nonfat dry milk (Carnation®) in PBS, pH 7.2, for 20 minutes and used in the Dot-ELISA immediately or stored dry for later use.
For use in the enzyme immunoassay, the discs were placed singly in a 24-well microtiter plate and washed in excess PBS, pH 7.2. The PBS was discarded and 500 μl of the test sample (serum or vaginal mucus), appropriately diluted, were added to each well containing an antigen-spotted disc and the plate was incubated on a shaker for 2 hours at room temperature. The discs were then washed three times with PBS containing 0.1% (v/v) Tween-20 (PBS-Tween) for 5 minutes each wash. After washing, the discs were each incubated with 500 μl of the appropriately diluted isotype-specific conjugate for 1 hour with gentle shaking at room temperature. They were again washed on the shaker 2 times in PBS-Tween followed by a final wash in excess PBS for 5 minutes each wash. The substrate BCIP/NBT was then added (500 μl/disc) and an enzyme-substrate reaction was let to proceed to completion (20 minutes) and stopped by washing away the excess substrate with deionized water. Positive reactions were evidenced by the development of a purplish gray color of varying intensities on the antigen dots. A negative reaction was evidenced by lack of color development.
Standard Enzyme-Linked Immunosorbent Assay (ELISA) for Measuring Systemic and Vaginal Antibody Responses to T. foetus Immunogens
For testing serum and vaginal mucus samples for T. foetus-specific antibodies (IgG and, IgG 1 and secretory IgA, respectively) by the standard ELISA, Linbro Titertek™ (ICN Flow Laboratories, McLean, Va.) 96-well microtiter plates were antigen coated by incubating the plates overnight at 4° C. with a homogenate of T. foetus (200 μl/well), which was pre-diluted 500 times with the antigen coating carbonate-bicarbonate buffer to optimize antigenic protein concentration for the assay. Following overnight incubation of the plates with the antigen, they were washed 3 times with PBS, pH 7.2, containing Tween-20 at a concentration of 0.05% (v/v). The plates were then blocked by adding to each well 200 μl of 2% (v/v) bovine serum albumin (BSA) in PBS, pH 7.2, and incubating at 37° C. for half an hour. These plates were either immediately used in the assay or stored at 4° C. for use later.
For the assay, 200 μl of the appropriately diluted test serum or vaginal mucus were added to each well and the plates were incubated at 37° C. for 2 hours. They were then washed 3 times with PBS-Tween (0.05%). The plates were subsequently incubated at 37° C. for 1 hour with the various previously described conjugates, washed three times, and 200 μl of the substrate is added to each well.
Each test sample was run in replicates of 4, and the corresponding 4 wells in a column were run as "blanks" containing unreacted substrate (i.e., blank wells were antigen-coated but were not exposed to either the test sample or the appropriate conjugate). To correct for "background" readings, the average value of the optical density (O.D.) readings of four blank wells was subtracted from the average value of the four replicate O.D. readings of the test wells. For a test sample to be considered positive in the assay, it had to yield a positive-to-negative O.D. reading ratio (P:N ratio) equal to or greater than 2; the negative reading being the O.D. value generated by the pre-immunization serum or vaginal mucus sample of the same animal (also an average of the O.D. readings of 4 wells similarly corrected for by subtracting "blank well" readings).
Western Immunoblot Method
The antigenic proteins of a preparation were separated by sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) under reducing conditions, following which they were electroblotted onto nitrocellulose paper. The blotted antigenic polypeptides were then probed with T. foetus-specific serum from a hyperimmunized rabbit, as well as serum from an immunized cow, by Western immunoblot analysis.
EXAMPLE
A. Animal Immunization
1. Immunization of Rabbits
Three antigen preparations: 3400×g membrane lysate, flagellar fraction and whole cell lysate as described in section C above were used. Each of these was vaccine-formulated and used to immunize 1 rabbit as follows:
For the initial injection, the antigen was emulsified in complete Freund's adjuvant at a concentration of 1.0 mg protein/ml (Formulation 1). For subsequent booster injections, the antigen was formulated with incomplete Freund's adjuvant at the same protein concentration (Formulation 2). A total of 0.5 mg of T. foetus protein in a 1.0-ml delivery volume (one dose-equivalent) was administered s.c. at several sites in the prescapular dorsal region of the rabbit. The first injection (Formulation 1) was administered on day 0. The second injection (Formulation 2) was administered on day 21. The third and fourth injections (Formulation 2) were administered on days 35 and 42, respectively. The rabbits were bled at regular intervals following immunization and serum collected on day 49 (one week after the fourth injection) was used for: (i) assaying for T. foetus-specific antibody by the indirect fluorescent antibody (IFA) test, (ii) use in the antigenic analysis of the organism by the Western immunoblot method, and (iii) use in parasite agglutination and immobilization assays.
The IFA test was conducted on serum samples from each of the three hyperimmunized rabbits using intact T. foetus D1 organisms as the IFA test antigen to compare the surface binding properties of the sera.
The anti-T. foetus antibodies in sera from the 2 rabbits immunized with the `whole cell` and `membrane` lysates, respectively, recognized the entire surface of the parasite. Anti-T. foetus antibodies in hyperimmune serum from the rabbit that was immunized with the `flagellar fraction`, on the other hand, did not appear to recognize the flagellum as well as was expected, but demonstrated a weak recognition of the rest of the parasite. This indicates the presence of surface antigens in the membrane lysates.
The rabbit anti-whole cell lysate immune serum caused agglutination of the organism with an agglutination titer of 640 (Table I). Similar results were obtained with the anti-flagellum immune serum. The anti-membrane lysate immune serum did not exhibit significantly different results (agglutination titer of 320). Agglutination was visually scored as being greater or less than 50%. All pre-immunization serum samples used as a pool did not cause agglutination.
The parasite immobilization effect of the rabbit anti-whole cell lysate and anti-flagellum sera was not significantly different between the two antigenic preparations (immobilization titers of 160 and 80, respectively). On the other hand, the anti-membrane lysate immune serum did not seem to have any appreciable immobilization activity as it was not able to cause immobilization at a titer greater than the baseline value of 20. As was the case with agglutination, there was no immobilization activity in all the pre-immunization sera collected from these rabbits.
TABLE I______________________________________Results of Agglutination and Immobilization of T. foetus D1In Vitro by Hyperimmune Rabbit Serum..sup.1 T. foetus D1 Antigen Whole Cell Membrane FlagellarSerum Titer.sup.2 Lysate Lysate Fraction______________________________________0.sup.3 -- -- --20 A/I A/I A/I40 A/I A A/I80 A/I A A/I160 A/I A A320 A A A640 A -- A1280 -- -- --2560 -- -- --______________________________________ .sup.1 Each rabbit administered four s.c. injections of the respective antigen preparation at 14 to 28day intervals over a 96day period. .sup.2 Reciprocal of the highest serum dilution giving a positive reactio in the agglutination/immobilization assay. .sup.3 Preimmunization serum. A = >50% agglutination observed. I = 100% immobilization observed. -- = Neither agglutination nor immobilization observed.
Using the various T. foetus D1 antigen preparations described previously, it was observed that the agglutinating activity of anti-T. foetus whole cell lysate serum from a hyperimmunized rabbit was greatly depleted by the 830×g membrane lysate antigen (Table II). Incubation of this antigen with the rabbit anti-T. foetus whole cell lysate hyperimmune serum for 30 minutes at 37° C. resulted in greater than 50% inhibition of the serum's ability to agglutinate viable T. foetus organisms in 2 to 5 hours in vitro. This inhibitory activity was observable within 2 hours of incubation and persisted up to 5 hours for both the D1 and IDOWY41492 isolates of the organism. The 50×g membrane lysate antigen produced-similar results, while the whole cell lysate antigen did not appear to have the same effect as it was not able to inhibit agglutination after 3 hours of incubation. Similarly, the 50×g pellet had no antigenic activity at all, as evidenced by the fact that there was agglutination observed within 2 hours of incubation which lasted the entire observation period. Furthermore, this lack of inhibitory capability was comparable to that observed with T. foetus-positive serum which was not pre-incubated with any of the antigen preparations known to have inhibitory activity (i.e., ability to absorb T. foetus-specific antibodies from the immune serum). The T. foetus-negative pre-immunization serum remained negative for the assay. This indicates that the membrane lysate is more effective than the whole cell lysate in binding the antibodies elicited by whole cell lysate immunization.
TABLE II__________________________________________________________________________Results of T. foetus Agglutination Inhibition AssayUsing Hyperimmune Rabbit Serum Antigen - Serum Reaction Mixture Without Whole-cell 50 × g 50 × g 830 × gT. foetus Incubation Antigen lysate Pellet .sup.1 Supernatant .sup.2 Supernatantisolate time (Hrs) Pos. Neg. Pos. Neg. Pos. Neg. Pos. Neg. Pos. Neg.__________________________________________________________________________IDOWY41492 2 A -- a -- A -- a -- a --IDOWY41492 3 A -- A -- A -- a -- a --IDOWY41492 4 A -- A -- A -- a -- a --IDOWY41492 5 A -- A -- A -- A/a -- a --D1 2 A -- a -- A -- a -- a --D1 3 A -- A -- A -- a -- a --D1 4 A -- A -- A -- a -- a --D1 5 A -- A -- A -- a -- a --__________________________________________________________________________ .sup.1,2 Membrane Lysates. A = >50% agglutination observed. a = <50% agglutination observed. -- = Agglutination not observed with negative serum.
2. Immunization of Two Yearling Holstein Heifers
Two 9-month old heifers (#3628 and #3798) were immunized with the flagellar fraction and 830×g membrane lysate antigen of the T. foetus D1 isolate, respectively. These antigens were prepared as described previously, except that they were processed further as aforementioned in section C.
Each of the heifers was administered, in a 2.0-ml dosage volume, 0.45 mg of antigenic protein s.c. and 1.45 mg of protein intravaginally. They were immunized twice, 3 weeks apart.
The purpose of this experiment was to determine the effect of the two antigen preparations on the production of (i) T. foetus D1-specific serum IgG and (ii) T. foetus D1-specific vaginal secretory IgA.
Immune vaginal mucus samples collected from the 2 Holstein heifers exhibited a greater than 50% agglutinating activity from day 21 post-primary immunization (p.p.i.) through day 35 post-secondary immunization (56 days p.p.i.). This activity (Table III) was exhibited by the immune vaginal mucus at dilutions ranging from 1:20 21 days p.p.i. to 1:640 24 days post-secondary immunization (45 days p.p.i.). The activity then waned down to 1:160 on day 33 post-secondary immunization (54 days p.p.i.) and was back to the 1:20 level by day 35 post-secondary immunization (56 days p.p.i.). On the other hand, the immobilization activity of these vaginal mucus samples remained extremely low throughout the post-immunization observation period, with an observable immobilization activity of less than 50% at the lowest dilution factor of 5.
TABLE III______________________________________Results of Agglutination and Immobilization of T. foetus D1by Vaginal Mucus Of Two Immunized Holstein Heifers.sup.1Dilution Days Post-ImmunizationFactor 0.sup.2 21.sup.3 45 54 56______________________________________5 -- A/i A/i A/i A/i10 -- A A A A20 -- A A A A40 -- a A A a80 -- a A A a160 -- a A A a320 -- -- A a --640 -- -- A a --______________________________________ .sup.1 Combined data of two heifers; one immunized with the membrane lysate and the other with the flagellar fraction. .sup.2 Preimmunization samples. .sup.3 Second intravaginal dose administered. A = >50% agglutination observed. a = <50% agglutination observed. I = >50% immobilization observed. i = <50% immobilization observed. -- = Neither agglutination nor immobilization observed.
Referring to FIG. 3, A depicts the effect of pre-vaccination mucus on the growth of T. foetus in vitro. B and C depict, respectively, the effect of post-vaccination mucus of heifers #3628 and #3798. The organisms were grown at 37° C. in T-25 tissue culture flask containing 10 ml of culture medium by adding 100 μl of the appropriate vaginal mucus. While incubating, 2.5 ml was removed from the flask and replaced with equal volume of fresh medium daily. Incubation of viable T. foetus organisms at 37° C. in the presence of immune vaginal mucus obtained from the 2 Holstein heifers resulted in not less than 95% parasite growth inhibition in vitro, over a 4-day period, by the animal that received the `membrane lysate` immunogen (animal #3798). The other heifer (#3628) that was immunized with the `flagellar fraction` exhibited a parasite growth inhibition of approximately 40-60% over a 3-day period, and, by the 4th day of incubation this inhibitory activity had waned, as evidenced by the increase in the number of viable organisms in the culture. The non-immune pre-vaccination vaginal mucus samples were significantly less inhibitory for the growth of the parasite in vitro (15-55% inhibition of growth from day 2 through day 4 in culture), and this relatively steady decline in the viability of the organism was attributed to normal changes in culture conditions over time.
The 2 Holstein heifers immunized with the flagellar fraction and the membrane lysate of T. foetus D1 (heifers #3628 and #3798, respectively) were tested for T. foetus-specific serum IgG and vaginal mucus secretory IgA at varying time intervals following immunization, using the Dot-ELISA. Both animals responded similarly with respect to T. foetus-specific IgG in their sera (Table IV). By day 10 post-secondary immunization (31 days p.p.i.) their serum T. foetus-specific IgG levels had risen two to threefold, i.e., from a titer of 320 on day 21 p.p.i. to a titer of 1280 for heifer #3798 and 2560 for heifer #3628 on day 10 post-secondary immunization (31 days p.p.i.). This response remained high through day 33 post-secondary immunization (54 days p.p.i.) when it started to decline. The vaginal mucus T. foetus-specific secretory IgA responses of the 2 heifers, on the other hand, were varied. While the heifer that was immunized with the membrane lysate antigen (heifer #3798) became positive for T. foetus-specific secretory IgA by day 17 post-secondary immunization (38 days p.p.i.) and remained IgA-positive throughout the rest of the test period (day 35 post-secondary immunization; 56 days p.p.i.), the flagellar faction (heifer #3628) did not appear to be a good T. foetus-specific secretory IgA inducer. This heifer did not exhibit the presence of parasite-specific IgA until nearly the end of the test period (day 33 post-secondary immunization or 54 days p.p.i.). Thus the membrane lysate was more effective than the flagellar fraction in inducing secretory IgGA production in the vaginal mucus membrane.
TABLE IV__________________________________________________________________________Results of Dot-ELISA of Sera and Vaginal Mucus for IgA andSecretory IgA, Respectively: Two Heifers Immunized withDiffering Fractions.sup.1 of T. foetus D1SampleSerum Vaginal SecretionsDays Post-VaccinationAnimal #5 12 21 31 38 45 54 56 5 12 21 31 38 45 54 56__________________________________________________________________________3628 - 80.sup.2 320 2560 N/A.sup.3 1280 1280 640 - - ± ± ± ± + +3798 - ± 320 1280 N/A 1280 640 320 - - ± ± + + + +__________________________________________________________________________ .sup.1 Animal #3628 was immunized with the flagellar fraction and animal #3798 with the membrane lysate. .sup.2 Titer = reciprocal of the highest serum dilution giving a positive reaction in the DotELISA. .sup.3 N/A = Sample not available. + = T. foetus D1specific IgA detected. - = T. foetus D1specific IgA not detected.
3. Immunization of 9 Adult Holstein Cows, Effect of Adjuvants
Nine Holstein cows were immunized with T. foetus D1 antigen formulated with three different adjuvants for the purpose of comparing the effect of each adjuvant on the cow's vaginal mucosal immune response as measured by the presence of T. foetus-specific IgA in vaginal secretions following immunization. Similarly, the effect of the adjuvants on the production of T. foetus D1-specific serum IgG was examined. The organisms were washed, homogenized, and further processed as previously described. The subunit fraction was converted into an ISCOM as described before, divided into three equal portions and treated for use in three groups of 3 cows each as follows:
Group 1: was immunized with the ISCOM supplemented with RP as described previously;
Group 2: was immunized with the ISCOM supplemented with the B subunit of cholera toxin at a concentration of 70 μg/dose;
Group 3: was immunized with the ISCOM supplemented with sodium fluoride at a concentration of 100 mg/dose.
The quantity of antigenic protein used in this experiment was 0.5 mg of protein/dose for the s.c. route and 1.27 mg of protein/dose for the intravaginal route.
Among the 9 adult Holstein cows immunized with three different T. foetus D1 antigen preparations, only the 3 cows in Group 1 (immunized with ISCOM+RP) yielded satisfactory results. By day 25 p.p.i., all 3 animals in this group had turned positive for T. foetus D1-specific vaginal secretory IgA (Table V), and this immunoreaction was maintained through the rest of the examination period (i.e., day 30 post-secondary immunization or 55 days p.p.i.). On the other hand, in Group 2 and 3, all but 2 animals (#26, Group 2; and #17, Group 3) remained negative virtually throughout the entire 55-day examination period.
TABLE V______________________________________Results of Dot-ELISA of Vaginal Mucus for SecretoryIgA Following Vaccination of 9 Adult Holstein CowsDays Post- Group 1 Group 2 Group 3Vaccination #7 #13 #66 #16 #26 #67 #8 #17 #19______________________________________*0 - - - - - - - - -15 - ± - - - - - - -25 + + + + - - ± + -40 + + + - - ± + + -55 + + + - + - ± ± -______________________________________ *Day 0 = prevaccination samples collected on the day the first intravaginal dose was administered. The second intravaginal dose was administered on day 25 postprimary vaccination. IMMUNOGENS: Group 1 ISCOM + Retinol palmitate Group 2 ISCOM + Cholera toxin B Group 3 ISCOM + Sodium fluoride REACTIONS: + = T. foetus D1specific IgA detected. - = T. foetus D1specific IgA not detected.
4. Immunization of 8 Yearling Holstein Heifers, Effect of 2 Different Antigen Preparations
Eight yearling Holstein heifers were randomly divided into four groups of 2 animals each. Groups 1 and 2 were immunized with the 50×g membrane fraction, and Groups 3 and 4 with the 830×g fraction. The immunogens (antigens for immunization) were prepared as already described except that OBDG was used at 70 mM, solubilization carried out for 2 hours, and the excess OBDG and saponin were removed by tangential flow ultrafiltration using the Mini-Tan™ (Millipore) system equipped with a 10 kD filter. For each preparation, 0.5 mg of protein/dose were administered s.c. and 1.0 mg of protein/dose was administered intravaginally. Two T. foetus IDOWY41492 antigen preparations and three different preservatives were used. The preparations were: ISCOM+formalin 0.1% (w/v)! and ISCOM+methiolate (1:10 000) for the s.c. route, and ISCOM-RP+formalin 0.1% (w/v)! +methiolate (1:10 000) and ISCOM-RP+methiolate (1:10 000)+glycerol 25% (v/v)! for the intravaginal route). Each dose was delivered in a 2.0-ml volume and each animal received two doses; the first dose administered on day 0 and the second dose on day 22 post-primary immunization. On days 14 and 7 pre-vaccination, serum and vaginal mucus samples were collected from all the animals and verified to be negative for T. foetus-specific antibodies.
On day 37 post-secondary immunization, each animal in the four groups of 2 heifers per group was artificially challenged intravaginally with approximately 1.0×10 7 viable, culture-derived, T. foetus organisms in a 3.0-ml delivery volume, using a 5 c.c. syringe to which an artificial insemination pipette was attached. In addition to the 8 vaccinated heifers, 2 non-vaccinated control heifers were similarly exposed to 1.0×10 7 viable T. foetus organisms per vaginum. Beginning one week following administration of the challenge dose, vaginal mucus samples were collected weekly for six weeks from all 10 heifers for the isolation of the parasite in vitro.
The 8 Holstein heifers that were immunized, in two groups of 4 animals per group, with two different subunits of the T. foetus IDOWY41492 membrane lysate exhibited identical serological responses when tested against homologous T. foetus antigens by the standard ELISA (Table VI). By day 14 p.p.i., every animal tested had an ELISA titer of at least 640, with the titers ranging from 640 to 2560. These titers increased two- to four-fold by day 12 post-secondary vaccination (34 days p.p.i.), and remained high for both groups (1280-10 240) throughout the remainder of the examination period (i.e., days 35 through 54 p.p.i., or 13 through 33 post-secondary immunization).
TABLE VI______________________________________Standard ELISA Results of Serological Responses of 8 HolsteinHeifers to Two Subunits of T. foetus IDOWY41492 Membrane AntigenAnimal Days Post-Vaccination#.sup.1 0.sup.2 14 22 28 34 42 49 54______________________________________20 - 1280.sup.3 1280 2560 10240 5120 2560 512021 - 2560 2560 5120 10240 10240 5120 512022 - 640 5120 5120 20480 10240 10240 1024023 - 1280 5120 5120 10240 10240 10240 512034 - 1280 640 320 1280 1280 640 64035 - N/A.sup.4 160 1280 5120 2560 2560 128038 - 640 320 640 2560 2560 2560 128039 - N/A 1280 2560 5120 5120 5120 2560______________________________________ .sup.1 Animals #20--#23 were immunized with the 50 × g membrane lysate, and animals #34, #35, #38 and #39 were immunized with the 830 × g membrane lysate. .sup.2 Day 0 = prevaccination samples collected on the day the first s.c. dose was administered. The second s.c. dose was administered on day 22 postprimary vaccination. .sup.3 Titer = reciprocal of the highest serum dilution giving a positive reaction in the standard ELISA; - = negative. .sup.4 N/A = Sample not available.
Testing of the 8 heifers by Dot-ELISA, for T. foetus-specific secretory IgA in their vaginal mucus following immunization with the respective membrane subunits revealed that by day 14 p.p.i. most of the animals had already started to express parasite-specific IgA in their vaginal secretions (Table VII). This became more evident by day 22 p.p.i., when 3 of the 4 animals that were immunized with the 50×g membrane subunit became conclusively positive, and all 4 animals that received the purer 830×g membrane subunit were similarly positive. this secretory IgA activity for T. foetus IDOWY41492 remained evident through the end of the examination period (day 54 p.p.i. or 32 post-secondary vaccination) for the latter group of animals, while only 2 of the 4 animals in the former group continued to exhibit some activity through the 27th day post-secondary vaccination (day 49 p.p.i.), with the other 2 showing no activity at all by the end of the examination period.
TABLE VII______________________________________Results of Dot-ELISA of Vaginal Secretory IgA Responses of 8 HolsteinHeifers to Two Subunits of T. foetus IDOWY41492 Membrane Antigen Days Post-VaccinationAnimals #.sup.1 0.sup.2 14 22 28 34 42 49 54______________________________________20 - + + + + + ± -21 - - ± + + + + +22 - ± + + + + + ±23 - - + + + + ± -34 - ± + + + + + +35 - + + + + + + ±38 - ± + + + + + +39 - ± + + + + + ±______________________________________ .sup.1 Animals #20-#23 were immunized with the 50 × g membrane lysate, and animals #34, #35, #38 and #39 were immunized with the 830 × g membrane lysate. .sup.2 Day 0 = prevaccination samples collected on the day the first intravaginal dose was administered. The second intravaginal dose was administered on day 22 postprimary vaccination. + = T. foetus IDOWY41492specific IgA detected. - = T. foetus IDOW41492specific IgA not detected.
Test results of the standard ELISA performed on the vaginal mucus samples collected revealed that all 8 vaccinated animals expressed T. foetus-specific IgG, antibody in their vaginal secretions throughout the 54-day examination period, beginning on day 14 p.p.i. (Table VIII). The animals that were immunized with the cruder 50×g membrane subunit showed a stronger IgG, response than those that received the purer 830×g subunit.
TABLE VIII______________________________________Standard ELISA Results of Vaginal Mucus IgG.sub.1 Responses of 8HolsteinHeifers to Two Subunits of T. foetus IDOWY41492 Membrane Antigen Days Post-VaccinationAnimal #.sup.1 0.sup.2 14 22 28 34 42 49 54______________________________________20 - + + + + + ± ±21 - + + + + ± ± ±22 - ± + + N/A.sup.3 + + +23 - + + + + + + +34 - + + + ± ± ± ±35 - ± + ± + ± + +38 - + + ± + ± ± ±39 - ± ± + + + + +______________________________________ .sup.1 Animals #20-#23 were immunized with the 50 × g membrane lysate, and animals #34, #35, #38 and #39 were immunized with the 830 × g membrane lysate. .sup.2 Day 0 = prevaccination samples collected on the day the first intravaginal dose was administered. The second intravaginal dose was administered on day 22 postprimary vaccination. .sup.3 N/A = Sample not available. + = T. foetus IDOWY41492specific IgG.sub.1 detected. - = T. foetus IDOWY41492specific IgG.sub.1 not detected.
Having detected the presence of T. foetus-specific secretory IgA and systemic IgG 1 in the post-vaccination samples of vaginal mucus collected from the 8 Holstein heifers, the samples were tested for agglutination and immobilization activity. The test results (Table IX) revealed that by day 20 post-secondary vaccination (42 days p.p.i.), all the animals that were immunized with the 830×g membrane subunit were positive for T. foetus agglutinating and immobilizing activity, which was at a greater than 50% level and was maintained through the end of the test period (day 32 post-secondary vaccination or 54 p.p.i.). On the other hand, the 50×g membrane subunit group of animals did not show any significant activity over the same post-vaccination period of examination, as all of them exhibited, on average, an agglutination and immobilization activity of less than 50%.
TABLE IX__________________________________________________________________________Summary of Results of Agglutination and Immobilization of T. foetusIDOWY41492by Vaginal Mucosal Secretions from 8 Holstein Heifers Post-VaccinationDaysPost- #20.sup.1 #21 #22 #23 #34 #35 #38 #39Vaccination A I A I A I A I A I A I A I A I__________________________________________________________________________0.sup.2 - - - - - - - - - - - - - - - -28 N/A.sup.3 N/A N/A N/A - - - - N/A N/A - - - - N/A N/A34 N/A N/A N/A N/A ± ± ± ± N/A N/A ± ± - - N/A N/A42 ± ± + + + + ± ± + + + + + + + +49 ± ± ± ± ± ± ± ± + + + + + + + +54 + + ± ± ± ± ± ± + + + + + + + +__________________________________________________________________________ .sup.1 Animal I.D. number (n = 8). .sup.2 Day 0 = prevaccination samples collected on the day the first dose was administered intravaginally. The second intravaginal dose was administered on day 22 postprimary vaccination. Animals #20-#23 were immunized with the 50 × g membrane lysate antigen, and animals #34, #35, #38 and #39 with the 830 × g membrane lysate antigen. .sup.3 N/A = Sample not available. A+ = >50% agglutination observed. A- Agglutination not observed. I+ = >50% immobilization observed. I- = Immobilization not observed.
Following artificial intravaginal challenge of the 8 vaccinated heifers and 2 controls with 1.0×10 7 viable T. foetus IDOWY41492 organisms, vaginal mucus samples were collected weekly beginning on day 7 post-challenge (p.c.) and incubated in T. foetus culture medium at 37° C. for 48 hours and examined for the presence of the parasite. Sample collection and incubation was done through day 37 p.c., when the examination of the animals was concluded. Results of the 48-hour incubations (Table X) showed that within one week of the challenge, all the animals, vaccinates plus non-vaccinated controls, had become infected with T. foetus IDOWY41492. Further weekly attempts to isolate the organism from these animals beyond day 7 p.c. revealed that by day 23 p.c. the infection was completely cleared by the group of heifers that was immunized with the 830×g membrane subunit, while the group that received the 50×g subunit as immunogen did not clear the infection until day 30 p.c. the non-vaccinated controls, on the other hand, remained infected throughout the six weeks of examination (i.e., the organism was isolated from both control heifers on day 37 p.c.).
TABLE X______________________________________In vitro *Isolation of T. foetus IDOWY41492Following Intravaginal Challenge of Each of 10Holstein Heifers with 1.0 × 10.sup.7 Parasites Days Post-ChallengeAnimal # 7 11 16 23 30 37______________________________________20 + + + + - -21 + + + + - -22 + + + - - -23 + + + - - -34 + + + - - -35 + + + - - -38 + + + - - -39 + + + - - -**68 + + + + + +**69 + + + + + +______________________________________ *48-hour incubation of vaginal mucosal samples. **Nonvaccinated controls. + = Organism isolated in culture. - = Organism not isolated in culture.
These experiments show that it is possible to induce the production of T. foetus-specific systemic and vaginal antibodies which can synergistically act to eliminate the infection. These experiments further indicate that with use of the proper combination of T. foetus antigen plus adjuvant(s), and the dual immunization by the parenteral (e.g., s.c.) and intravaginal routes, it is possible to stimulate the production of parasite-specific serum IgG, as well as parasite-specific vaginal mucosal secretory IgA, antibodies which are protective against T. foetus infection. Specifically, T. foetus-specific secretory IgA appears to work in a synergistic manner with T. foetus-specific IgG, and other subclasses of IgG (possibly IgG 2 ) which are found in vaginal mucus of vaccinated animals, presumably as components of the inflammatory transudate. The use of a purified membrane subunit fraction of the organism complexed with Quil-A saponin (ISCOM) and fortified with the immunopotentiating compound, retinol palmitate, appears to be the most effective way to induce solid immunity to infection with T. foetus. Attempts to isolate the organism from the heifers that were immunized with the most purified subunit of the parasite's membrane and then artificially challenged with an extremely high dose of T. foetus, yielded negative results. The protection of the host against infection with T. foetus, therefore, is dependent on the expression of specific IgA antibodies in the lower reproductive tract prior to the onset of the infection. The present invention is the first vaccine of its kind capable of inducing the production of parasite-specific secretory IgA antibody in the absence of an active infection.
5. Immunization of Bulls
Twelve 4-year old Black Angus bulls were randomly divided into 2 groups of 8 vaccinates and 4 non-vaccinated controls. All the bulls were confirmed T. foetus culture-positive at 4 and 2 weeks prior to treatment.
The subunit vaccine was prepared as described in section 4. above. Eight of the 12 infected bulls were vaccinated s.c. and treated intrapreputially on days 0 and 29. For s.c. administration, only the ISCOM was used at 0.5 mg of antigenic protein per dose in a 2.0-ml volume, while ISCOM-RP in glycerol was administered intrapreputially at 1.0 mg of antigenic protein in a 5.0-ml delivery volume. Preputial samples for parasite isolation in vitro were collected from 6 vaccinates and 3 controls in transport medium on days 19 and 33 after the administration of the second dose.
Culturing of the preputial samples for the isolation of the organism in vitro revealed that by day 19 post-secondary treatment (day 48 post-primary treatment), when the first sample was collected, all 6 treated bulls had cleared the infection, while the 3 non-treated controls were culture-positive for T. foetus. Repeat sampling 14 days after the first collection (day 33 post-secondary treatment) revealed that the 3 control bulls were still harboring the infection, while the 6 bulls that had cleared the infection within 19 days following secondary treatment remained culture-negative for T. foetus.
The results of the experiment described above clearly show that the protection conferred by the synergistic effect of local and systemic immune stimulation has caused actual elimination of T. foetus from the infected bulls. This finding suggests that a complete resolution of the natural infection was achieved as a direct result of the use of the subunit vaccine as an `immunotherapeutic.` Until now, chemotherapy has been the only means of treating T. foetus-infected bulls, albeit with unpredictable results. The immunotherapy for bovine trichomoniasis using the present invention represents a safer method of controlling T. foetus infection, with a potentially longer lasting effect.
The aforementioned experiments clearly demonstrate the effectiveness of the invention in immunization against the infection of T. foetus. The invention may be practiced otherwise than as described without departing from its spirit. These experiments are not to be interpreted as limiting the scope and claims of the invention, which are defined by the appended claims: | A subunit vaccine for Tritrichomonas foetus and method for preparing such vaccine for use in immunizing and treating animals is provided. The method disclosed involves separating out the antigens by centrifuging homogenized Tritrichomonas foetus cells, preferably at about 830×g for about 15 minutes, solubilizing the antigen with an nonionic detergent and completing with saponin. Topical administration, such as intravaginal or intrapretutial administration, of such vaccine preparation in conjunction with subcutaneous administration in combination with other adjuvants is effective to eliminate infection. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a method and an apparatus for measuring freeness of paper stock to be fed to a paper machine during paper making process. This freeness indicates the rate of drainage of the stock on wire cloth of the paper machine. The method and apparatus makes it possible to automatically and continuously measure the freeness of the stock on the way to the paper machine or at a place where the stock is prepared.
Previously, paper stock has been treated by a beater or other similar refining equipment. The extent of beating has been measured by taking out a test sample of the stock from the beater and measuring the freeness thereof by a conventional freeness tester such as a Schopper-Riegler or Canadian Standard type freeness tester; the beating has been continued until the desired degree of beating is obtained. Recently, the refining process has been improved so that it can be performed continuously and automatically; furthermore, refined stock is sent to machine room directly and automatically. Thus, it has become necessary to measure the freeness automatically during the process, for example by taking out a sample from a feeding pipe connected to the paper machine room or from stock chest at an intermediate portion of the feeding pipe. Thus the freeness measurement of the stock in the continuous flowline now employs the steps of periodically sampling from the feeding pipe an adequate amount of sample, screening the sample and measuring the filtrate or screened water, by volume or weight, which passes through a screen during a predetermined time (usually 10 to 60 seconds). The quantity of filtrate is the index of freeness.
However, in the conventional measuring system mentioned just above, the value of the freeness varies according to variance in consistency and/or temperature of the stock. Therefore, the consistency and the temperature of the stock must be inspected from time to time and the obtained value of the freeness must be adjusted for these factors. Furthermore, according to such a measuring system, accurate measurement of the freeness of any paper stock which has been refined or beaten to a considerably high degree is impossible, since in such stock the difference in freeness is hardly detectable even if the degree of refining or beating treatment of the stock is changed.
A similar method is also applied in the feeding pipe by introducing the paper stock into a freeness tester by means of fluid pressure in the feeding pipe, and measuring the quantity of filtrate passing through a screen during a predetermined time. In such a way, the filtrate must be discharged and the fibrous mat of the paper stock left on the screen must be removed before the next test begins. However, the filtrate contains fine fibers and size, and counter flow cleaning causes the fine fibers and size to stick to the back side of the screen. Such a phenomenon is likely to cause error in the next test. Therefore, the screen must be dismounted and cleaned from time to time and the consistency of the stock in the feeding system is varied because of white water flow into the feeding pipe.
SUMMARY OF THE INVENTION
This invention is to eliminate the aforementioned problems in the measurement of the freeness of stock which flows in a continuous feeding line.
Therefore, an object of the invention is to provide a method and an apparatus for measuring the freeness in which there is substantially no error in test data resulting from variation in consistency and/or temperature of the stock.
Another object of the invention is to provide a method and an apparatus for measuring the freeness in which the obtained data gives an accurate indication of the rate of refining or beating of the stock which has been refined to a relatively high degree.
A still further object of the invention is to provide a method and an apparatus for measuring the freeness of stock in which a sample taken out in every test is discharged out of the stock feeding line without adversely affecting the consistency of stock in the feeding line; and the stock stuck to a filter screen may be also completely removed.
For achieving the aforementioned objects, in this invention, a collected sample is diluted with water. For accurate measurement, it is necessary to uniformly disperse stock in the water. In this invention, the uniform dispersion is obtained in short time by injecting pressurized air into the suspension. Hitherto, in the technical field of the paper making, especially measurement of the freeness, it has never been considered to agitate such suspension by using pressurized air thereinto since air bubbles adhere to the fibers in the suspension. However, the inventors of this application confirmed that even if air is employed for agitation, accurate measurement of freeness can be performed by maintaining constant air blowing conditions such as pressure and quantity of the air and also keeping constant consistency of the stock. The thus obtained liquid in which the stock is evenly diluted by the agitation of the air is then filtered or drained through a screen. Preferably, slight pressure is applied to the stock suspension liquid during this filtration. The freeness of the stock is measured as the quantity of the liquid which has drained from the slurry or stock suspension liquid in a predetermined time. After the measurement, the apparatus is fully flushed by water suppled by water jet nozzles at least one of which is to direct a jet of cleaning water on the back side the screen. Thereafter, all liquid in the apparatus, including the cleaning water, is fully discharged from the apparatus.
According to the present invention, since the test sample is diluted, variations in the consistency and temperature of the diluted sample are negligible, even if the consistency and temperature of the stock in the flow line varies substantially. Thus, accurate test results may be effected. If underground water, the temperature of which is relatively invariable is used, the feature mentioned just above is made even more significant. Still better results may be obtained by using water of constant temperature. By the dilution as mentioned above and in addition thereto the screening of the diluted sample, preferably under slight pressure, the difference in the freeness can be sensed according to the difference in the degree of refining of the stock even in the measurement of the freeness of the stock refined to a considerably high degree, measurement of which has hitherto been impossible. Furthermore, in accordance with the present invention, the uniformity of the diluted suspension is obtained in a short time by air agitation. While this invention realizes the aforementioned superior advantages, a full test cycle is performed in short time. The time for a test cycle is shortened further if the screening is operated under slight pressure.
The features of the invention will be made clear in more detail by the following description referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a portion of an example for diluting and agitating a test sample in this invention:
FIG. 1A is a sectional view of a modification of the plunger of the pump employed in the apparatus shown in FIG. 1; and
FIG. 2 is a schematic illustration showing the relation between the portion for dilution and agitation which is taken along the line II--II in FIG. 1 and a cylinder for measuring the quantity of liquid.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the apparatus for measuring the freeness according to this invention comprises a dilution and agitation tank 1 having a lid 2 on which a liquid level sensor 3, a pipe 4 for introducing pressurized fluid and a water jet nozzle 5 for flushing the interior of the tank are mounted. The lower portion of the tank forms a cylindrical portion 6 which is normally attached to a stock feeding pipe 26. A plunger 7 of a pump P for taking out a test sample is associated with the cylindrical portion 6. The plunger 7 is operated by an actuating cylinder 8. At the center of the bottom of the cylindrical portion 6, a drain pipe 9 is attached which is provided with a pipe 10 for supplying dilution water and a pipe 11 for pressurized air for agitation. As is shown in FIG. 2, a screen 13 for measuring the freeness is connected to the side portion of the cylindrical portion 6 with a communication valve V1 therebetween. At the back side of the screen 13, a filtrate case 14 is fitted, which is provided with a water jet nozzle 15 for flushing the screen and a filtrate outlet 16 at the bottom thereof.
A cylinder 17 for measuring the quantity of the filtrate is made of transparent material such as glass or plastic and is provided with a scale. At the bottom of the measuring cylinder 17, a filtrate conduit 18 is provided and is connected with the outlet 16. The measuring cylinder 17 has a cleaning water jet nozzle 19 at the lid thereof and a drain valve V2 at the bottom thereof. A drain valve V3 is provided in pipe 9 which works in the same manner as that of valve V2. These valves are adapted to be automatically opened and closed by suitable sequencing means. While any conventional device may be used for measuring the quantity of the liquid in the measuring cylinder, in the embodiment illustrated in the drawings, the quantity of the liquid accumulated in the measuring cylinder 17 during a predetermined time period is determined by a low pressure gauge 21 provided at the bottom of the cylinder. In such case, it is possible to obtain electric signals by an electrical transducer and to indicate the output by a pointer needle.
In the procedure for the freeness test, a valve V4 is first released to introduce water through the dilution water pipe 10 into the dilution and agitation tank 1 until a predetermined amount of the water is obtained. The predetermined amount is sensed by the liquid level sensor 3. Even if stock of different consistency is fed through feeding pipe 26, either of following two procedure can be adopted. One is to keep the consistency of the diluted sample constant by adjusting the quantity of the dilution water according to the consistency of the stock through re-setting of the liquid level sensor. The other is to keep the quantity of the dilution water constant allowing the consistency of the diluted sample to vary according to the variation in the consistency of the stock and to calibrate the test data against the consistency of the stock. Then, a fixed amount of the paper stock fed through the feeding pipe 26 is taken out therefrom and introduced into tank 1 by the actuation of the plunger 7 of the sample take out pump P. Thereafter, pressurized air for agitating of the paper stock is injected into the tank through the air pipe 11 by opening a valve V5, whereby the stock are evenly dispersed in the water. During the introduction of the air, the air is released to the atmosphere through a pipe 4 by opening a valve V6 so that the interior of the tank is kept off air pressure during air agitation.
Any type of pump may be applied to the stock sampling. The pump P illustrated in FIG. 1 is one example in which the sample gathering portion C is defined by discs 23 and 24 mounted on the plunger 7. The size and configuration of the discs 23 and 24 are such that they intimately and slidably engage the inner wall of a sample quantifying portion 6' provided as a part of the cylindrical portion 6. When a sample is to be taken out, the plunger is shifted rightward by the effect of the fluid introduced into the cylinder 8 to the extent that disc 23 reaches the position indicated by dotted line X, whereby portion C is exposed in the stock in the flowing line 26. Then, the plunger 7 is returned to the initial position. Quantification of the sample is effected when both of the discs 23 and 24 reside in the quantifying portion 6' on the return stroke of the plunger. By this quantification, a fixed amount of sample is introduced into the tank 1. The disc 25 forms a cover for positively preventing the stock in the feeding pipe from going into the tank 1 even if the pump is left in an inoperative position for a long time. The disc 25 may be eliminated by modifying the plunger to the structure shown in FIG. 1A in which a disc 24' is accompanied with a seal member such as an oil seal S which is excellent in sealing function and enhances the sealing effect thereof.
After all the sample has been put into the tank 1, pressurized air is supplied to the tank for a predetermined time. Agitation by pressurized air insures that the components in the sample stock are evenly dispersed in the water in the tank 1 (including the cylindrical portion 6), and a uniform dispersion is obtained in a short time. Thereafter, the valve V1 communicating with the case 14 is opened and thereupon the interior of the apparatus is isolated from the atmosphere by closing the valve V6. At the same time, slight pressure is caused by opening a valve V7 through the air intake pipe 4 and under such conditions, the sample is screened through the screen 13. The liquid which passes through the screen 13 is delivered to the measuring cylinder 17 through an outlet 16 and a conduit 18. After a predetermined time, the supply of the pressurized air is stopped and the valve V8 at the inlet of the cylinder 17 is closed. Now, the freeness can be obtained by measuring the quantity of liquid in the cylinder 17. The quantity of liquid in the cylinder may be measured by sensing the pressure relating to the quantity of the liquid by the pressure gauge positioned at the bottom of measuring cylinder 17 and transforming the sensed pressure into electric signals to supply as an input to a recorder, or by feeding air to the measuring cylinder through the valve V9 and measuring the back pressure thereof.
Upon completion of the test or measurement, the valves V2 and V3 associated with the drain pipes, respectively, are opened. At the same time, flushing water is spouted from the water nozzles 5, 15 and 19 for cleaning the dilution and agitation tank 1 (including cylindrical portion 6), screen 13 and measuring cylinder 17. The wash liquid remaining after the cleaning is discharged from the system through the drain valves. During the cleaning, the screen 13, which is the most important part of the apparatus, is cleaned by the nozzle 15 which is positioned at the back side area of the screen and arranged to be normal to the surface of the screen. Therefore, the components of the paper stock which have been deposited on the screen 13 to form a mat are easily peeled therefrom and discharged from the apparatus. The flush water is stopped after sufficient cleaning, and the drain valves V2 and V3 and the valve V1 communicating with the measuring device are closed for the subsequent cycle of the test. The operations explained above may be effected automatically and repeatedly by suitable sequence control means.
In the test, the quantity of water used for dilution and the quantity of air used for agitation is varied according to differences in the kinds of cellulose used, degree of refining or beating treatment and the consistency of the stock. Generally, a standard wire screen are used. The optimum test conditions can be achieved by selecting a screen of appropriate mesh. By using a screen which is the same as that actually used in a paper machine, the test may be adapted to meet the actual production.
One example of test conditions using the apparatus of this invention is listed in the table given below.
______________________________________items condition______________________________________consistency of sample 0.1 - 0.3%pressure of air used foragitation 3 - 5 kg/cm.sup.2air pressure for screening 0.1 - 0.2 kg/cm.sup.2pressure of flushing water 3 - 6 kg/cm.sup.2dimension of apertures ofscreen 177μ______________________________________
The draining portion is not arranged to be vertical or horizontal but is inclined to some extent as shown in the drawings so that the outlet 16 is positioned at the lowermost portion thereof. By this arrangement, all of the screened or drained liquid can be fed from the measuring portion to the measuring cylinder thereby minimizing test error. Furthermore, if water for industrial usage such as underground water and constant temperature water is used, the error in the test result is limited to within 1%. Furthermore, the method and the apparatus enables one to accurately test the freeness of the stock which is treated or refined to considerably high degree. | An apparatus for accurately measuring the freeness of paper stock in a short time is disclosed.
The apparatus comprises a pump and plunger which take a sample of stock from a flowline or a place in which paper stock is prepared and places the sample in an agitation tank. A water supply dilutes the sample in the agitation tank to a predetermined consistency and a first pressurized air supply agitates the diluted sample so that fibrous material in the stock is evenly dispersed in the water. The agitation tank is closed to the atmosphere and a second pressurized air supply provides a pressure in the tank for draining the liquid from the sample through a screen. The liquid which passes through the screen is delivered to a measuring cylinder. | 3 |
FIELD OF THE INVENTION
The field of the invention relates to guiding means for a spinning projectile. More particularly, the present invention relates to an optical guiding seeker for a spinning projectile which is based on a shaped opening within the projectile.
BACKGROUND OF THE INVENTION
Optical seekers for use in guidance of spinning projectiles or spinning missiles (hereinafter, when the term “projectile” is used, it should be understood that it relates also to a “missile”, and vice versa, when the term “missile” is used, it should be understood that it relates also to a “projectile”) are known in the art. Such a seeker generally senses during the projectile flight light that is emitted or reflected from the target, and produces a signal, which is proportional to the deviation of the projectile direction from correct course toward the emitted light, i.e., the target. The correcting signal is then conveyed to a guiding or correcting unit within the projectile, which in turn performs the required course correction.
WO 98/31978 discloses a reticle for use in a guidance seeker for a spinning projectile. The projectile has a front opening, through which the light from the target can enter, and an essentially cylindrical hollow behind said opening in which the reticle and some additional optical elements are disposed. On the reticle, opaque lines are disposed in a specific manner. Light coming from the object and passes through the reticle is interrupted on its way to a light sensor by said lines due to the spinning of the projectile, therefore producing a modulated light signal which is relative to the deviation of the projectile direction from the route to the target. This modulated light, when sensed by a light sensor suitable for sensing light in the relevant wavelength, can be used for correcting the projectile route toward the target. The arrangement as suggested in WO 98/31978 is well suited for analog signal processing. This is particularly due to the form of the signals produced by the seeker of WO 98/31978, signals which are generally Pulse Width Modulated (PWM) signals. Other publications disclose reticles which produce AM signals that can be interpreted in a similar manner.
It is an object of the invention to provide a seeker for use in guiding a spinning projectile, which is very simple, compact in structure, and more suitable for digital signal processing.
It is still another object of the present invention to simplify the manner and circuitry needed for the processing of the output signals.
It is another object of the invention to provide a seeker for use in guiding a spinning projectile, which can be mounted on a projectile or missile having essentially any caliber.
It is still another object of the invention to provide a seeker for use in guiding a spinning projectile, in which the number of optical and electrical elements is reduced to a minimum.
It is still another object of the invention to provide a seeker for use in guiding a spinning projectile, which is simple to manufacture.
Other objects of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
The present invention relates to a projectile seeker which comprises: (a) A hollow in the projectile for accommodating a light sensor; (b) A light sensor located within said hollow for sensing light which is emitted or reflected from a target, and for producing an electronic signal upon sensing such emitted light; and (c) A longitudinal shaped opening at the slanted front-side surface of the projectile for enabling a shaped field of view to said light sensor which is limited by the boundaries of said opening, the opening width varies in a direction from the front to the back of the projectile in order to cause said electronic signal to depend on the spinning of the projectile and to be proportional to the orientation of the projectile with respect to the object.
Preferably, in transversal cross section of the projectile, at least one boundary of the shaped opening is at most only partially, if at all coincides, with an imaginary radial line in said the transversal cross-section.
Preferably, the opening is covered, and the cover is transparent to only a specific light wavelength.
Preferably, the seeker comprises a filter for allowing passage of light only in a specific wavelength to the light sensor.
Preferably, the wavelength of the emitted or reflected light is specific, and the said light sensor is limited to sense light only in said specific wavelength.
Preferably, the projectile is further provided with a processor for receiving said electronic signal and for calculating from said electronic signal one or more correcting signals that are provided to a flight correcting unit within the projectile.
Preferably, the flight correcting unit is capable of correcting the projectile flight based on said correcting signals.
Preferably, the flight correcting unit comprises one or more jets around the projectile, and wherein said correcting signals determine the jets for activation, time of activation, and amount of thrust to be produced by each jet.
Preferably, the flight correcting unit comprises wings whose locations and/or orientations are changed based on said correcting signals.
Preferably, the width of the opening is increased in the direction from the front to the back of the projectile. Preferably, the opening width increase is non-linearily changed in the direction from the front to the back of the projectile.
Preferably, the width of the opening is decreased in the direction from the front to the back of the projectile. Preferably, the opening width decrease is non-linearily changed in the direction from the front to the back of the projectile.
The invention also relates to a projectile seeking system which comprises a seeker as described, and a light pointer for impinging light on the target, and wherein the light sensor of the seeker is adapted to sense light in the wavelength of the light produced by the light pointer.
Preferably, the wavelength of the emitted or reflected light is within the UV bandwidth.
Preferably, the wavelength of the emitted or reflected light is within the IR bandwidth.
Preferably, the seeker is further provided with timer means for determining the time of activation of the processor.
Preferably, said timer means is fed with the range to the target and with the projectile velocity prior to shooting, in order to determine said processor activation time.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 illustrates in general the system and object of the invention;
FIG. 2 shows a side view of a projectile, according to an embodiment of the invention;
FIG. 2 a shows a front view of a projectile, according to an embodiment of the invention;
FIG. 2 b shows a rear view of a projectile, according to an embodiment of the invention;
FIG. 3 shows how the error in the deviation, or error, in the accuracy of direction is determined;
FIG. 4 shows a front view of a projectile according to a first embodiment of the invention;
FIG. 4 a shows signals corresponding to the shape of the cover of FIG. 4 , which can be used for the determination of the accuracy of direction;
FIG. 5 shows a front view of a projectile according to a second embodiment of the invention;
FIG. 5 a shows signals corresponding to the shape of the cover of FIG. 5 , which can be used for the determination of the accuracy of direction;
FIG. 6 shows a front view of a projectile according to a third embodiment of the invention;
FIG. 6 a shows signals corresponding to the shape of the cover of FIG. 6 , which can be used for the determination of the accuracy of direction; and
FIG. 7 illustrates in block diagram form the procedure for providing flight correction to a projectile, according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 briefly illustrates the targeting procedure which is performed according to an embodiment of the present invention.
According to an embodiment of the present invention, a light source or pointer 7 is used for marking a point of light on the target. Such light pointer may be, for example, a laser or infra-red source capable of transmitting a narrow and concentrated light ray. The light pointer may be mounted, for example, on the projectile launcher 8 , but this is not a requirement, as it may be separated thereof, for example, the pointer may be operated by another party. Alternatively, the invention may operate with a light which is emitted from the target. The invention can operate as long as a light-point exists on the target or emitted by it, and is noticeable by a light sensor located within the projectile. The pointer light is preferably limited to a specific wavelength, distinguished from the surrounding light.
In the embodiment of FIG. 1 , a light pointer 7 is provided on launcher 8 . Before launching the projectile, the user directs the launcher 8 and pointer 7 towards a target, and turns on the pointer light, which in turn produces a target 4 . Then, the user launches the projectile 17 . The projectile 17 generally goes along a trajectory 16 in its route towards the target (indicated by target light spot 4 ). An object of the invention is to determine, some distance before the target 4 , the deviation of the projectile 7 from the route to the target, and to provide correction that will direct the projectile to hit or as close as possible, or at least closer to target 4 . For example, launching projectile along trajectory 16 with no intervention will provide hitting at point 12 relatively far from target 4 . According to the present invention, when such a deviation from the target is determined, for example while the projectile is at point 13 , a correction is made in order to deviate the projectile 7 to a corrected route 18 that will result in hitting at point 19 much closer to target 4 .
FIGS. 2 , 2 a and 2 b show a general structure of the projectile 17 according to an embodiment of the present invention. FIG. 2 a shows a front view of the projectile, and FIG. 2 b shows a rear view of the projectile. The projectile 17 is provided with a shaped, transparent opening 21 which is made on the slanted front-side surface of the projectile, and a hollow 32 in which a light sensor 22 is positioned. The projectile is provided with an optical arrangement (not indicated) causing the light emitted from the target 4 (see FIG. 1 ), which is impinged on any portion of opening 21 to arrive sensor 22 . Such optical arrangement may include conventional optical elements, such as one or more lenses, mirrors, etc. The cover 21 , or optionally the optical arrangement or the sensor 22 itself generally include a filter that transfers light selectively, i.e., only in the spectrum of light spot 4 . For example, if a laser pointer is used to produce light spot 4 , the filters allows only laser light to pass, and the sensor senses only light in the laser spectrum.
Therefore, light from the target 4 reach sensor 22 as long as any portion of cover 21 faces light spot 4 . On the other hand, dark is sensed by sensor 22 as long as no portion of cover 21 faces the light spot 4 .
The present invention assumes the following assumptions:
1. The longitudinal velocity vector of the projectile is essentially constant (at least during the relevant time of the measurement needed for the correction determination) 2. The angular velocity of the projectile is essentially constant (at least during the relevant time of the measurement needed for the correction determination); 3. The velocity vector of the projectile coincides with the longitudinal axis x (see FIG. 2 ) of the projectile.
FIGS. 4 , 5 , and 6 show three examples for the shape of the opening 21 , as seen from the front of the projectile 17 . FIGS. 4 a , 4 b , and 4 c show 3 corresponding approximate signal diagrams that are produced by the sensor 22 , depending on the deviation of the spinning projectile axis from the target.
FIGS. 4 , 5 , and 6 all show a front view of a projectile, having three different types of shapes of cover 21 . The front profile 100 of the projectile is of course circular. As said, the projectile 17 spins during its flight towards the target. During the flight, the light spot 4 is alternatively sensed by sensor 22 , depending on whether cover 21 faces the light spot or not. Furthermore, and with respect to FIGS. 4 , 5 , and 6 , the better the direction of the projectile towards the target light spot 4 is, the closer to the center 40 of the projectile the spot image is impinged. In other words, during the spinning of the projectile on its way towards the target, light spot 4 produces a virtual circle on the front profile 100 of projectile 17 . The radius of said virtual circle is used by the present invention as an indication for the accuracy of direction towards the target. Such an indication (i.e., the distance from the center) for the accuracy of direction was actually known by the prior art, and WO 98/31978, for example, proposes a reticle with lines disposed on it in a specific arrangement in order to produce a modulated signal which is a function of the distance from the center, thereby enabling determination the direction accuracy.
The present invention proposes another way for determining the accuracy of direction. According to the present invention, the shape of cover 21 enables such accuracy determination. More particularly, and as shown in FIGS. 4 , 5 , and 6 , the borders of the opening are so designed that they are not coincide (as in FIGS. 5 and 6 ) with any radial lines 98 of circle 100 , or at most partially coincide (as in FIG. 4 ) with such lines. It has been found by the inventor that if the cover edges are so shaped, the determination of the direction accuracy is possible.
FIGS. 4 a , 5 a , and 6 a , respectively show signals that enable determination of the direction accuracy for the cover shapes of FIGS. 4 , 5 , and 6 . The signals indicated as numerals # 1 –# 9 in FIGS. 4 a , 5 a , and 6 a relate respectively to circles of radius # 1 –# 9 of FIGS. 4 , 5 , and 6 .
With reference to FIG. 4 , in a case (not the one shown) when cover 21 spans the whole area between radial lines 98 , the resulted signals, no matter how accurate the projectile direction is, are the same. For example, this is the reason why signals 54 g , 54 h , and 54 i are the same. However, it can be seen that signals 54 a – 54 f differ one from the other, thanks to the shape of the cover 21 farther from the center. Therefore, the determination of the accuracy of direction can be made in the range of circles # 4 –# 9 in the embodiment of FIG. 4 . In the range of circles # 1 –# 3 it can be assumed that the accuracy of direction is better that within circles # 4 –# 9 , but no further determination can be made. In any case, within circles # 4 –# 9 it can be seen that the farther from the center the light spot impinges on cover 21 , and the larger the radius is, the shorter the resulted pulse duration becomes. Furthermore, as the period of completion of one projectile spin is given, the duty cycle of the signals # 4 –# 9 can be used for the determination of the accuracy of direction.
In the embodiment of FIGS. 5 and 5 a the duration of the pulses increases as the distance from the center increases in view of the shape of the cover 21 of FIG. 5 Also, the duty cycle increases as the distance from the center increases. More particularly, the pulse # 1 relating to the smallest radius # 1 has a shorter duration than the duration of pulse # 9 relating to the largest radius # 9 . The change in pulse duration follows the curvature, or more generally, the function of lines 109 . Therefore, the accuracy of the projectile direction can be determined by measurement of the duration of the pulse, or of the duty cycle, and given the shape of the cover border lines.
In the embodiment of FIGS. 6 and 6 a the duration of the pulses decreases as the distance from the center increases in view of the shape of the cover 21 of FIG. 6 . Also, the duty cycle decreases as the distance from the center increases. For example, the pulse # 1 relating to the smallest radius # 1 has a longer duration than the duration the other pulses # 2 –# 9 . The change in pulse duration follows the curvature, or more generally, the function of the cover 21 border lines 119 .
The present invention can therefore determine the rate of the projectile route accuracy to the target, and therefore also can determine the rate of correction which is required. In one embodiment of the invention, the correction is made by means of providing a correction impulse at the back of the projectile. Therefore, the determination of the correcting impulse involves determination of both its absolute volume, and its direction. The absolute volume of the required impulse of correction is determined from the duty cycle or the width of the pulse that is generated by sensor 22 and it of course depends on the shape of the cover. More particularly, as has been shown with respect to FIGS. 4 , 5 , 6 , the direction accuracy of the projectile is a function of the pulse width, and this is the case as long as the cover 21 shape does not fully coincides with radial lines such as 98 .
Preferably, the correction is made when a projectile is in close range to the target.
The projectile also comprises an electronic circuitry 47 (indicated in FIG. 2 ) for performing the projectile correction. FIG. 7 shows in block diagram form the structure of said circuitry 47 according to an embodiment of the invention. The pulses as received from the sensor 22 are provided into a pre-amplifier 67 , which amplifies the pulses and conveys them into processor 60 . Timer 61 activates processor 60 at a predetermined time, for example at a time in which the projectile is close to the target (and in which a minimal correction is required). The timer may determine this activation time from the parameter R of the range to the target and from the known velocity V of the projectile. The range to the target can be determined before the shooting by any known technique, for example, by means of using a range finder. The processor starts processing the inputs from pre-amplifier 67 upon receipt of the activating signal 69 from timer 61 , and it determines the amplitude and direction of the correcting signal, which is thereafter provided to the flight correcting unit 62 . The flight correcting unit 62 may, for example comprise two or more jets 74 , that are disposed at the back of the projectile 70 as shown in FIG. 2 b . Each of the jets is capable of providing thrust to a specific direction. The amplitude and direction of the correcting impulse thrust may therefore be a sum of the thrust as resulted from the activation of two or more of such jets 74 . In that case, the processor 60 determines the time of activation of the jets, the specific jets for activation (if there are more than two), and the amount of thrust which is activated by each jet, if this option is available, in order to acquire the desired impulse of correction.
FIG. 3 illustrates an example for the providing of an impulse of correction to the projectile. As previously said, the amount of the error is proportional (directly or inversely, depending on the cover's shape) to the width of the measured pulse. The error can likewise be measured from the center of the pulse indicated as “ 0 ”, as shown in FIG. 3 (“error 1 ” and “error 5 ” represent two different errors relating pulse # 1 and pulse # 5 respectively). As said, an impulse at the back of the projectile that will best correct the course of the projectile to the target is one which is directed opposite to the opening 21 longitudinal axis of symmetry (assuming that the opening is symmetric), and which is activated at the time of the pulses center (time “ 0 ”). For example, if in FIG. 2 b the pulse center occurs exactly when the opening 21 faces up, the resulted impulse should be directed exactly downward. The time of the center of each present pulse can be determined by dividing the width D of the previously measured pulse by 2, assuming that the width of the present pulse is the same as the width D of the previous one, and by measuring time D/2 from the beginning of the present pulse. This assumption is generally very accurate, as the pulse width almost does not change between two consecutive revolutions.
It should be noted herein that although the explanation above has referred to a shaped “cover”, or “opening” of the projectile, this is not a requirement, and has been done for the sake of brevity only. Various alternative optical solutions are known in the art for enabling the passage of light within a shaped area and blocking elsewhere. For example, the borders of the “opening” can be provided by means of a filter or mask, which allows light (in the required wavelength) within a specific area having a shape with characteristics described, and blocking such light elsewhere. In such a case, the cover itself may have other shapes then described, and the “shape” may be determined by the filter. Still alternative solution may be to provide a shaped aperture below the cover, in the light passage to the sensor. Various other similar solutions may be adapted for providing a shaped “opening”, all are within the scope of the invention. Therefore, in this application and the claims when the term shaped “cover” or shaped “opening” is used, such term intends also to cover said alternatives.
As has been shown, the output signals from the light sensor of the invention are very simple signals. The processing of said signals involves only measurement of the duration of the pulse which is produced, calculation of the duty cycle, and determination from these two values the accuracy of direction. The determination of the width of the pulse, as well as said other determinations are simple, and well suited to digital processing.
According to the present invention the flight correcting unit may alternatively be of other types known in the art. For example, in the case of using the seeker of the invention in a guided missile, the flight correcting unit 62 may comprise the wings of the missile, and the correction may involve changing the orientation of the wings in a known manner in order to obtain the flight correction as determined by processor 60 . The direction of correction and the volume of correction can, in any case, be determined as described above.
While some embodiments of the invention have been described by way of illustration, it will be apparent that the invention can be carried into practice with many modifications, variations and adaptations, and with the use of numerous equivalents or alternative solutions that are within the scope of persons skilled in the art, without departing from the spirit of the invention or exceeding the scope of the claims. | The present invention relates to a projectile seeker which comprises: (a) A hollow in the projectile for accommodating a light sensor; (b) A light sensor located within said hollow for sensing light which is emitted or reflected from a target, and for producing an electronic signal upon sensing such emitted light; and (c) A longitudinal shaped opening at the slanted front-side surface of the projectile for enabling a shaped field of view to said light sensor which is limited by the boundaries of said opening, the opening width varies in a direction from the front to the back of the projectile in order to cause said electronic signal to depend on the spinning of the projectile and to be proportional to the orientation of the projectile with respect to the object. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 61/591,410, filed Jan. 27, 2012. The content of this application is hereby incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates generally to devices having Automatic Gain Control (AGC) systems, e.g., hearing prostheses, and, more particularly, to processing an input sound signal in order to adjust signal levels.
RELATED ART
Automatic Gain Control (AGC) systems are commonly used in devices, e.g., audio processing devices, to cope with a large range in sound levels. AGC systems are applicable to hearing prostheses, audio headsets, telecommunications systems, and the like. AGC systems are particularly beneficial in hearing prostheses because hearing prostheses generally have a restricted dynamic range. In some systems, the audio signal is split into multiple frequency bands by a filter bank or a transform (e.g., a Fast Fourier Transform). The gain of each band can then be controlled separately. This is referred to as a multi-band type of AGC.
SUMMARY
In one aspect of the present invention, there is provided a computer-implemented method comprising: determining one or more features of a subject signal; revising one or more control signals on the basis of the one or more features; modifying a level of the subject signal based on the control signals. At least one of the features is determined by: comparing the subject signal against a boundary signal to produce a boundary comparison signal; and summarizing the behavior of the boundary comparison signal over a time interval.
In another aspect, there is provided a device comprising: one or more feature extractors, each being configured to extract a respective feature from a subject signal; a controller configured to refine one or more control signals based on the one or more features; and a compressor configured to adaptively perform signal compression on a subject signal according to the one or more control signals to produce a compressed signal.
In yet another aspect, there is provided a method, comprising: determining one or more features of a subject signal; and revising a scaling value for the subject signal on the basis of a comparison between the one or more features and one or more decision thresholds. At least one of the features is determined by: comparing the scaled analysis signal to a predetermined boundary value, to produce a boundary comparison signal; and summarizing the behavior of the boundary comparison signal over a time interval.
In yet another aspect, there is provided a device comprising: a set of feature-based regulators configured to produce a set of control signals from a set of subject signals, respectively; and compressors configured to perform signal compression by adaptively applying loudness growth functions (LGFs) to the set of subject signals according to the set of control signals, respectively. Such a set of control signals includes: a compressor-common control signal applicable to all of the compressors; and a set of compressor-specific control signals, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative embodiments of the present invention are described herein with reference to the accompanying drawings, in which:
FIG 1A illustrates a multi-band AGC system for use in a cochlear implant, according to an embodiment of the present invention;
FIG. 1B and 1C illustrate adaptive LGF systems for use in a cochlear implant, according to embodiments of the present invention;
FIG. 2 illustrates a multi-band AGC system for use in an application that provides an audio output, according to another embodiment of the present invention;
FIG. 3A, 3B, and 3C illustrate feature-based regulators according to embodiments of the present invention;
FIG. 3D illustrates a feature combiner according to an embodiment of the present invention;
FIG. 3E illustrates a feature-based gain module according to an embodiment of the present invention;
FIG. 4 illustrates a feature decision module according to an embodiment of the present invention;
FIGS. 5A, 5B, 6, 7, 8 and 9 illustrate feature extractors according to embodiments of the present invention;
FIG. 10A illustrates a gain rule according to an embodiment of the present invention;
FIGS. 10B, 10C, and 10D illustrate decision logic according to embodiments of the present invention;
FIG. 11 illustrates a short segment of one band of a speech signal;
FIG. 12A illustrates an input-output function of a Loudness Growth Function (LGF) and FIG. 12B is a block diagram of an LGF according to an embodiment of the present invention;
FIGS. 13 through 15 illustrate feature-based gain modules according to embodiments of the present invention;
FIG. 16 is a schematic diagram of a sound processor module configured to be incorporated into a multi-band feature-based level control system (which can be implemented in a cochlear implant system) according to an embodiment of the present invention;
FIGS. 17, 18, and 19 illustrate flow diagrams that describe multi-band processing procedures implemented by, e.g., a sound processor module, according to embodiments of the present invention;
FIG. 20 illustrates a feature-based saturation level regulator, according to an embodiment of the present invention;
FIG. 21 illustrates a feature-based base level regulator, according to an embodiment of the present invention; and
FIG. 22 illustrates a feature-based multi band base level and saturation level regulator, according to an embodiment of the present invention.
DETAILED DESCRIPTION
Embodiments of the present invention may be implemented in sound-processing technologies that benefit from gain control systems, e.g., hearing prostheses, telecommunications systems, and the like. Such systems typically perform a frequency analysis (e.g., via a filter bank or a Fast Fourier Transform unit) that splits an audio signal into analysis signals distributed across multiple frequency bands and then separately adjust the gain of each band.
The processing of an audio signal for a device having an AGC system, e.g., a hearing prosthesis such as a cochlear implant, according to an embodiment of the present invention is shown in FIG. 1A . This example shows a four-band AGC system for simplicity of illustration, but a higher number of bands (for example 22) is more typical. An audio signal 100 (e.g., derived from a source such as a microphone, telecoil, etc., typically with a pre-amplifier or front-end AGC, not shown in FIG. 1A ) is split into four frequency bands by four band-pass filters 101 through 104 (which can comprise a frequency analysis unit, e.g., a Fast Fourier Transform unit, not shown). Each band-pass filter (BPF) passes a different band of frequencies. Band-pass filters 101 through 104 produce band signals 111 through 114 that are applied to envelope detectors 121 through 124 to produce envelopes 131 through 134 . Some implementations use a quadrature pair of band-pass filters in each band, followed by quadrature envelope detection to produce envelopes 131 through 134 . Envelopes 131 through 134 are applied to variable-gain amplifiers 141 through 144 to produce scaled envelopes 161 through 164 . This operation is equivalent to multiplying envelopes 131 through 134 by band gains 151 through 154 . Scaled envelopes 161 through 164 are applied to instances 171 through 174 of a type of feature-based regulator (FBR) that determines gain (namely, an FBR-G) (discussed in more detail below) to determine gains 151 through 154 . Scaled envelopes 161 through 164 are applied to instantaneous non-linear compression blocks 181 through 184 , also known as loudness growth functions (LGFs), to produce magnitude signals 191 through 194 . Magnitude signals are further processed (not shown in FIG. 1A ) to determine the stimulation on a corresponding electrode, for example as described Loizou (1998), Mimicking the human ear, IEEE Signal Processing Magazine, 15: 101-130.
When fitting a cochlear implant system to a recipient, the appropriate stimulation levels for each electrode must be determined. Typically, electrical stimulation is delivered in the form of biphasic pulses. The loudness of a pulse train on an electrode depends on the phase width (typically 10 to 50 microseconds), the gap between phases (typically 0 to 20 microseconds), the current (typically 10 to 1000 microamperes), and the pulse rate (typically 250 to 4000 pulses per second). Typically, the timing parameters (phase width, phase gap and pulse rate) are held constant, and the loudness is varied by varying the current. The lowest current that is delivered on an electrode is here denoted as the lower current level. The highest current that is delivered on an electrode is here denoted as the upper current level. The lower and upper current levels vary between recipients, and also vary between electrodes in a single recipient.
An example LGF input-output function is shown in FIG. 12A . As seen in FIG. 12A , scaled envelope amplitudes equal to a specified saturation level are mapped to magnitude value of 1.0, which will result in stimulation at the upper current level. The saturation level is often taken as a reference point, e.g., labeled as 0 dB in FIG. 12A . Scaled envelope amplitudes equal to a specified base level are mapped to magnitude value 0.0, which will result in stimulation at the lower current level. The dynamic range is defined as the ratio of the saturation level to the base level. Typical dynamic range values are from 30 to 50 dB; FIG. 12A shows a dynamic range of 40 dB. The LGF prevents excessive loudness by limiting the current on each electrode to the corresponding upper current level. However, scaled envelope amplitudes greater than the saturation level are clipped to magnitude value 1.0, and hence the upper current level. This clipping is a form of distortion, and one goal of the present invention is to reduce this clipping.
FIG. 12B shows an LGF module 1200 according to an embodiment of the present invention. Envelope 1201 is applied to level modifier 1202 to produce signal 1203 . The operation of level modifier 1202 can be expressed in the MATLAB® brand of high-level programming language made available by MathWorks®, Inc., e.g., as follows:
if v >= sat_level r = 1; elseif v <= base_level r = 0; else r = (v − base_level) / (sat_level − base_level); end
where v is the envelope sample, base_level is the LGF base level 1206 , sat_level is the LGF saturation level 1207 , and r is signal 1203 . In sonic embodiments of the present invention (e.g., FIG. 1A ), base level 1206 and saturation level 1207 are predetermined values. In other embodiments (e.g., FIG. 1B ), base level 1206 and saturation level 1207 are control signals that are generated by feature-based regulators (discussed in more detail below).
In some embodiments of level modifier 1202 , the division operation is avoided by taking logarithms. In this case, the operation of level modifier 1202 can be expressed in the MATLAB® language, e.g., as follows:
log( r )=log( v −base_level)−log(sat_level−base_level);
Signal 1203 is applied to logarithmic compression module 1204 to produce magnitude signal 1205 . The operation of module 1204 can be expressed in the MATLAB® language, e.g., as follows:
m =log(1+alpha* r )/log(1+alpha);
where alpha is a coefficient determining the amount of compression, and m is magnitude 1205 . In some embodiments, module 1204 is implemented as a look-up table. In other embodiments, module 1204 is implemented as a piece-wise linear function using interpolation. In an embodiment in which level modifier 1202 takes logarithms, then module 1204 can compensate by incorporating an exponential operation.
The processing of an audio signal for a cochlear implant according to another embodiment of the present invention is shown in FIG. 1B . This example shows a four-band system for simplicity of illustration, but a higher number of bands (for example 22) is more typical. Audio signal 100 is processed to produce envelopes 131 through 134 in the same manner as in FIG. 1A . Envelopes 131 through 134 are applied to variable LGF blocks 1081 through 1084 , to produce magnitude signals 1091 through 1094 . Envelopes 131 through 134 are also applied to instances of a type of feature-based regulator (FBR) that determines base level (namely, an FBR-B) 1041 through 1044 (discussed in more detail below), producing base level signals 1051 through 1054 . Envelopes 131 through 134 are also applied to instances of a type of feature-based regulator that determines saturation level (namely, an FBR-S) 1061 through 1064 (discussed in more detail below), producing saturation level signals 1071 through 1074 . In contrast to the LGF blocks 181 through 184 in FIG. 1A , which have a fixed base level and saturation level, the variable LGF blocks 1081 through 1084 in FIG. 1B have base levels and saturation levels which are determined by the control signals 1051 through 1054 and 1071 through 1074 respectively.
The processing of an audio signal for a cochlear implant according to another embodiment of the present invention is shown in FIG. 1C . This example shows a four-band system for simplicity of illustration, but a higher number of bands (for example 22) is more typical. Audio signal 100 is processed to produce envelopes 131 through 134 in the same manner as in FIG. 1B . Envelopes 131 through 134 are applied to variable LGF blocks 1081 through 1084 , to produce magnitude signals 1091 through 1094 . Envelopes 131 through 134 are also applied to feature-based multi-band base level and saturation level regulator 1100 (discussed in more detail below), producing base level signals 1151 through 1154 and saturation level signals 1171 through 1174 . The difference between the regulator 1100 in FIG. 1C and the regulators 1041 through 1044 and 1061 through 1064 in FIG. 1B is that regulator 1100 allows dependency or coordination between the bands.
The processing of an audio signal for an application that provides an audio signal output, according to an embodiment of the present invention is shown in FIG. 2 . Such applications include conventional hearing aids, bone-anchored hearing aids, and telecommunication systems. This example shows a four-band AGC system for simplicity of illustration, but a lower or higher number of bands may be used. An audio signal 200 is split into four frequency bands by four band-pass filters 201 through 204 (which can comprise a frequency analysis unit, e.g., a Fast Fourier Transform unit, not shown). Each band-pass filter (BPF) passes a different band of frequencies, Band-pass filters 201 through 204 produce band signals 211 through 214 that are applied to variable-gain amplifiers 221 through 224 to produce scaled band signals 241 through 244 . This operation is equivalent to multiplying band signals 211 through 214 by band gains 231 through 234 . Scaled band signals 241 through 244 are applied to envelope detectors 251 through 254 to produce scaled envelopes 261 through 264 . Scaled envelopes 261 through 264 are applied to gain-type feature based regulators (FBR-Gs) 271 through 274 (discussed in more detail below) to determine gains 231 through 234 . Scaled band signals 241 through 244 are applied to combine module 280 to produce an audio output signal 290 . Combine module 280 typically includes a summing operation. Alternatively, if audio signal 200 is divided into bands by an FFT, then combine module 280 incorporates an inverse FFT.
Embodiments of the present invention as shown in FIG. 1A , FIG. 1B , FIG. 1C and FIG. 2 may be implemented as analog signal processing, digital signal processing (DSP), or a mixture of analog and digital. In a DSP implementation, the audio sample rate is defined as the rate at which audio signal 100 or 200 is sampled. Some telecommunications systems use an audio sample rate of 8000 Hz. A typical cochlear implant system uses an audio sample rate of 16000 Hz. To reduce the processing load, envelopes 131 through 134 of FIG. 1A or FIG. 1B or FIG. 1C can be down-sampled to a lower rate. For example, if the cochlear implant stimulates at 1000 pulses per second on each channel, the envelopes can be calculated at 1000 Hz. This rate will be termed the envelope sample rate.
The gain-type feature-based regulators (FBR-Gs) 171 through 174 in FIG. 1A and 271 through 274 in FIG. 2 , and the base-level-type feature-based regulators (FBR-Bs) 1041 through 1044 and the saturation-level-type feature-based regulators (FBR-Ss) 1061 through 1064 in FIG. 1B are all examples of feature-based regulators.
A feature-based regulator (FBR) 460 according to an embodiment of the present invention is shown in FIG. 3A . The overall operation is that signal 300 is processed by FBR 460 to produce control signal 450 . In more detail, signal 300 is applied to a set of feature extractors (EX) 311 through 313 , to produce feature value (FV) signals 321 through 323 , which are applied to feature combiner 330 . Feature combiner 330 produces combined feature signal 410 , which is applied to parameter scaler 420 , producing signal 430 . Signal 430 is applied to parameter limiter 440 to produce control signal 450 .
In both FIG. 1A and FIG. 2 , the control signal produced by each FBR is a gain, and the input is a scaled envelope (i.e., an envelope whose amplitude is affected by that gain). In FIG. 1B and FIG. 1C , the inputs to the FBRs are envelopes, and the control signals produced are the base levels and saturation levels of the LGF modules. In each case, the control signal 450 affects the signal level in one band of the overall system, based on the information obtained by the feature extractors,
For the purposes of illustration, FBR 460 shown in FIG. 3A utilizes three features. However, an FBR may utilize any number of features. Suitable methods for the feature combiner 330 to combine the feature value signals include a weighted sum, the maximum value, the minimum value, or the median value.
FIG. 3B shows an FBR 461 according to another embodiment of the present invention. FBR 461 utilizes a single feature extractor 311 , which produces feature value signal 321 . As there is only one feature, no feature combiner is needed, and feature value signal 321 is taken directly to parameter scaler 421 .
FIG. 3C shows a FBR 462 according to another embodiment of the present invention. FBR 462 is similar to FBR 461 , except that feature value signal 321 is applied to feature decision module (FDM) 331 (described in more detail below), to produce feature decision signal 341 . Feature decision signal 341 is a Boolean signal (true or false), or equivalently a binary signal, taking the values 1 or 0. The feature decision signal 341 is applied to parameter scaler 422 .
FIG. 3D shows a feature combiner 700 according to another embodiment of the present invention. Feature value signals 321 through 323 are applied to corresponding feature decision modules 331 through 333 . Feature decision signals (Boolean signals) 341 through 343 are applied to decision logic 1701 , which produces direction signal 1702 . Decision logic 1701 is typically implemented as a sequence of if-then-else logical statements. In one embodiment, direction 1702 is represented by a variable with three possible values: +1 (meaning increase the control signal), −1 (meaning decrease the control signal), or 0 (meaning no change in the control signal).
For example, if FBR 460 of FIG. 3A was implemented as an FBR-G, control signal 450 would be gain, and so parameter scaler 420 would be referred to as a gain scaler, and parameter limiter 440 could be referred to as a gain limiter. Similarly, for example, with reference to FIG. 3D , decision logic 1701 can be referred to as gain logic.
A gain-type feature-based regulator (FBR-G) 370 according to an embodiment of the present invention is shown in FIG. 3E . FBR-G 370 is an example of FBR-G modules 171 - 174 and 271 - 274 . The overall operation is that scaled envelope 300 is processed by FBR-G 370 to produce gain 360 . Note that in both FIG. 1 and FIG. 2 , the output of each FBR-G is a gain, and the input is a scaled envelope (i.e., an envelope whose amplitude is affected by that gain). In more detail, scaled envelope 300 is applied to a set of feature extractors (FX) 311 through 313 , to produce feature value signals 321 through 323 , which are applied to feature decision modules (FDMs) 331 through 343 , to produce feature decision signals 341 through 343 . Each feature decision signal is a Boolean signal (true or false), or equivalently a binary signal, taking the values 1 or 0. The feature decision signals are applied to gain rule 350 (described in more detail below) which produces gain 360 .
A characteristic of a FBR (e.g., 460 , 461 , 462 , or 370 ) is the update rate, defined as the rate at which the control signal (gain, base level or saturation level, e.g., 450 , 451 , 452 , or 360 ) is changed. This may be equal to the envelope sample rate (for example 1000 Hz), or may be lower. Typically, the feature extractors (e.g., 311 through 313 ) produce their feature value signals 321 through 323 at the update rate.
The FDMs (e.g., 331 through 333 in FIG. 3C , FIG. 3D and FIG. 3E ), e.g., all have the same structure. An FDM 331 according to an embodiment of the present invention is shown in FIG. 4A , where FDM 331 is an example of FDMs 331 - 334 , FDM 331 includes comparator 403 that produces feature decision signal 341 indicating whether feature value signal 321 exceeds feature decision threshold 402 . Feature decision threshold 402 is, e.g., a predetermined value stored in memory 401 .
FIG. 10A shows a gain rule 350 according to an embodiment of the present invention. Feature decision signals (Boolean signals) 341 through 343 are applied to gain logic 701 , which produces gain direction 702 . Gain logic 701 is typically implemented as a sequence of if-then-else logical statements. In one embodiment, gain direction 702 is represented by a variable with three possible values: +1 (meaning increase gain), −1 (meaning decrease gain), or 0 (meaning no gain change). For the purposes of illustration, gain rule 350 shown in FIG. 3E and FIG. 10A utilizes three features. However, a gain rule may utilize any number of features.
Gain logic 701 in FIG. 10A is equivalent to decision logic 1701 in FIG. 3D . FIGS. 10B, 10C, and 10D show examples 710 , 720 and 730 of gain logic 701 or decision logic 1701 according to additional embodiments of the present invention, with different numbers of features, e.g., expressed in the MATLAB® language. FIG. 10B shows decision logic 710 that utilizes a single feature. FIG. 10C shows decision logic 720 that utilizes two features. FIG. 10D shows decision logic 720 that utilizes three features.
In some embodiments utilizing decision logic (e.g., 1701 in FIG. 3D ), the parameter scaler modifies the existing control signal in a proportional manner, according to the value of direction 1702 . The operation of parameter scaler can be expressed in the MATLAB® language, e.g., as:
if direction < 0 param = param * down_factor elseif direction > 0 param = param * up_factor end
where param is a variable representing the control signal (e.g., one of gain, base level, saturation level, etc.), up_factor is a pre-determined factor for increasing the control signal, and down_factor is a pre-determined factor for decreasing the control signal.
An example calculation of the up_factor and down_factor can be expressed in the MATLAB® language, e.g., as follows:
up_step_dB = up_slew_rate / update_rate; down_step_dB = down_slew_rate / update_rate; up_factor = 10 {circumflex over ( )} (up_step_dB / 20); down_factor = 10 {circumflex over ( )} (down_step_dB / 20);
where update_rate is the rate at which the control signal is updated, up_slew_rate is the increase in dB per second and down_slew_rate is the decrease in dB per second.
Parameter limiter ( 440 , 441 , or 442 ) constrains the control signal to lie between a maximum and a minimum value. The operation of the parameter limiter can be expressed in the MATLAB® language, e.g., as:
if param > param_max param = param_max elseif param < param_min param = param_min end
where param_min is the minimum value of the control signal and param_max is the maximum valued
As a specific example, in FIG. 10A , gain scaler 703 modifies the existing gain in a proportional manner, according to the value of gain direction 702 . The operation of gain scaler 703 can be expressed in the MATLAB® language, e.g., as:
if gain_direction < 0 gain = gain * gain_down_factor elseif gain_direction > 0 gain = gain * gain_up_factor end
where gain_up_factor is a pre-determined factor for increasing the gain, and gain_down_factor is a pre-determined factor for decreasing the gain.
An example calculation of the gain_up_factor and gain_down_factor can be expressed in the MATLAB® language, e.g., as follows:
gain_up_step_dB = gain_up_slew_rate / update_rate; gain_down_step_dB = gain_down_slew_rate / update_rate; gain_up_factor = 10 {circumflex over ( )} (gain_up_step_dB / 20); gain_down_factor = 10 {circumflex over ( )} (gain_down_step_dB / 20);
where update_rate is the rate at which the gains are updated, gain_up_slew_rate is the gain increase in dB per second (e.g., 3 dB per second) and gain_down_slew_rate is the gain decrease in dB per second (e.g., −10 dB per second).
Gain limiter 705 constrains the gain to lie between a maximum and a minimum value. The operation of gain limiter 705 can be expressed in the MATLAB® language, e.g., as:
if gain > gain_max gain = gain_max elseif gain < gain_min gain = gain_min end
where gain − min is the minimum gain and gain_max is the maximum gain.
A variety of features may be usefully employed in an embodiment of a feature-based regulator (FBR), for example, peak level, minimum level, noise floor, percentiles, modulation depth, specific loudness, and signal-to-noise ratio. Some additional feature extractors 500 , 600 , 620 , 640 and 660 are disclosed below in the context of FIGS. 5 through 9 , respectively.
FIG. 5A shows a feature extractor 500 according to an embodiment of the present invention. Comparison module 530 compares envelope 300 to boundary signal 520 , and produces boundary comparison (BC) signal 540 . Several embodiments of comparison module 530 are described below. BC 540 can contain fluctuations on the same time scale as envelope 300 . BC signal 540 is applied to time interval observer 550 . Time interval observer 550 summarizes the behavior of BC 540 over the most recent time interval, and produces summarized boundary comparison (SC) type of feature value (FV), namely FV(SC), signal 560 , which fluctuates more slowly than envelope signal 300 . Examples of suitable time interval durations range from 50 milliseconds to several seconds. Several embodiments of time interval observer 550 are described below. FIG. 5B shows feature extractor 501 , according to another embodiment of the present invention, in which boundary signal 520 is a predetermined value stored in memory 510 . In other embodiments, boundary signal 520 is a time-varying signal (described in more detail below), rather than a predetermined value.
FIG. 6 shows feature extractor 600 according to an embodiment of the present invention, where feature extractor 600 is an example of feature extractor 500 . Comparator 531 is an example of comparison module 530 of FIGS. 5A-5B . Comparator 531 produces BC signal 541 indicating whether scaled envelope 300 exceeds boundary value 520 . BC signal 541 is a Boolean signal (true or false), or equivalently a binary signal, taking the values 1 or 0. Time interval observer 601 is an example of time interval observer 550 in FIGS. 5A-5B . Accumulator 602 operates according to a series of time intervals, where the segment length is defined as the number of samples of scaled envelope signal 300 in each time interval. Accumulator 602 is cleared at the beginning of each time interval. During each time interval, accumulator 602 sums BC 541 (a binary signal). In other words, it counts the number of samples for which scaled envelope 300 exceeds boundary signal 520 . The output of accumulator 602 is count 603 , which is an example representation of the proportion of scaled envelope samples that exceeds the boundary signal. At the end of each time interval, the value of count 603 lies in the range zero up to the segment length (i.e., up to the maximum number of samples that can be operated upon during the interval). The segment length determines the minimum number of bits for accumulator 602 . For example, if the segment length is 25, then accumulator 602 must have at least 5 bits, while if the segment length is 250, then accumulator 602 must have at least 8 bits. Although accumulator 602 operates at the envelope sample rate, only the final value of count 603 at the end of each time interval is provided as the output of time interval observer 601 , namely as FV(SC) 610 , which is an example of a summarized boundary comparison (SC) type of feature value (FV) signal. This reduction in processing rate is represented by down-sample block 604 . For example if the envelope sample rate is 1000 Hz, and the time intervals are 100 milliseconds in duration, then the segment length is 100, and the update rate is 10 Hz.
The operation of feature extractor 600 can be expressed in the MATLAB® language, e.g., as:
count = 0; for n = 1:segment_length if v(n) > boundary(n) count = count + 1; end end
where v is a segment of the envelope signal 300 containing segment length samples, n is the sample index within the segment, boundary is a segment of boundary signal 520 , and count is the feature value signal 610 .
In an alternative embodiment of feature extractor 600 , the output of accumulator 602 is normalized (i.e., divided by the number of samples in the time interval) to obtain a feature value signal 610 that represents the proportion of envelope samples that exceed the boundary signal. This step can be expressed in the MATLAB® language, e.g., as:
proportion_exceeds_boundary=count/segment_length;
Such a proportion necessarily lies in the range 0 to 1. This normalization step is not strictly necessary, and is typically omitted from a fixed-point DSP implementation. And yet the normalization step has an advantage of providing a feature signal that has a more readily understood meaning, and it allows the corresponding decision threshold to also be expressed as a proportion, independent of the time interval duration or update rate.
It can be desirable to increase the time duration over which the system observes the envelope levels when making decisions on the appropriate control signal. Feature extractor 600 has the property that increasing the time interval duration leads to a lower update rate and larger control signal steps, which may become objectionable to the listener. This issue can be alleviated by utilizing overlapping time intervals. For example, the time interval duration can be increased to one second (i.e., segment length=1000 samples), while keeping a 10 Hz update rate, so that each time interval has a 90% overlap with the previous time interval. To increase computational efficiency, for example, each time interval can be divided into 10 non-overlapping sub-segments, each having 100 samples. The number of envelope samples exceeding the boundary signal is counted for each sub-segment, and the resulting counts are stored in a first-in, first-out (FIFO) buffer, of length 10. The final count for the time interval ending at each sub-segment is obtained as the sum of the last 10 sub-segment counts. This operation is equivalent to a finning sum operation on the sequence of sub-segment counts, i.e., a finite-duration impulse response (FIR) filter with all coefficients equal to one. An embodiment that operates in this manner is shown in FIG. 7 .
FIG. 7 illustrates feature extractor 620 according to an embodiment of the present invention, where feature extractor 620 is another example of feature extractor 500 . Feature extractor 620 is similar to feature extractor 600 , the difference being in time interval observer 621 , which is another example of time interval observer 550 from FIGS. 5A-5B . Time interval observer 621 comprises accumulator 622 and down-sample block 624 , which operate as in feature extractor 600 , and further includes a low-pass filter 626 applied to count signal 625 . Low-pass filter 626 operates at the update rate, and extends the time interval over which BC 541 is observed. Normalization, as previously described, can optionally be applied to count signal 625 or to filter output FV(SC) 630 , which is an example of a summarized boundary comparison (SC) type of feature value (FV)
In one example embodiment, low-pass filter 626 is an FIR filter with all coefficients equal to one, as previously described. Alternatively, the FIR coefficients can be designed to give a specified time response, for example to give less weight to past segments. Alternatively an order-statistics filter can be applied to the sequence of counts, such as for median filtering, or for example taking the maximum count over the last 10 segments.
Alternatively filter 626 can be an infinite-duration impulse response (IIR) filter. This has an advantage that the signals can be observed over much longer time intervals whilst minimizing the memory requirements. For example, a first-order smoothing filter can be expressed in the MATLAB® language, e.g., as:
smoothed_count=(1−alpha)*count+alpha*smoothed_count;
where smoothed_count is the filtered count signal 630 , and alpha is a decay factor in the range 0 to 1. This requires one additional word of storage per band and per target.
As a special case, if alpha is set equal to 0.5, the expression becomes:
smoothed_count=0.5*(count+smoothed_count);
In this special case, no additional storage is required: at the start of each segment, instead of initializing the counts to zero, the previous values of the counts are halved, and then the counts are incremented from these non-zero starting points; thus, one memory location holds the sum of the current count and its history. Effectively the accumulator 622 and the filter 626 have been combined. This arrangement can be further generalized as shown in FIG. 8 .
FIG. 8 illustrates feature extractor 640 according to an embodiment of the present invention, where feature extractor 640 is another example of feature extractor 500 . Time interval observer 641 is an example of time interval observer 550 in FIGS. 5A-5B , and comprises low-pass filter 642 and down-sample block 644 . Filter 642 acts directly on the BC 541 . Because BC 541 is a binary signal, filter 642 can be implemented efficiently, e.g., in hardware, with many multiplications replaced by conditional addition. Filter output signal 643 represents the average value of BC 541 , in other words, it represents the proportion of time that envelope signal 300 exceeds the boundary signal 520 . Filter 642 can be designed to give a specified time response; for example, to give more weight to more recent samples. In one example embodiment, filter output signal 643 is calculated at the envelope sample rate, and is down-sampled by down-sample block 644 to give FV(SC) 650 at the update rate, where FV(SC) is which is an example of a summarized boundary comparison (SC) type of feature value (FV) signal. The skilled artisan would understand how to merge down-sample block 644 into filter 642 , e.g., for the purposes of enhancing efficiency. Alternatively, down-sample block 644 can be omitted if it is desired to make the update rate equal to the envelope sample rate.
FIG. 9 illustrates feature extractor 660 according to an embodiment of the present invention, where feature extractor 660 is another example of feature extractor 500 . Block 661 is an example of comparison module 530 of FIGS. 5A-5B . In contrast to feature extractors 600 , 620 , and 640 , which use comparator 531 to determine whether the envelope signal 300 exceeds boundary signal 520 , block 661 calculates the amount by which envelope signal 300 exceeds boundary signal 520 . Subtractor 662 subtracts boundary signal 520 from envelope signal 300 to produce difference signal 663 , which is rectified by half-wave rectifier (HWR) 664 . The operation of block 661 can be expressed in the MATLAB® language, e.g., as:
d = v − boundary; excess = max(d, 0);
where v is envelope signal 300 , boundary is boundary signal 520 , d is difference signal 663 , and excess is a boundary comparison (BC) signal 665 . BC 665 is then applied to time interval observer 666 , which is an example of time interval observer 550 in FIGS. 5A-5B , which comprises low-pass filter 667 and down-sample block 669 , and which produces a signal FV(SC) 670 , which is an example of a summarized boundary comparison (SC) type of feature value (FV) signal. FV(SC) 670 characterizes the average amount by which the envelope 300 exceeds boundary signal 520 over the most recent time interval.
FIG. 11 illustrates a short segment of one band of a speech signal and can serve to illustrate differences between feature extractor 660 and feature extractors 600 , 620 , and 640 . This example is a gain-type feature-based regulator (FBR-G), in which the control signal 670 is gain (as in FIG. 1A ), and the boundary signal 520 is a predetermined boundary level (as in FIG. 5B ). The shaded region indicates the amount by which the scaled envelope signal 300 exceeds the boundary level 520 , which is 0 dB in this example. There are two excursions of the scaled envelope signal above the boundary level: the first excursion 1001 starts at a time of about 0.15 seconds and the second excursion 1002 starts at a time of about 0.45 seconds. If feature extractor 600 , 620 , or 640 is used, then the first excursion 1001 produces a smaller gain decrement than the second excursion 1002 , because the first excursion has a shorter duration. However, if feature extractor 660 is used, filter 667 acts as an integrator, estimating the area of the shaded regions, and so the first excursion 1001 produces a greater gain decrement than the second excursion 1002 , because the first excursion has a larger area. Thus, feature extractor 660 is more responsive to large-amplitude, short-duration transients.
Some specific examples of gain-type feature-based regulators (FBR-Gs) are described below. Each, e.g., has the same overall structure as FBR-G 370 in FIG. 3E , but with different numbers and types of internal components.
An FBR-G 810 according to an embodiment of the present invention is shown in FIG. 13 . Like FBR-G 370 , FBR-G 810 is an example of FBR-Gs 171 - 174 and 271 - 274 . FBR-G 810 utilizes a single feature extractor, namely peak detector 811 . Peak detector 811 produces feature value signal, designated peak level 812 . An embodiment of peak detector 811 can be expressed in the MATLAB® language, e.g., as:
x ( n )=max( v ( n ), x ( n -1)*peak_decay_weight);
where v(n) is a sample of scaled envelope signal 300 , x(n) is a sample of peak level 811 , x(n-1) is the previous sample of peak level 811 , and peak_decay_weight is determined from the envelope sample rate and a predetermined peak decay time, which can be expressed in the MATLAB® language, e.g., as follows:
T = 1 / envelope_sample_rate;
peak_decay_weight = exp(- T / peak_decay_time);
Feature decision module 813 compares peak level 812 to peak threshold 815 , and produces feature decision signal 817 , denoted peak − too_high. Feature decision signal peak_too_high 817 is applied to gain rule 818 , which utilizes, e.g., decision logic 710 from FIG. 10B . The overall operation of FBR-G 810 is that if the peak level is too high, the gain is reduced, otherwise the gain is increased. In a cochlear implant system, an example value for the peak threshold is a point mid-way between the base level and the saturation level, for example 20 dB below the saturation level in FIG. 12A . Example values for other parameters are: peak decay time of 0.5 seconds, gain slew up rate of 6 dB per second, and gain slew down rate of 6 dB per second. Thus, FBR-G 810 acts so that during speech activity, the peak levels spend about half of the time above the peak threshold, thus, aiding audibility. In the absence of speech activity, the gain increases up to the maximum gain, which is set so that background noise is not objectionable.
FIG. 14 illustrates an FBR-G 820 according to an embodiment of the present invention. Like FBR-Gs 370 and 810 , FBR-G 820 is an example of FBR-G 171 - 174 and 271 - 274 . FBR-G 820 can be used, e.g., with a cochlear implant, as in FIG. 1A . FBR-G 820 utilizes two feature extractors, 821 and 831 . Feature extractor 821 , denoted clipping extractor, is an instance of feature extractor 620 from FIG. 7 , and incorporates normalization as described previously. It is configured with boundary value 520 equal to the LGF saturation level shown in FIG. 12A . Thus, BC 541 indicates whether scaled envelope 300 exceeds the LGF saturation level; in other words, it indicates whether the scaled envelope is clipped. Thus, feature value signal 822 represents the proportion of scaled envelope samples that were clipped during the last time interval, and is denoted clipping_proportion. Feature decision module 823 compares feature value signal clipping_proportion 822 to decision threshold 825 , to produce feature decision signal 827 . An example decision threshold is 0.1. In this case, feature decision signal 827 will be high (true) if more than 10% of scaled envelope samples were clipped in the last time interval. Feature decision signal 827 is denoted as clipping_too_often in a logic statement below.
Feature extractor 831 is a noise floor estimator. An example embodiment of feature extractor 831 is described in Martin R (2001), “Noise power spectral density estimation based on optimal smoothing and minimum statistics,” IEEE Transactions on Speech and Audio Processing, 9: 504-512. Feature value signal 832 is the estimated noise floor. Feature decision module 833 compares the noise floor to decision threshold 835 , to produce feature decision signal 837 . An example decision threshold is the LGF base level shown in FIG. 12A . If feature value signal (estimated noise floor) 832 exceeds decision threshold 835 , then feature decision signal 837 is set to a state indicating that the noise floor exceeds the LGF base level. Feature decision signal 837 is denoted as noise_floor_too_high in a logic statement below.
Feature decision signals clipping_too_often 827 and noise_floor_too_high 837 are applied to gain rule 838 . The gain logic can be expressed in the MATLAB® language, e.g., as:
if clipping_too_often
gain_direction = −1;
elseif noise_floor_too_high
gain_direction = −1;
else
gain_direction = +1;
end
FIG. 15 illustrates another FBR-G 840 according to an embodiment of the present invention. Like FBR-Gs 370 , 810 and 820 , FBR-G 840 is an example of FBR-Gs 171 - 174 and 271 - 274 . FBR-G 840 is similar to FBR-G 820 , except for the addition of a third feature extractor 841 . Feature extractor 841 is denoted a mid-level extractor, and is an instance of feature extractor 620 from FIG. 7 , and incorporates normalization as described previously. It is configured with boundary value 520 lying midway between the LGF saturation level and base level shown in FIG. 12A . Thus, BC 541 indicates whether scaled envelope 300 is mapped into the upper section of the dynamic range; in other words, is relatively loud. Thus, feature value signal 842 represents the proportion of scaled envelope samples that were relatively loud during the last time interval. In a logic statement below, feature value signal 842 is denoted as loud_proportion. Feature decision module 843 compares feature value signal loud_proportion 842 to decision threshold 845 , to produce feature decision signal 847 . An example decision threshold is 0.3. If feature value signal loud_proportion 842 exceeds decision threshold 845 , then feature decision signal 827 is set to a state indicating that more than 30% of scaled envelope samples were relatively loud in the last time interval. Feature decision signal 827 is denoted as loud_enough in a logic statement below.
Feature decision signals clipping_too_often 827 , noise_floor_too_high 837 , and loud_enough 847 are applied to gain rule 848 . The gain logic can be expressed in the MATLAB® language, e.g., as:
if clipping_too_often
gain_direction = −1;
elseif noise_floor_too_high
gain_direction = −1;
elseif not(loud_enough)
gain_direction = +1;
else
gain_direction = 0;
end
FIG. 20 illustrates a saturation-type feature-based regulator (FBR-S) 900 according to an embodiment of the present invention. It is an example of FBR 461 of FIG. 3B , and FBR-Ss 1061 through 1064 in FIG. 1B . The overall operation is that envelope signal 901 is processed by FBR-S 900 to produce saturation-level signal 908 . Feature extractor 910 is an example of feature extractor 500 of FIG. 5A . Comparator 902 compares envelope 901 and saturation-level signal 908 . If the comparator output is high, it indicates that the envelope is higher than the existing LGF saturation level, i.e., clipping will occur. Time interval observer 903 can utilize e.g., embodiment 601 in FIG. 6, 621 in FIG. 7 , or 641 in FIG. 8 . Feature value signal 904 represents the proportion of envelope samples that were clipped during the last time interval, and is denoted clipping_proportion. The operation of saturation level scaler 905 can be expressed in the MATLAB® language, e.g., as:
if clipping_proportion > 0 slew_rate = up_slew_rate * clipping_proportion; else slew_rate = down_slew_rate; end step_dB = slew_rate / update_rate; factor = From_dB(step_dB); sat_level = sat_level * factor;
where up_slew_rate is the maximum increase in dB per second and down_slew_rate is the decrease in dB per second, and sat_level is a variable representing the LGF saturation level.
Saturation level limiter 907 constrains the saturation level between a minimum and maximum value. The minimum value of the saturation level in an adaptive LGF system is analogous to the maximum value of gain in an AGC system. It is also beneficial to set a minimum offset between the base level and the saturation level.
Thus, FBR-S 900 employs a feedback loop, where if clipping occurs, then the saturation level is increased, with a slew rate proportional to the proportion of clipping; and if no clipping occurs, then the saturation level is decreased, so that the LGF saturation level tends to follow the peak level of the envelope signal.
FIG. 21 illustrates a base-level-type feature-based regulator (FBR-B) 900 according to an embodiment of the present invention. It is an example of FBR 462 of FIG. 3C , and FBR-Bs 1041 through 1044 in FIG. 1B . The overall operation is that envelope signal 901 is processed by FBR-B 910 to produce base level signal 918 . Noise floor extractor 911 is an example of feature extractor 311 of FIG. 3C , and is similar to noise floor extractor 831 in FIG. 14 and FIG. 15 . Feature value signal 912 is the estimated noise floor. Comparator 913 compares the noise floor 912 to base level 918 , to produce feature decision signal 914 , which is denoted as noise_floor_too_high. The operation of base level scaler 905 can be expressed in the MATLAB® language, e.g., as:
if noise_floor_too_high base_level = base_level * up_factor else base_level = base_level * down_factor end
where up_factor and down_factor are predetermined values, as described previously. Base level limiter 917 constrains the base level between a minimum and maximum value.
Thus, FBR-B 910 employs a feedback loop, where if the noise floor is higher than the base level, then the base level is increased; and otherwise the base level is decreased, so that the LGF base level tends to follow the noise floor of the envelope signal.
FIG. 22 illustrates a feature-based multi-band base level and saturation level regulator (FBR-R & FBR-S) 920 according to an embodiment of the present invention. It is an example of FBR-R & FBR-S 1100 of FIG. 1C . In FIG. 22 , thick lines represent a collection of signals, one for each band of the system. The overall operation is that the set of envelope signals 921 is processed by FBR-R & FBR-S 920 to produce a set of base level signals 941 (where a signal set is denoted in FIG. 22 via curly brackets enclosing the corresponding label) and one saturation level signal 931 . In this embodiment, all LGF blocks 2281 - 2284 have a shared saturation level signal 931 . In more detail, a set of envelopes 921 are applied to a set of feature-based base level regulators 940 , to produce the set of base level signals 941 that includes member signals 941 A- 941 D that are provided to LGF blocks 2281 - 2284 , respectively. There is, e.g., one feature-based base level regulator, and a corresponding base level signal, for each band. Each feature-based base level regulator can be implemented as described previously, e.g., as in FIG. 21 . The set of envelopes 921 are also applied to maxima block 922 , which at each instant produces an output signal 923 equal to the largest of its input signals, i.e., output signal 923 is the largest envelope. Largest envelope 923 is applied to a fast saturation level regulator 924 , producing a fast saturation level 925 . In one embodiment, fast saturation level regulator 924 comprises a peak detector with an instantaneous rise time, and a release time in the range 50 to 750 milliseconds.
Largest envelope 923 is also applied to a slow saturation level regulator 926 , producing a slow saturation level 927 . In one embodiment, slow saturation level regulator 926 is implemented as in FIG. 20 . A purpose of slow saturation level regulator 926 is to improve transitions from one environment to the next, e.g., to compensate for transitions from one talker and another talker or from a quiet room and a noisy street.
The set of base level signals 941 is also applied to maxima block 942 , which at each instant produces an output signal 943 equal to the largest of its input signals, i.e., output signal 943 is the largest base level. The largest base level 943 is applied to constrain range block 944 , producing minimum saturation level 945 . The operation of constrain range block 944 can be expressed in the MATLAB® language, e.g., as:
min_sat_level=largest_base_level+min_range
where the quantities are all expressed in decibels, and min_range is for example 20 dB. This has the purpose of ensuring that the saturation level is kept at least a specified number of decibels above the base level, i.e., to ensure that the dynamic range between saturation level and base level exceeds a minimum allowed value.
Fast saturation level 925 , slow saturation level 927 and minimum saturation level 945 are applied to maxima block 930 , which at each instant produces an output saturation level signal 931 equal to the largest of its input signals.
FIG. 16 is a schematic diagram of a sound processor module 1686 configured to be incorporated into a multi-band feature-based regulator system (which can be implemented in, for example, a hearing prosthesis 1684 , e.g., a cochlear implant system) according to an embodiment of the present invention. Sound processor module 1686 can include any of the feature-based regulator systems (and their various FBR-G, etc.) discussed herein.
In FIG. 16 , the cochlear implant system comprises an external component 1685 (e.g., a behind-the-ear (BTE) unit) which is directly or indirectly attached to the body (not shown) of the recipient, and an internal or implantable component (not shown) which is temporarily or permanently implanted in the recipient. External component 1685 typically comprises one or more sound input elements for detecting sound such as a microphone 1683 , a sound processor module 1686 , a power source (not shown) and an external transmitter unit (not shown). Sound processor module 1686 processes the output of microphone 1683 , which is typically positioned by an auricle of the recipient. Sound processor module 1686 generates encoded signals, sometimes referred to as encoded data signals, which are provided to the external transmitter unit via a cable (not shown). Sound processor module 1686 can include a programmable processor 1688 , e.g., a digital signal processor (DSP), application-specific integrated circuit (ASIC), etc. Processor 1688 is operatively coupled to a memory 1689 , e.g., random access memory (RAM) and/or read-only memory (ROM). Processor 1688 also is operatively coupled via interface 1687 , e.g., to the microphone and the external transmitter unit.
FIG. 17 illustrates a flow diagram that describes a multi-band feature-based gain procedure implemented by, e.g., a sound processor module for a cochlear implant (e.g., 1686 ), according to an embodiment of the present invention. Starting at block 1701 , a frequency analysis (e.g., by a filter bank or by an FFT) is performed upon a digitized audio signal to generate analysis signals. At block 1702 , envelope detection is performed on each analysis signal. At block 1703 , each of the envelopes is multiplied by a corresponding one of a plurality of gain values, to generate scaled envelopes. At block 1704 , one or more features (as discussed herein) are extracted from each scaled envelope. At block 1705 , the features are compared to decision thresholds, to generate feature decision signals. At block 1706 , the gains are revised (or in other words, refined), based on the feature decision signals. At block 1707 , loudness growth functions are applied to the scaled envelopes to generate magnitude signals. At block 1708 , the magnitude signals are further processed to produce a set of stimulus pulses.
FIG. 18 illustrates a flow diagram that describes a multi-band feature-based adaptive LGF procedure implemented by, e.g., a sound processor module for a cochlear implant (e.g., 1686 ), according to an embodiment of the present invention. Starting at block 1801 , a frequency analysis (e.g., by a filter bank or by an FFT) is performed upon a digitized audio signal to generate analysis signals. At block 1802 , envelope detection is performed on each analysis signal. At block 1803 , one or more features (as discussed herein) are extracted from each envelope. At block 1804 , the LGF base levels and saturation levels are revised (or, in other words, refined), based on the extracted features. At block 1805 , loudness growth functions, utilizing the revised base levels and saturation levels, are applied to the envelopes to generate magnitude signals. At block 1806 , the magnitude signals are further processed to produce a set of stimulus pulses.
FIG. 19 illustrates a flow diagram that describes a multi-band feature-based gain procedure implemented by, e.g., a sound processor module for an application that provides an audio signal output, according to an embodiment of the present invention. Starting at block 1901 , a frequency analysis (e,g., by a filter bank or by an FFT) is performed upon a digitized audio signal to generate analysis signals. At block 1902 , each analysis signal is multiplied by a corresponding one of a plurality of gain values, to generate scaled analysis signals. At block 1903 , envelope detection is performed on each scaled analysis signal. At block 1904 , one or more features (as discussed herein) are extracted from each scaled envelope. At block 1905 , the features are compared to decision thresholds, to generate feature decision signals. At block 1906 , the gains are revised (or, in other words, refined), based on the feature decision signals. At block 1907 , the analysis signals are combined (e.g., by summation or by an inverse FFT) to produce an output signal.
Throughout the specification and the claims that follow, unless the context requires otherwise, the words “comprise” and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.
Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, operation, or other characteristic described in connection with the embodiment may be included in at least one implementation of the present invention. However, the appearance of the phrase “in one embodiment” or “in an embodiment” in various places in the specification does not necessarily refer to the same embodiment. It is further envisioned that a skilled person could use any or all of the above embodiments in any compatible combination or permutation.
While various 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 limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail may be made therein without departing from the scope of the present invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A computer-implemented method comprising: determining one or more features of a subject signal; revising one or more control signals on the basis of the one or more features; modifying a level of the subject signals based on the control signals. At least one of the features is determined by: comparing a given one of the subject signals against a boundary signal to produce a corresponding given boundary comparison signal; and summarizing the behavior of the given boundary comparison signal over a time interval. | 7 |
BACKGROUND OF THE INVENTION
Many station wagons, vans and the like are unsafe for their storage capability, but one significant problem with vehicles of this type is that the material stored in the vehicle is readily seen by passersby. Particularly in a station wagon-type vehicle, the material in the rear of the vehicle is readily seen by anyone who cares to look in the window. It is common knowledge that station wagons are often used for deliveries by small business and the like, and pilferage is rampant in large cities where delivery men often fail to lock the doors of the station wagon or are absent from the vehicle for an extended period of time, thereby permitting unauthorized entry into the vehicle.
An obvious method of hiding the material in the vehicle from ordinary view is to blacken or otherwise darken the windows, but this is generally unsatisfactory when the station wagon is also used as a family vehicle. Curtains or the like are another alternative, but they too present problems when the vehicle is used as a family vehicle, and therefore, do not present the answer to the posed problem.
SUMMARY OF THE INVENTION
This invention relates to a storage partition for a motor vehicle, and more particularly to a storage partition which is adjustable longitudinally of the vehicle, thereby to accommodate storage compartments of varying lengths.
An important object of the present invention is to provide a storage partition for a motor vehicle comprising an elongated flexible and opaque material, longitudinally spaced apart brace means extending transversely of the material, and fastening means on both the longitudinally extending side edges of the flexible material for connection to complementary fastening means on the motor vehicle.
Another object of the present invention is to provide a storage partition of the type set forth wherein the brace means are a plurality of longitudinally spaced apart transversely extending convex shaped bars housed in individual pockets in the flexible material.
Another object of the present invention is to provide a partition means of the type set forth which is easily foldable or capable of being rolled rearwardly to accommodate storage compartments of varying lengths.
These and other objects of the present invention will be more readily understood by reference to the following specification read in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a station wagon with the roof partially broken away and the tail gate in the down or open position showing the partition of the present invention;
FIG. 2 is a view of the rearmost section of the station wagon illustrated in FIG. 1 with the roof broken away and the partition partly rolled up and the back seat of the station wagon in the raised position;
FIG. 3 is an enlarged sectional view of the brace means and the pocket therefor;
FIG. 4 is a top elevational view of the brace means illustrated in FIG. 3; and
FIG. 5 is an enlarged sectional view of the station wagon floor sills and the partition and the connection means therefor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is disclosed a station wagon 50 of the usual type having a body 51 including a roof 52 which is partially broken away. There is a front seat 53 and a fold-down rear seat 54, the rear seat 54 being folded down into the storage position in FIG. 1 and being raised into the seating position in FIG. 2. The usual tail gate 56 is shown in the folded or open position in the drawings, and of course, the station wagon 50 is provided with the usual accompaniment of windows 57.
Interiorly of the station wagon 50 are spaced apart longitudinally extending floor sills 60 and 70. As seen particularly in FIG. 5, the floor sill 60 has a horizontal surface 61 and a vertical surface 62 integral therewith, the horizontal surface 61 being provided with longitudinally spaced apart fasteners 65. Each of the fasteners includes a base plate 66 fixedly secured to the horizontal surface 61 and an upstanding post 67 having an enlarged head 68. Similarly, the floor sill 70 is provided with a horizontally extending surface 71 and a vertically extending surface 72 integral therewith. The floor sills 60 and 70 both extend substantially the entire longitudinal length of the station wagon 50 from adjacent the tail gate 56 to adjacent the rear of the front seat 53. Longitudinally spaced apart and extending the entire length of the floor sill 70 are fasteners 75 each of which includes a flat base 76 fixed to the horizontal surface 71 and an upstanding post 77 having an enlarged head 78.
Intermediate the two floor sills 60 and 70, and more particularly intermediate the vertical portions 62 and 72, respectively, there is defined a storage area 80 into which various packages, such as those illustrated at 81 and 82 in FIGS. 1 and 2 are positioned. Normally, an onlooker can see the nature of the packages 81 and 82 in the storage space 80 by looking into the various windows 57 of the station wagon 50. In order to hide the packages 81 and 82 being transported in the station wagon 50 there is provided a partition 90.
The partition 90 includes a body portion 91 which may be fabricated of a cloth such as canvas or cotton poplin or the like, or may be fabricated from a synthetic organic resin which is opaque such as a colored polyethylene or polypropylene or other suitable plastic material. The partition 90, and more particularly the body portion 91 thereof, has transversely spaced apart longitudinally extending edges 92 and 93. The edge 92 is provided with longitudinally spaced apart fasteners 95 positioned to be in registry with the corresponding ones of the fasteners 65 on the floor sill 60. Each of the fasteners 95 includes a disk portion 96 which is reinforcingly adhered to the body 91 along the side edge 92 and has an aperture 97 therein which may be spring loaded (not shown). Each of the fasteners 95 is adapted to snap fit over the enlarged head 68 of the corresponding fastener 65, thereby to provide secure relationship between the row of fasteners 65 and the partition 90 and particularly the fasteners 95 thereon. Similarly, there is a row of fasteners 105 along the edge 93 of the partition 90. Each of the fasteners 105 is provided with a base disk 106 reinforcingly adhered to the body 91 along the edge 93 thereof in registry with a respective one of the fasteners 75. Each of the fasteners 105 has an aperture 107 therethrough which may be spring loaded (not shown). Again, each of the fasteners 105 is in registry with a corresponding one of the fasteners 75, thereby to permit securement of the partition 90 to the floor sill 70 longitudinally of the station wagon 50.
Longitudinally spaced apart along the length of the partition 90 are a plurality of braces 110. Each brace 110 is an aluminum bar having a convexly curved portion 111 with an incurved flange 112 at one end thereof and an incurved flange 116 at the other end thereof. The incurved flange 112 is part-circular and has an end 113 terminating adjacent the lower surface of the convexly shaped portion 111. Similarly, the incurved and part circular flange 116 has an end 117 thereof which terminates near the undersurface of the convexly shaped portion 111. The configuration of the brace 110 is such that it adds strength and maintains the partition body 91 taut. Braces 110 each extend substantially from the floor sill 60 to the floor sill 70 and are sized to slide easily within each of the individual pockets 120 which house the braces 110. Each of the pockets 120 includes a top portion 121 which is actually formed of the top surface of the partition body 91, and an underflap 122 which is sewn at each of two seams 123 extending transversely across the entire width of the partition body 91. Preferably, one of the braces 110 is adjacent the rearmost end of the station wagon to provide support thereat and to prevent the partition 91 from being ripped or otherwise torn during loading and unloading of the packages 81 and 82 into the compartment 80.
As seen from the drawings, the partition 90 is easily adjustable for varying lengths of the storage compartment 80. FIG. 1 illustrates the entire unfolded length of the partition 90 which extends from adjacent the tail gate 56 to adjacent the rear of the front seat 53. FIG. 2 illustrates the easy adjustability of the length of the partition 90 by rolling the partition 90 rearwardly from the front seat 53 to a position slightly behind the rear seat 54, thereby to accommodate a shortened storage area 80 when the rear seat 54 is used to transport passengers. Strategic location of the fasteners 65 and 75 such that one each is located adjacent the rear seat 54 when the seat is in the upward or raised position insures that the partition 90 will function adequately in the position illustrated in FIG. 2 without any chance that the partition might roll back inadvertently during transportation, thereby exposing the material stored within the area 80.
While there has been described what at present is considered to be the preferred embodiment of the present invention, it will be understood that various modifications and alterations may be made therein without departing from the true spirit and scope of the present invention, and it is intended to cover in the appended claims all such variations and modifications thereof. | A storage partition for a motor vehicle and particularly a station wagon which provides a compartment for storing material that is hidden from view from the casual onlooker, thereby to permit storage of valuable articles in an unattended vehicle while reducing the chance of the vehicle being broken into and the articles stolen. | 1 |
This is a continuation of co-pending application Ser. No. 07/175,407 filed on Mar. 30, 1988, now abandoned.
Applicant claims convention priority based upon the identical application, number 2245/87, filed in Austria on Sept. 4, 1987.
Field of the Invention and Prior Art
In the last few years, it has become known from several papers, some of which are described later, that in containers for liquid and gaseous substances that are easily inflammable and therefore pose an explosion hazard, a three-dimensional lattice-like shape made of metal, especially light metal, can be inserted, therefore avoiding a local overheating of the substance in the container by a quick heat conduction and therefore, in case of an accident, permitting a fire to occur but not explosions.
For example, it is known from WO-A1-85/00113 to fill the tanks for combustible liquids or gasses with safety elements that possess a good heat or electric conductivity. The safety elements are in the shape of bottle brushes and in many different shapes with laminations, spheres, cubes, etc., as well as general type filling pieces that extend in one direction only to permanently exceed the diameter of the largest opening of the container, therefore permitting the later filling of existing tanks or similar containers through existing openings in these containers.
An explosion protection system for a container is known from EP-A1-3657, which, in addition to the partial filling with a stretched metal network, has an exterior coating of heat insulating and expanding substance.
An arrangement to reduce or avoid explosions in high pressure containers for combustible liquids is known from CA-PS-1 150 682. The closed container that consists of heat conducting walls, is fitted with an equally heat conducting interior lining that extends into the material stored in the container and is permeable to it. Stretched aluminum foil is given as the material for the interior lining, which occupies approximately 2% of the interior space of the container.
CA-PS-836363 deals with a process or an explosion protection system of a known type, whereby a stretched lattice-like network with good heat conductive properties forms a filling piece for the interior space of a container, which is extensively filled by the filling piece and guaranties the free flow of the liquid. In view of the strength requirement or the natural stability of the filling piece, the latter is made of coiled parts, which are built up of base foils of different thicknesses. Some of the regular mesh structures of the individual coiled pieces are also made with mesh openings of different sizes, whereby the possibly larger mesh openings that in view of the natural stability occur in the thicker base material, obstruct the flow to a lesser extent.
An arrangement that is very similar to the one in the last-named paper is also known from US-PS-3 356 256, whereby this paper also indicates a composition of the filling pieces of individual coiled pieces of different thicknesses and mesh honeycombs of different sizes.
Another explosion protection systems for containers for inflammable substances is known from GB-A-2 028 129, in accordance to which stretched aluminum foil in filling pieces--cylindrical and spherical filling pieces are explicitly dealt with--is used to fill containers that are already in use.
All of the known arrangements of the above-mentioned types or of the type mentioned at the beginning as well as the associated manufacturing processes have one disadvantage in common, namely, that the filling that was originally placed into the container, especially in containers that are used on a non-stationary basis or containers that are exposed for other reasons to vibrations and movements, do not really remain stable over a long period of time and therefore subject to compounding; this may, as a function of the extent of the deformation and therefore the retraction of the network, whose heat conducting properties are needed in the case of an emergency from specific areas of the interior space of the container, cause a reduction in or the loss of its effectiveness regarding explosion protection. However, this problem may not be solved by simply increasing the wall thickness of the base material or the foil strip used for the manufacture of the filling piece, since, on the one hand, the weight and the volume of the filling piece increase immediately and the filling volume that is available for the substance in the container decreases accordingly and, on the other hand, it has been determined that the caking of the filling is at most delayed but not avoided.
The purpose of this invention is improved the process or the explosion protection system of the type mentioned at the beginning in such a manner, that the disadvantages named do not occur and that filling pieces may be manufactured as a part of the explosion protection system that keep their natural stability during rough treatment and over a long period of time and that safely fill the interior space of the container.
SUMMARY OF THE INVENTION
For the manufacture of an explosion protection system for a container for inflammable substances, individual areas of a foil strip made of a material with good heat conducting properties are formed out of the plane of the foil strip, whereby by means of division and/or deformation at least one three-dimensional filling piece with a large interior surface is manufactured and then inserted into the interior space of the container for the purpose of filling it out. The arrangement or the formation of the individual deformed areas is irregular, which permits the manufacture of a filling piece that keeps its natural stability during the use of the container and that is not subject to compounding caused by the release of individual areas in the interior space of the container.
This invention achieves its purpose by forming and/or arranging the individual sections in an irregular manner during the process phase where the individual sections on the surface of the foil strip are permanently bent out of the plane of the untreated foil strip, therefore creating a filling piece from the such treated foil strip, that keeps its natural stability during the use of the container. In accordance with the invention, the explosion protection system itself is developed such, that the construction and/or arrangement of the individual deformed sections is irregular. Therefore, the invention starts with the idea that the caking or the compound of the filling pieces that serve an explosion protection--it makes no difference, if one deals with an individual filling piece that is adapted to the shape of the interior shape of the container or with a multitude of smaller filling pieces that have been inserted into the container after its manufacture--is, in the first place, not the result of a lack of strength or stability of the foil strip material, but the result of the direct fitting or the always regular shapes on the surface of the foil strips that have already been treated in accordance with one of the above mentioned methods. The individual sections on the surface of the foil strip that have been permanently bent out of the plane of the untreated foil strip as described, may also continuously slide into each other in some areas during the manufacture of the coiled pieces or similar, thereby causing a "lumping together" of the material--not unlike stackable furniture or similar--and this, in turn, may be the immediate cause for the fact that there will be areas in the interior space of the container without any filling, making them an explosion hazard. A design in accordance with the invention assures that the fitting into each other of the individual sections on the surface of the treated foil strip cannot occur, therefore producing a definite three-dimensional filling piece that keeps its natural stability without any stiffening or thickening of the material itself and that does not lose its effectiveness as an explosion protective device if the container is subject to movements or is exposed to vibrations.
A further development of the process in accordance with the invention provides for individual filling pieces with a natural stability that have been extensively matched to the interior space of the container and that have been inserted into the container before the final assembly. This filling piece may, for example, be manufactured by simply coiling the treated foil strip as described at the beginning, and also by crumpling up or by pressing into forms or similar. It is important that no area-related compounding of the formed shapes on the surface of the foil strip can occur during the manufacture in accordance with the invention to ascertain, that the explosion protection system can function under any operating conditions.
A further development of the process in accordance with the invention provides that several filling pieces with natural stability are manufactured, whose dimensions are small in relation to the dimensions of the container and that are inserted into the container through a filling opening or similar. If provided in accordance with the invention, these filling pieces may again be manufactured in many ways and offer the advantage, that compounding with adjacent areas cannot occur even with the small sections on the deformed surface of the foil strip, therefore also assuring the natural stability of small filling pieces and at the same time eliminating the danger that several filling pieces may fit into each other because of surface structures of equal shape; this does not only cause the earlier described caking of the filling, but also poses the danger that stable bridge-like supports or similar occur in the container, therefore creating cavities whose space cannot be filled with filling pieces that serve to protect from explosion hazards during the filling or the operation.
A further design of the last named process phase provides for the shape of the filling pieces to be of a rotational form, especially spheres or cones. The use of rotational forms favors the filling of the container with the filling pieces, since a safe and regular filling is assured due to the lack of any bulky contours. In addition to this, it is only natural that it is easier to make rotational forms from the foil strips that have been treated as described.
A design in accordance with the invention of the explosion protection system itself, whereby the three-dimensional filling piece is formed of a stretched network, is as a further development of the invention, characterized by the fact that the stretched network shows an irregular mesh structure and especially honeycombs of different sizes and in an irregular arrangement. A simple manufacturing process for the individual bent sections on the surface of the foil strip is therefore assured, whereby these areas nevertheless maintain their favorable arrangement in accordance with the basic concept of the invention and therefore guarantee the effectiveness of the explosion protection system.
DESCRIPTION OF THE DRAWINGS
In the following, the invention is explained further with the help of a drawing that schematically represents some design examples. A part of a regular stretched network in accordance with the latest state of technology is shown in FIG. 1;
FIG. 2 shows a top view of an already precut foil strip, which has been provided with irregular cuts by the process in accordance with the invention;
FIG. 3 shows a top view of the foil strip that has already been stretched in a vertical direction to the cuts shown in FIG. 2;
FIG. 4 shows a partial cross-section of a container with an explosion protection system in accordance with the invention;
FIG. 5 and FIG. 6 show differently constructed individual filling pieces for the fabrication of an explosion protection system in accordance with the presented invention and FIG. 7 shows an oblique view of a preformed surface of a foil strip made of a material with good heat conductive properties for the manufacture of another explosion protection system in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the network shown in FIG. 1 and consisting of aluminum foil as a base material is usually manufactured by providing a strip of foil of the base material with intermittent cuts of equal length and arranged in a longitudinal direction or may be also in a cross-direction, whereby this precut foil strip is stretched in a direction perpendicular to the direction of the cuts. This may be done on a continuous basis with suitable equipment or step-by-step for individual sections; in this connection, it does not matter which method is chosen. It is essential to know that the individual network holes or the webs between the network holes of this regular network shown in FIG. 1 have a tendency to slide into each other during the formation of filling pieces for a container such as the one shown in FIG. 4, causing the compounding of the network in the filling pieces especially due to the influence of vibrations and other movements of the container, which therefore do not completely fill the container any more. It makes no difference if that respective filling piece consists of one coiled piece or several coiled pieces (as indicated in FIG. 4) or of a formed piece as shown in FIG. 5 or FIG. 6.
In accordance with FIG. 2, the foil strip 1 made of a material with good heat conductive properties is provided with longitudinal cuts that are irregular in arrangement and length, which may, for example, be produced by reciprocally rotating cutting rollers or similar (not shown here). After that process phase the foil strip 1 with the longitudinal cuts 2 is stretched in a cross-direction in the direction of the arrow 3, forming a network in accordance with FIG. 3, that now exhibits honeycombs 5 of different sizes and in an irregular arrangement, which are surrounded by individual areas 6 that are permanently formed out of the plane of the untreated foil strip 1 and form the webs. It must be pointed out in that connection that the width of these areas 6 or their webs is not shown to scale in FIG. 3--the foil strips or the networks would normally be shown with web widths as indicated in FIG. 1; however, the irregularities in accordance with the invention would be less distinct than as shown in FIG. 3.
If the network 4 shown in FIG. 3 is now made into a three-dimensional filling piece by means of coiling, rolling, crumpling, forming, compressing etc., it is assured that, because of the irregular honeycombs 5, whose arrangement may be repeated after a complete revolution of a cutting roller or similar, the sliding into each other and therefore the compounding of the individual honeycombs 5 or the areas 6 is impossible; the finished filling piece remains therefore very stable even if the material for the foil strip is then (for example, thickness of between 0.06 and 0.08 mm are typical for aluminum foil strips) and offers therefore the best possible explosion protection for the container.
The container 7 shown in FIG. 4 may, for example, be used as a fuel tank in a vehicle. It has an exterior wall 8 that is usually made of metal, to which a filler neck 9 is attached at the top. Additional openings such as, for example, for fuel level indicator and the connections for the container 7 are not shown. A three-dimensional filling piece 10 consisting here of some coiled pieces 11 that is permeable to the substance to be filled into the tank, e.g. fuel, is placed into the interior space of the container 7; the coiled pieces may have been formed by simply crumpling the network 4 shown in FIG. 3 and then installed in the container 7 before its final assembly. A weld for the permanent closing of the container 7 is indicated as 12. A rolled plug 13, which may also be made of the network 4, is also inserted in the filler neck 9.
In the application of an aluminum foil with a thickness ranging from 0.06 to 0.08 mm, which has been described above as an example, a filling piece 10 made of a network as shown in FIG. 3 occupies approximately 2 to 3% of the filling piece 10 and the large number of honeycombs 5 that can be freely penetrated, the substance filled can move practically freely in the container. A local heating up that may start at the exterior wall 8 quickly dissipates over a large area and therefore over a large volume of the interior space of the container because of the excellent heat conductivity of the filling piece material, partly because of the direct contact the network has with the exterior wall and partly by means of the liquid that is in contact with the inside of the exterior wall; the conditions that may encourage the occurring of explosions are therefore avoided in most cases.
The individual filling piece 10', 10", that are shown as a cylinder in FIG. 5 and as a sphere in FIG. 6 may, for example, also be made of the network 4 in accordance with FIG. 3--these filling pieces 10', 10" have smaller dimensions that the opening of the filling neck 9, therefore permitting the later installation of the total filling volume that consists of many such filling pieces into an already manufactured container or a container that remains in a vehicle. As can be seen in FIG. 4, this indicates that the weld 12 can be made before the installation of the filling pieces--in place of a few coiled filling pieces, the interior space of the container will be filled with many of the small filling pieces 10', 10". The above-mentioned advantages in the manufacture of large individual filling pieces hold of course also true in connection with the manufacture of many small filling pieces; by making the compounding of the individual honeycombs or network webs between the honeycombs impossible by means of their irregular formation or arrangement, the filling pieces again retain their natural stability and therefore make the filling volume for the explosion protection of the container also retain its natural stability.
A foil strip 1 that has been preformed in a different manner is shown in FIG. 7, according to which it has been provided with permanently punched out holes 14 on one side instead of being developed as a network. These punched out holes 14 may be made in one working step, for example, between two rotating rollers out of the plane of the untreated foil strip 1--many different shapes and sizes of punched out holes 14 are possible, which again has the advantage that the compounding of regular surface areas is impossible during the forming of the finished filling pieces from the preformed foil material. A hemispherically shaped perforated type of punched out hole 14 is shown in the lower right corner of FIG. 7, which represents another possibility for the manufacture of a filling piece that retains its natural stability.
While there has been illustrated and described a single embodiment of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention. | The invention concerns a process for the manufacture of an explosion protection system for a container for inflammable liquid for gaseous substances, whereby individual sections on the surface of a foil strip that is made of a material with good heat-conducting properties, are permanently bent out of the plane of the untreated foil strip; from the such treated foil strip, at least one three-dimensional filling piece with a large interior surface is manufactured by division and/or deformation and said filling piece is inserted into the container, therefore filling at least the major part of the interior space of the container, as well as an explosion protection system of that kind. | 5 |
REFERENCE TO OTHER APPLICATIONS
This application is a continuation of Ser. No. 07/220,607, filed Jul. 18, 1988, now abandoned; which is a continuation in part of Ser. No. 06/680,849, filed Dec. 12, 1984, now abandoned; which is a continuation in part of Ser. No. 06/309,979, filed Oct. 8, 1981, now abandoned. Also this application contains subject matter in common with my now pending application Ser. No. 220,527, filed Dec. 29, 1980; Ser. No. 06/348,497 filed Feb. 11, 1982; Ser. No. 06/455,509 filed Jan. 4, 1983; and Ser. No. 06/529,487 filed Sep. 6, 1983. Attention is also directed to application Ser. No. 06/692,319, filed Jan. 16, 1985.
It is the object of the present application to present extended operational functions of the hydraulic circuitry disclosed in application Ser. No. 06/309,979; additionally to present additional hydraulic circuitry control methods associated with these extended operational functions.
BACKGROUND OF THE DISCLOSURE
The present apparatus is directed to a fluid mud pump and, more particularly, to a mud pump to be utilized to intensify fluid pressure for use in drilling oil wells or in conditioning oil wells such as fracturing with extremely high pressure or abrasive fluids. Various mud pumps and pressure intensification pumps are already known to exist that employ various and sundry means to overcome the difficulties encountered in prolonged pumping of high volume, high pressure, and abrasive materials. The present invention is an apparatus which will provide improvement in mud pumping operations in such areas as reduced mud pressure pulsation, less operating energy required for fluid pressure intensification, slower operating piston speeds and longer piston strokes thus resulting in extending life of all operating parts, wider range of mud flow and pressure controllability, greater simplicity of manufacture, improved adaptability and operation, plus other less apparent improvements. Thus the context of the problem to be dealt with in the present invention is that of a non pulsating output, highly efficient and controllable hydraulic powered fluid output pump.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of multicylinder mud pump system in accordance with the teachings of the present invention.
FIG. 2 is a section view taken along the line 2--2 of FIG. 1.
FIG. 3 is a schematic drawing showing a hydraulic system and power system used to power a typical mud pump of the present invention.
FIG. 4 is an end view of the independent driven metering valve that is used to distribute hydraulic fluid to the hydraulic drive cylinders of FIG. 3.
FIG. 5 is a section view taken along the line 5--5 of FIG. 4.
FIG. 6 is a section view taken along the lines 6--6 of FIG. 5.
FIG. 7 is a section view taken along the lines 7--7 of FIG. 5.
FIG. 8 is a schematic drawing showing hydraulic line interconnection between FIG. 6, FIG. 7, and the hydraulic drive cylinder of FIG. 3.
FIG. 9 is a view of the reciprocating mud piston and valve drawn to a larger scale than shown in FIG. 2.
FIG. 10 is a view, drawn to a larger scale than shown in FIG. 2 of the mud piston rod seal that is shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is first directed to FIG. 1 where the numeral 10 generally indentifies the pump according to the present invention. In this illustrated embodiment a plan view of a mud pump employing three pumping cylinders is shown. Three or more pumping cylinders is the preferred arrangement for this pump. Each pumping cylinder is the same in cross section and is connected to a common mud inlet manifold and to a common mud outlet manifold. Attention is also directed to FIG. 2 which is a section view taken along the lines 2--2 of FIG. 1. This section view is the same for each of the three pumping cylinders that comprise the mud pump of this invention.
Referring specifically to FIG. 2, a suction manifold 11 is connected by bolts 12 to valve housing 13, manifold 11 connected to valve housing 13 of each pumping section and has an annulus 14 which is common to all valve inlets. Flange 15 is located on each end of manifold II to allow connection of annulus 14 to a suitable mud supply source. Valve housing 13 is a circular member with a circular bore 16 therethrough that is formed to receive unidirectional inlet valve assembly 17, valve assembly 17 consists of a valve seat, a spring loaded valve spool, and a compression spring element. Valve housing 13 is sealingly connected to a head flange 18 by bolts 19 and seals 20. Head flange 18 is elongated rounded member with a flat surface 21 on one side to receive member 13. The flat surface 21 has a rounded bore 22 extending inward which is concentric to and communicates with bore 16. Within bore 22 a circular shaped valve retainer plate 23 is positioned and held in place by snap ring 24 to retain unidirectional valve assembly 17 in position. Valve assembly 17 is positioned to allow relatively free fluid flow from annulus 14 to annulus 16 and to block fluid flow from bore 16 to annulus 14.
Head flange 18 contains a circular recess 31 on one end into which is fitted one end of a spacer tube 32, the second end of spacer tube 32 is likewise fitted into a circular recess 34 of one end of a head cap 33. An access opening 180 is provided through the side of member 32. Head cap 33 also contains a circular recess 35 on its second end into which is fitted a tubular shaped cylinder adaptor 36. An access opening 181 is provided through the side of adaptor 36. 18, 32, 33 and 36 are held together by tie rods 37 which are connected by threads to head flange 18 on one end and pass through headcap 33 and cylinder adaptor 36 on the second end. The second end of each tie rod 37 is threaded to receive a nut 38 which tightens against cylinder adaptor 36 to clamp together and retain flange 18, space tube 32, headcap 33, and adaptor 36 as a single unit with a concentric bore therethrough.
Head flange 18 contains a circular annulus 25 therethrough which communicates with annulus 22. Within annulus 25 an end cap 26 is slideably fitted and held in place by a circular retainer plate 27 and bolts 28. End cap 26 is an elongated circular member with a raised flange on each end that contains circular seals 29 on one end and circular seals 49 on the other end. Seals 29 and 49 form slideable sealing contact with the walls of annulus 25. The diameter of the flange that holds seals 29 is of a slightly reduced size than the diameter of the flange that holds seals 49, these seals also mate with correspondingly different sized diameters in annulus 24. These different sized sealing surfaces are to facilitate ease of assembly. End cap 26 also contains a recessed bore 30 on its inner face and side part 48 which communicates with annulus 25. The inner face of end cap 26 has a smooth, concentric circular tapered face 39 against which is fitted a correspondingly tapered face on the first end of a tubular shaped piston liner 40. The tapered face of the liner 40 contains a circular groove 41 into which a circumferential seal 50 is fitted to form a static seal between liner 40 and end cap 26. The second end of liner 40 contains a similar tapered face and sealing element 51 which mate with a corresponding tapered face 42 on an end seal member 43. Member 43 slidably and sealingly fits within a circular bore 44 of member 33. Member 43 is an elongated circular member with raised flanges on each end which each contain seals 121 fitted in circumferential grooves to form slidable seals within the bore 44 of member 33. Member 43 seats against a shoulder 45 of member 36 that limits its movement in one direction. Seal member 43, liner 40, and end cap 26 are pulled together by retainer plate 27. Retainer plate 27 being so positioned as to provide a space 46 that allows plate 27 to tighten against end cap 26 as bolts 28 are tightened. Liner 40 has a smooth inner bore 47 that is concentric with both tapered end faces. End cap 26 and its tapered bore 39 is positioned to be concentric with seal cap 43 and its tapered face 42. Thus as plate 27 is moved inward by tighting bolt 28, liner 40 will assume a concentric and sealed position with respect to end cap 26 and seal cap 42. Thus liner 40 can be of a wide range of bore diameters and maintain stable, concentric sealing contact with end cap 26 and seal cap 43. End cap 26 and seal cap 43 are positioned to maintain concentric positions through concentric alignment of annulus 25 and annulus 44.
End cap 43 has concentric bore 52 therethrough and a recessed groove 53 on its diameter which are in communication through part 54. Head cap 33 has a flat surface 55 on one side through which extends a port 56. Port 56 is in communication with groove 53. The flat surface 55 of head cap 33 is fitted to receive an outlet manifold 57 which is sealingly connected to number 33 by bolts 58 and circular seals 59. Manifold 57 connects to each of the three pumping cylinder assemblies and has a contained bore 60 therethrough which sealingly mates with bore 56 of each pumping cylinder to form an outlet annulus 60 that is common to each pumping cylinder. Manifold 57 is also fitted with flange 61 on each end for connection to a suitable outlet supply line.
Referring now to FIG. 9, liner 40 houses a member 62 which is a combination piston and unidirectional flow valve. Member 62 connects to piston rod 63 by threads 64 and is secured by snap ring 65. Member 62 consists of valve housing 66, piston seal 67, cap ring 68, piston backup ring 69, retainer cap 70, valve seat 72, seal 74, and valve plug 75. Member 66 is an elongated rounded member that is fitted on one end with a pliable sealing element 67. Element 67 is further positioned and held in place by a cap ring 68 and a backup ring 69, backup ring 69 being secured by a thread at 71. Retainer cap 70 further holds a valve seat 72 in place. Valve seat 72 is a circular ring type member with a smooth, hardened and tapered face 73 that houses a seal 74. Face 73 and seal 74 are fitted to receive a valve plug 75 that is slidably fitted into an annulus 76 of member 66. Valve plug 75 contains a smooth and hardened face 77 that is tapered to mate with face 73 and seal 74 to form a seal between member 75 and member 72. Member 75 is further fitted with a spring 78 that tends to exert a slight force against member 75 to position member 75 in normally sealed position against face 73, but which may be compressed to allow member 75 to assume a non-sealed position relative to face 73. Member 66 is fitted with slots 79 therethrough which are in communication with annulus 76. Member 70 has a bore 80 therethrough which becomes blocked when valve plug 75 is in a sealed position against face 73 but which is in communication with slots 79 when valve plug is not in a sealed position with face 73. When valve cap 75 is in a sealed position against face 73, then the annulus of liner 40 is separated into two distinct pressure chambers shown as a second pressure chamber 81 on the rod end of member 62 and as a first pressure chamber 82 on the back side of member 62. Unidirectional valve member 62 will open when pressure is applied from the first chamber 82 and allow flow from chamber 82 into chamber 81. Valve member 62 will close and hold pressure when flow attempts to travel from chamber 81 to chamber 82. Seal 67 is slidable within piston liner 40. Referring now to FIGS. 2 and 9, piston rod 63 extends forward from member 62, through a piston rod seal member 83 and connects by thread 122 to a cylinder rod 84. Cylinder rod 84 is the piston rod of a hydraulic cylinder assembly 85. Hydraulic cylinder assembly 85 consists of piston rod 84, piston rod seal 86, piston assembly 87, piston retainer cap 88, cylinder barrel 89, end cap 90, head cap 91, tie rod 92, and tie rod bolts 93. Tie rods 92 extend through end cap 90 and head cap 91 and are threadingly connected to an adapter flange 94. Adapter flange 94 is concentrically fitted to cylinder adapter 36 and retained in place by bolt 95. Thus as nuts 93 are tightened, piston cylinder 85 is secured and concentrically positioned with piston rod 63. Piston assembly 87 is fitted to slidably and sealingly form two pressure chambers within cylinder assembly 85; A rear chamber 96 with fluid inlet ports 97, and a front chamber 98 with fluid inlet ports 99. Thus as hydraulic fluid under pressure is directed to either chamber 96 or chamber 98, then piston 87 and piston rod 84 will respond with movement as directed by hydraulic fluid flow and pressure.
Attention is further directed to FIG. 10 which is an enlarged view of seal assembly 83. Assembly 83 is concentrically and sealingly fitted to end seal member 43 by bolts 100 and circumferential seal 101. Assembly 83 consists of a housing 102, end cap 103, slideable seal ring 104, seal end ring 105, seals rings 106, seal head ring 107 and retainer ring 108. Retainer ring 108 is a flat rounded ring that is centrally retained within member 43 by a shoulder 110 and member 102. Ring 108 positions in place a wiper ring 109 and retains member 107 from movement in a one direction. Housing member 102 is a rounded member with a bore therethrough into which is fitted seal head ring 107, seals 106, seal end ring 105, slidable seal ring 104, and end cap 103. End cap 103 is sealibly connected to member 102 by seal 111 and bolts 112, and is fitted to exert slight compression pressure on member 108, 107, 106, 105, and 104 as bolts 112 are tightened. Seal 106 is a rod seal which creates a slidable seal contact with piston rod 63 as compression pressure is exerted against the seal ends. Member 104 is a flat rounded plate with a slidable seal 113 on its outer circumference and a rod seal 114 on its inner circumference. Seal ring 104 also contains a small diameter orifice 115 which forms an annular communication with a recessed circumferential groove 116 that is formed in the face of member 103. Orifice 115 creates an annular communication between groove 116 and the surfaces surrounding member 105 and 106. Groove 116 further communicates with a small port 117 extending through the wall of member 102. Port 117 being threaded on the outer end at 118 to receive a suitable hydraulic connection for supply of pressurized hydraulic fluid. End cap 103 is a somewhat rounded member with a bore therethrough which is fitted with seals 119 and 120 to slidably seal against piston rod 63.
Thus as pressurized hydraulic fluid is supplied to connection 118, it will flow through port 117 to groove 116 where it will pressurize seal ring 104 thus exerting added pressure against seal 106. Pressurized fluid will further flow through orifice 115 and surround and lubricate seal 106. This process being continual with a minimum of leakage of hydraulic fluid across seal 106 as long as the pressure differential between groove 116 and pressure chamber 81 is held to a minimum. Seal 106 can be supplied with hydraulic fluid containing good lubricating characteristics and this supply of hydraulic fluid can be at a controlled pressure slightly higher than the mud pressure in chamber 81, thus seal 106 will effectively seal against mud leakage from chamber 81 as piston rod 63 reciprocates. Seal 106 will function with less friction and wear thus giving longer life and better sealing characteristics than if it were not lubricated by hydraulic fluid. The loss of hydraulic fluid will be held to a minimum due to the compression that is acting against seal 106.
Therefore, referring to FIGS. 10 and 2, as pressurized hydraulic fluid is supplied to Ports 99 and 97 of hydraulic cylinder 85, in such a manner to cause piston 87 to be powerly reciprocated, then piston rod 63 will cause piston assembly 62 to likewise reciprocate. As piston 62 moves toward the rod end or to decrease chamber 81, then valve plug 55 will assume a closed position and pressurized fluid will be forced out of chamber 81 through annulus 60 of outlet manifold 57. Simultaneously chamber 82 will create a vacuum due to the displacement of piston 62 and will pull in fluid from annulus 14 of inlet manifold 11. Incoming fluid will flow across inlet valve assembly 17, through annulus 16, 22, 25, through ports 48, and into chamber 82 to replace fluid that is being discharged from annulus 60. The amount of fluid drawn into chamber 82 will be greater than the amount displaced from chamber 81 by an amount equal to the volume associated with the piston rod 63.
Correspondingly as piston 62 moves away from the piston rod end or in the direction to decrease chamber 82, then the movement of member 62 will be in a direction to compress the entrapped fluid in chamber 82 and thus the fluid will flow through valve member 62 into chamber 81 and out annulus 60. When piston 62 moves in this direction the pressure in both chambers 82 and chambers 81 will be equal to the discharge pressure of annulus 60, and the fluid flowing from chamber 81 to annulus 60 will be equal to the volume of fluid displaced due to the volume of piston rod 63. Thus it is shown that as piston rod 63 continually reciprocates, fluid will be displaced from pressure chamber 81 to the discharge annulus 60 in both directions of travel of piston rod 63. Further, the pressure in chamber 81 and discharge annulus 60 will be equal in either directions of travel of piston rod 63.
Attention is next directed to FIG. 3 which is a schematic drawing of a typical hydraulic circuit employed to power the hydraulic cylinders 85 of this mud pump. In this circuit only two cylinders 85 are illustrated for clarity of explanation, the addition of a third or more cylinders 85 will be explained later. The main components of this circuit are a main pump 125 that is driven by a prime motor 126, a charge pump 127 that is also driven by motor 126, one way check valves 128 and 129, high pressure relief valve 130, independently driven metering valve 132 that is independently driven by motor 133, one way check valve 134, flow control valve 135, flow control valve 136, one way check valve 137, relief valve 138, pneumatic type accumulator 139, hydraulic piston and cylinder combination 85, hydraulic reservoir 140, high pressure supply line 141, low pressure hydraulic return line 142, hydraulic flow lines 143, 144, 145, 146, 147, 148 and 149, and low pressure relief valve 131. The hydraulic system shown is a closed loop charged type hydraulic system employing a variable volume single direction, main pump. Most of the components in this hydraulic circuit and the usage thereof are well known by anyone versed in the art, so I will give detailed explanation only of unique and new pressurized fluid control means disclosed by this hydraulic circuit.
It will be noted that the hydraulic circuit shown in FIG. 3 is basically the same, except for some unique and new pressure control features, as has been prior disclosed in my patent application Ser. No. 06/133,948, Grp. Art unit 343, filed Mar. 25, 1980.
Attention is further directed to FIG. 4 which is an end view of metering valve 132. FIG. 5 is a section view taken along the line 5--5 of FIG. 4. FIG. 6 is a section view taken along the lines 6--6 of FIG. 5. FIG. 7 is a section view taken along lines 7--7 of FIG. 5. FIG. 8 is a schematic drawing imposed between FIG. 6 and FIG. 7 showing hydraulic line connections between FIG. 6, FIG. 7 and hydraulic cylinders 85. Referring to FIG. 5, valve 132 contains a housing 150 with a finely finished central bore 151 therethrough. Housing 150 has an end plate 152 on one end which retains in place a seal 153 for sealing against flows therebetween. End plate 152 also contains a thrust bearing 154 which is fitted into a recessed counterbore for containment, and a fluid return port 155 which passes therethrough and is fitted on its outer end for receipt of hydraulic fluid return line 142. End plate 152 is retained in place by bolts 156. On the other end housing 150 has a second end plate 157 which is retained in position by bolts 158 and which retains in place a seal 159. End plate 157 also contains a central bore therethrough into which is fitted a second thrust bearing 160 and a shaft seal 161. Seal 161 is retained in place by snap ring 162.
Mounted within bore 151 of housing 150 is a rounded rotatable valve spool 163 which is fitted to make rotatable sealing contact with the walls of bore 151. Spool 163 has a drive shaft 164 of reduced diameter extending from one end which extends through the bore of plate 157 and thus through seal 161 to form a drive connection means to rotate spool 163 about a rotational centerline 176 by an external rotary drive means. Contained within valve spool 163 is a groove 164 that circles the circumference and continually communicates with an inlet port 165 that is positioned in housing 150 and that is fitted to receive pressure line 141. Leading inward from groove 164 is a rounded annulus 166 which connects to an annulus 167. The centerline of annulus 167 passes through the rotational centerline of spool 163 and is perpendicular to the rotational centerline of spool 163 thus forming two equal annulus outlets from spool 163 which are at 180 degree spacing. The outer ends of annulus 167 is finely finished to form square like and equal recesses 168 into spool 163. Housing 150 contains a first bore 169 therethrough and a second bore 170 therethrough being positioned in line with bore 169 but at a 90 degree spacing to bore 169, both bore 169 and bore 170 being positioned perpendicular to the rotational centerline of spool 163. Bores 169 and 170 are positioned to alternately mate with annulus 167 of spool 163 as spool 163 rotates, thereby forming two alternating fluid outlet connections to annulus 167. Bore 169 is fitted on each end for hydraulic line connections to line 149. Bore 170 is fitted on each end for hydraulic line connection to line 148. Thus as spool 163 is rotated and pressurized hydraulic fluid is supplied to inlet port 165, it is equally and alternately distributed to ports 169 and 170. Further, it is distributed with no hydraulic pressure originated side loading being applied to spool 163 as the pressure outlets are directly opposed. Further a relatively large quantity of fluid can be distributed from spool 163 since it is being distributed simultaneously at two outlets.
Referring to FIGS. 5-8, valve spool 163 further contains a second annulus 171 the centerline of which passes through the rotational centerline of spool 163 and is perpendicular to the rotational centerline of spool 163. Annulus 171 is positioned at a 90 degree spacing relative to the centerline of annulus 167. The outer ends of annulus 171 are finely finished to form square line end equal recesses 172 into spool 163 and 180 degree spacing. Housing 150 contains a third bore 173 and a fourth bore 174, bore 173 being in the same plane as bore 174 but at a 90 degree spacing from bore 174. Both bore 173 and bore 174 are in a plane perpendicular to the rotational centerline of spool 163. Bore 173 is fitted at each end to receive hydraulic line connection from line 149. Bore 174 is fitted at each end to receive hydraulic line connection from line 148. Bores 173 and 174 are positioned to alternately mate with annulus 171 of spool 163 as spool 163 rotates thus forming two alternating fluid inlet connections to annulus 171. Spool 163 further contains a centrally located end port 175 which communicates with annulus 171 and continually communicates with fluid return port 155 in end plate 152. Bore 169 and bore 173 are positioned in the same longitudinal plane relative to rotational axis 176. Thus as spool 163 is rotated fluid return port 155 will equally and alternately be in communication with exhaust bores 173 and 174. Recess 168 and recess 172 can be sized to regulate the timing of fluid distribution as required.
Attention is directed to FIG. 8 and FIG. 5 where it is clearly shown that as spool 163 is rotated, pressure inlet port 165 of valve 150 is firstly in communication through line 149 with the pressure chamber on the rod end of a first cylinder 85 while simultaneously fluid return port 155 of valve 150 is first in communication through lines 148 with the pressure chamber on the rod end of a second cylinder 85. Secondly inlet port 165 is in communication through line 148 with the pressure chamber on the rod end of the second cylinder 85, while simultaneously fluid return port 155 of valve 150 is secondly in communication through line 149 with the pressure chamber on the rod end of the first cylinder 85. Thus as the spool 163 of valve 132 is rotated and pressurized fluid is applied to inlet port 165, then the pressure chamber of a one cylinder 85 can be supplied fluid to cause it to expand while the pressure chamber of a second cylinder 85 can exhaust the same amount of fluid through return port 155. It will be noted that a third cylinder 85 can be added to operate from valve 132 by addition of a third bore through housing 150 in the plane of FIG. 6 and in the plane of FIG. 7 and thusly positioning the three through bores at a 60 degree spacing relative to the rotational axis. The same would be true if any additional cylinders are used. For example, if a fourth cylinder 85, then four bores would be positioned at 45 degree, intervals about housing 150. However, to allow uninterrupted and continuously equal flow into inlet port 165 from outlet port 155 of valve 132, without allowing a substantial amount of fluid to bypass cylinders 85, three cylinders 85 must be used. Stated another way, three or more pressure chambers of equal displacement must be used unless fluid is to be added to the hydraulic fluid circuit. Thus, the pump of this invention will normally employ three or more cylinders 85, the fluid circuit depicted in FIG. 3 illustrating two cylinders 85 only for ease of explanation. Also in the circuit depicted in FIG. 3 outlet 169 and 173 are illustrated as emerging from one side only of valve 132 for ease of explanation, as are outlets 170 and 174. It is obvious that lines 149 and 148 could be so internally ported within housing 150 as to eliminate excessive outside piping.
Referring to FIG. 3, motor 126 powers charge pump 127 to precharge the hydraulic circuit to a pressure as determined by the setting of relief valve 131, preferably in the 200 P.S.I. range. Motor 126 also powers main pump 125 to supply pressurized fluid to line 141. Pressurized fluid travels through line 141 and enters valve 132 at port 165. Valve 132 being controllably rotated by motor 133; the rotation of valve 132 being independent of fluid flow or fluid pressure. Pressurized fluid is first directed to line 149 by valve 132 to pressurize chamber 98 of a first hydraulic cylinder 85 while chamber 98 of a second hydraulic 85 is vented by valve 132 to hydraulic return line 142 through outlet 155. Chambers 96 of cylinders 85 are connected by a common fluid line 146, thus as pressurized fluid enters chamber 98 of first cylinder 85 it will force fluid out of chamber 96 of said first cylinder end into chamber 96 of a second cylinder 85. The fluid entering chamber 96 of said second cylinder 85 will in turn force fluid from chamber 98 of said second cylinder, which fluid will be returned to line 142 through port 155 to be repressurized by pump 125. The amount of fluid returning to line 142 will be the same as is leaving from line 141, less leakage which is made up by charge pump 127. This process is alternately and continually repeated by cylinders 85 thus continually powerly stroking cylinder rods 84 of cylinder 85. The stroke length of cylinder rod 84 being determined by the amount of fluid passed through line 141, or by the rotational speed of valve 132. The pressure within hydraulic line 146 and thus within chamber 96 of cylinder 85 is controlled by relief valve 138. Thus fluid pressure is applied to chamber 98 of a first cylinder 85 to powerly drive piston rod 84. In a one retracting direction the secondary pressure created in chamber 96 can powerly drive piston rod 84 of a second cylinder in a second extending direction. Thus work can be performed simultaneously by all cylinders 85. When three cylinders 85 are used as will normally done according to the present invention, then the pressure chamber 98 of two cylinders 85 can simultaneous be receiving pressurized fluid while the chamber 98 of the third cylinder 85 is exhausting fluid. Conversely the pressure chamber 98 of one cylinder 85 can be receiving pressurized fluid while the chamber 98 of the second and third cylinder 85 are simultaneously exhausting fluid.
It will again be pointed out and stressed that valve 132 of this invention is an independently driven valve, which means that its rotation is completely independent from the movement of the piston 87 within cylinder 85. This independently driven control valve 132, to effectively control the movement of free floating pistons 87, is a new, innovative and advantageous concept of hydraulic powered cylinder control. The two major difficulties that have hindered development of high horsepower hydraulic driven reciprocating piston pumps in the past has been the seemingly impossible solution of supplying a large quantity of non-pulsating pressurized fluid to the cylinders while controlling the timing of each of the cylinder strokes.
Referring again to the hydraulic circuit of FIG. 3 it will be pointed out tha for the circuit to be operable piston 87 of cylinder 85 must be in a position to move when pressurized fluid is admitted to chamber 98. Stated another way, since piston 87 is not positively timed in relation to valve 132, then upon start-up of the pump according to the present invention if piston 87 is positioned at the expanded directional end of its stroke, and pressurized hydraulic fluid is directed to said expanded chamber, then damaging pressure pulsation will occur because the pressure will surge to the relief setting of high pressure relief valve 130. To assure that this situation does not normally arise, a variable volume pump 125 is employed as the fluid power source, and the pressurized driving fluid is directed to the rod end of cylinder 85. Note from the circuit of FIG. 3 that on start up or at any time that prime motors 126 and 133 are operating and hydraulic pump 125 is positioned in its neutral or no flow, position, the charge pump 131 will charge the complete system to the pressure as dictated by the low pressure 131 relief valve setting. This puts the same pressure on chambers 96 and 98 of cylinder 85, thus tending to expand chamber 96 due to the area of piston rod 84, thus piston 87 will always tend to position itself so that chamber 98 may expand and thus automatically assume a timed cycle relative to valve 132 as valve 132 rotates, without causing a high pressure surge. A low pressure source will occur which is determined by the relief valve setting of relief valve 138. Further, since pump 125 is a variable volume pump, the fluid going to cylinders 85 is gradually increased which correspondingly gradually increases the stroke length of piston 87 and allows piston 87 to automatically assume a timed relationship to valve 132 as piston 87 starts reciprocating. Further when the system is operating and the piston stroke length within cylinder 85, is decreased to zero by changing the output of pump 125 to zero, then the pistons 87 will automatically assume a near centered position relative to cylinder 85, thus providing for piston 87 to be in a position to expand and automatically assume a timed position with valve 132 as fluid is again supplied from pump 125.
Referring to FIGS. 2 and 3, indicated, the pump according to this invention is a double acting pump which means that cylinder rod 84 must supply force in each direction of travel. This force requirement depends upon the mud pressure being pumped and thus varies greatly. Therefore, the pressure requirements within pressure chamber 96 and thus line 146 varies considerably. The fluid reservoir created by chambers 96 and lines 146 will be of constant volume for a given cylinder stroke length and is in essence a closed reservoir. However, the reservoir of chambers 96 are subjected to sliding seals and to leakage so additional make up fluid must be continually supplied to this closed reservoir from a source of higher pressure. This is done by allowing a volume of fluid to continually flow from high pressure line 141 to line 146 through an adjustable metering valve 135.
Since there is no practical way to always supply the correct amount of make up fluid to the closed reservoir of chamber 96 and line 146, and since this reservoir must remain at or above the required volume, then an excessive amount of fluid must be allowed to flow across metering valve 135 and a suitable means must be provided to allow this excessive fluid to discharge from chamber 96 without causing excessive pressure surges. Note that the excessive fluid passed therethrough chamber 96 is also a means to provide cooling to chamber 96.
Piston 87 of cylinder 85 will automatically force fluid from chamber 96 across relief valve 138 as the piston strokes and chamber 96 will automatically assume the correct volume. However, there will be damaging pressure surges on the complete high pressure circuit unless valve 138 is set to dump fluid at a pressure only slightly above the pressure that is required in chamber 96. The required pressure in chamber 96 being that pressure that is necessary to move piston rod 84 against its load. Its load being varied as previously described. Thus relief valve 138 must be capable of sensing the loading requirement of chamber 96 and adjusting to allow fluid bypass therethrough at a pressure slightly higher that the load requirement, if this system is to function with a minimum of pressure surges. it will be noted that the pressure surge required to remove fluid from chamber 96 can be excessive, if not controlled, due to the larger piston area of piston 87 that it is acting against, and also due to the fact that the surge is sudden because the excess fluid will be discharged very suddenly when a one of pistons 87 has reached the end of its stroke. When piston 87 has reached the end of its stroke as described, than the pressure in chambers 96 will suddenly jump from whatever the required pressure to move piston rod 84, to whatever the relief valve 138 is set to relieve.
To overcome the above described conditions and maintain the said pressure surge to an acceptable and workable range, unique circuitry employing a gas operated accumulator 139 is used. Accumulator 139 contains a pressure chamber 177 filled with a compressible gas, a pressure chamber 178 for connection to hydraulic fluid, and moveable piston or diaphragm element 179 sealibly separating the two chambers. Chamber 177 is filled with a compressible gas and pressurized to approximately the same pressure as the charge relief valve 131. Chamber 178 is connected through check valve 137 and metering valve 136 to the closed reservoir formed by chamber 96 of cylinder 85. A line 147 connects the vent port of relief valve 138 to hydraulic chamber 178. As anyone versed in the art of hydraulics is aware, the vent port of a relief valve 138 can be utilized to control the pressure at which the relief valve 138 allows fluid to pass therethrough. Fluid will pass across said relief valve at a pressure equal, or just above the pressure at which fluid is allowed to pass from the vent port because of a spring loaded plunger positioned within the valve 138. I will not describe the internal operations or relief valve 138 as this is well known in the art. Chamber 178 of accumulator 139 is connected to chamber 96 of cylinder 85 through a one way check valve 137 that allows fluid from chamber 178 to flow to chamber 96, but blocks flow in the opposite direction. Chamber 178 is also connected to chamber 96 through a variable volume metering valve 136. Thus when pump 125 is supplying pressurized fluid to lines 141, then the pressure chamber formed by chamber 96 will be continually maintained at a pressure required to cause piston rod 84 to move against its load through metered pressurized flow across valve 135. The pressure in chamber 178 of accumulator 139 will also be equal to or slightly above the required pressure of chamber 96 because of valve 137 and valve 136. If chambers 96 contain an excessive amount of fluid then as a one piston 87 of cylinder 85 reaches the end of its stroke in the rod end direction, then the pressure in chamber 96 will start to rise. The rise in pressure will cause fluid to flow from the vent port of relief valve 138 to chamber 178 of accumulator 139 and thus allow relief valve 138 to pass fluid therethrough to low pressure line 142 thus allowing the excessive fluid to be dumped from chamber 96 at a pressure just higher than the required pressure in chamber 96. Chamber 178 will assume the pressure of chamber 96 through valve 137 and valve 136. However, chamber 178 will not be subject to a sudden pressure surges due to blockage of fluid flow at valve 137 and a metering of fluid at valve 136. Fluid vented from valve 138 is also internally metered within valve 138. Thus due to the compressibility of the gas in chamber 177, the fluid pressure in chamber 178 will rise at a slower rate that the pressure in chamber 96, thus allowing valve 138 to dump excess fluid from chamber 96. This process is continually repeated, thus keeping the fluid volume and pressure requirement of chamber 96 as necessary to continually operate cylinder rod 84 in a powerly reciprocating manner.
Thus it is noted that as a quantity of pressurized fluid is supplied to valve 132 by pump 141, and valve 132 distributes this fluid to chamber 98 of cylinder 85, then piston 87 will assume a stroke that is synchronized with the rotation of valve spool 163. This synchronization will occur pulse free as long as chamber 98 is free to expand and piston rod 84 has equal loading, and the correct pressure is maintained in chambers 96. The pressurized fluid within chamber 96 assures that piston 87 either assumes a somewhat centralized position or a rod end position within cylinder 85 whenever the fluid flow to cylinders 98 is decreased thus decreasing the stroke. Thus piston 87 will always assume a position to allow surge free synchronization with valve 132 and to allow surge free increase and decrease of its stroke length. The requirement for surge free synchronization between piston 87 and valve 132 being that the stroke length of piston 87 is reduced to a given amount prior to ceasation piston movement. On start-up of piston movement, the supply of pressurized fluid to chamber 98 be at a given minimum. The given minimum being dependent mainly upon the rotational speed of valve 132. However, a surge free synchronization can always be assured by bringing the pressurized fluid flow supply to valve 132 to a zero value at a reasonable reduction rate to cause piston 87 to cease stroking, while correspondingly increasing the pressurized fluid flow rate to valve 132 at a reasonable increase rate to commence stroking of pistons 87.
Thus it has been shown that independently operated valve 132 can receive, distribute, and return a large or a varying quantity of pressurized fluid without flow interruption or without damaging pressure side effects acting upon said valve. Further, free floating piston 87, and therefore cylinder rods 84 can be reciprocally and alternately powered in both directions of travel by large or varying quantities of pressurized fluid. Finally the piston stroke length of pistons 87 is controllable as desired; and piston stroke length can be started, stopped, or operated continuously without excessive pressure surges, and with an automatically assumed synchronization between the rotation of valve 132 and the stroke cycle of piston 87.
It has additionally been shown from the previous discussion that the loading upon each piston rod 84 will be equal when the above reciprocating piston system is employed to drive the pump of this invention. This equal loading of piston rod 84 being obvious from the disclosure that each piston of said mud pump discharges its flow directly into a pressure chamber common to all pistons of said mud pump.
Further unique operating characteristics of this pump are provided by the illustrated circuitry of FIG. 3 combined with the independently operated rotary valve 132. In the operation of the hydraulic drive system, there can actually be two distinct modes of operation--depending upon the start up relation between valve and cylinder. If the cylinders are all retracted completely, then the actual timing position between valve and piston can be slightly different from what it is if the pistons are positioned near mid range and free to move in each direction. The preferred mode of operation is with the pistons starting from a position not completely retracted. There are numerous means to assure that the pistons are in the preferred position at start up. It would normally occur when the circuitry is arranged as shown in FIG. 3 because valve 131 would normally be set at a low enough pressure so that frictional forces upon the cylinder piston rod would be enough to keep the piston of cylinder 85 in the "stopped" position unless drive pressure were applied to line 141. Another means that could be employed would be to remove check valve 134 and block line 146 at this position, then install a shut off valve on one side of valve 135 thus the pistons of cylinder 85 would be "locked" into the "stopping" position until the system is again started. It will also be noted that the line 145 leading from high pressure relief valve 130 can be connected to line 142 if desired to prevent a pressure drop in line 142 when fluid is by-passed across valve 130. It is also noted that the line leading from relief valve 138 can be connected to line 142 if desired instead of to reservoir 140 as illustrated to assist in prevention of a pressure drop in line 142.
It is additionally pointed out that the two modes of operation as discussed above actually encompass two different methods of the excess fluid being dumped from the interconnect chamber 96. In one case--the preferred case, the excess fluid is forced from the interconnected cylinder spaces as the valve relatively inhibits fluid flow from a cylinder 98 space; In the second case, when the system is started with the cylinders in the fully retracted position, the valve can assume a relative position where the excess fluid is dumped prior to the opening of a cylinder 98 space. The degree of change between the relative position of valve and piston is small; however, the degree of operational characteristics is large as the preferred case, the first case, allows a much broader range of cylinder piston speed and stroke length adjustment without system malfunction.
The pump of this invention has the capability to operate effectively at a large horsepower capacity. Oilfield pumps generally need to operate at a horsepower capacity of anywhere from 100 to 2000 horsepower. Thus when operating a hydraulic system of this type, it is an absolute requirement from a practical standpoint to have a system that does not experience sudden fluid flow blockage or does not experience a continued bypass of a large quantity of pressurized fluid. For example a 1000 horsepower system would require a fluid flow of approximately 500 gallons per minute at 3000 p.s.i. pressure. This represents a tremendous amount of energy and the machinery required to produce this energy cannot in actual application withstand shocks or heat that is generated from such practices as such that due to sudden flow stoppage to allow a valve to shift, or for a piston to move from a dead ended position, or for venting back to a holding tank a large quantity of pressurized fluid to control piston stroke length. For example, if half the above indicated fluid was vented to tank to cause a piston stroke length to change by one half, then it would require an additional 500 horsepower system to control the cooling of the vented fluid. To this end the pumping system that I have disclosed is an extremely versatile and controllable fluid pumping system that is relatively simple and can effectively and in a practical manner be continually operated to transmit a high horsepower capacity.
The foregoing is directed to the preferred embodiment but the scope of the present invention is determined by the claims which follows: | A multicylinder, double acting improved mud pump is disclosed. The preferred embodiment incorporates a hydraulic powered piston in a cylinder which connects with a piston rod which, in turn, drives a second piston in a cylinder adapted to pump fluid mud. The first piston is driven by hydraulic oil delivered under pressure to intake manifolds through an independently driven valving apparatus which times the delivery of the hydraulic fluid for the main power stroke and further times the discharge of the hydraulic fluid for the return secondary power stroke, the system being controlled independently of piston action in timing of multiple pistons in multiple cylinders by the valve system. Additionally an intake valve delivers fluid mud at lower pressure on the intake side of the mud compression piston, and an outlet valve transverses with the piston rod to direct the outlet mud flow. Additionally a mud piston is provided which defines a first compression chamber for receipt of incoming fluid mud and a second compression chamber for discharge of pressurized fluid mud. Additionally the outlet flow valve being contained within the confines of the mud piston and additionally the unidirectional flow valve being operatively controlled by the movement of the mud piston driving rod. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a structural support base wherein the legs of the base overlap to form an interlocking geometric pattern for independently supporting articles that are placed upon the base. More particularly, the base is formed entirely from interlocking leg members alone, and it is capable of advantageously supporting such articles as a plastic tree stand container.
2. Description of the Prior Art
A variety of Christmas tree holders are known in the art. These devices typically incorporate a dish or pan for holding water, three or four legs that contact the floor, a number of threaded bolt-type members, and structure associated with the legs for assisting the bolt members in supporting a centrally positioned tree. The tree is typically cut at its lowermost point, which condition means that it has been permanently separated from its root structure. These traditional types of devices are most often made of metal.
Manufacturers have attempted to advantageously employ high density plastic in place of the traditionally metal tree stand pan, but problems exist that have limited the potential applications for plastic construction. As compared to metal constructs, plastic at least offers the potential advantages of economy in production and a rust-free product life. Unfortunately, plastic tree stand containers are not often seen commercially, because plastic has a tendency to creep or otherwise deform under the heavy loading that tree stands generally must endure. The tree stand must continuously bear the weight of a heavy tree for a substantial period of time, and plastic deformation fatigue failure can cause a very short product life if the plastic is not adequately supported. Particularly, the interaction between the prior art structural legs and the plastic tree stand container causes unwarranted stress in the plastic container.
SUMMARY OF THE INVENTION
The problems outlined above are substantially present invention. That is to say, the stand hereof incorporates a plastic tree stand container that is not readily deformable under normal loading conditions, because the invention also incorporates a support base formed from a number of legs that interlock to support the dish without unduly straining the plastic.
In a broad sense, the support base of the present invention incorporates a number of legs that come together in a geometric pattern (e.g., a square or a triangle) to overlap and interlock for withstanding a loading force. In more preferred forms, flexible fasteners couple the legs with one another to retain them interlocked in their geometric configuration. Even without these preferred fasteners, however, the legs themselves form a self-supporting base by means of a structural brace overlap type of interlocking geometrical pattern. In other preferred forms, the legs each incorporate a curved section on one end that assists the legs in interlocking with one another.
In particularly preferred forms, the invention contemplates a tree stand container or other platform that rests on top of the support base described above. The platform is designed for supporting articles, and it has a bottom that incorporates channel fasteners for holding the legs of the support base together in their interlocked position. Additionally, particularly preferred forms of the tree stand incorporate an external water level indicator having a special retaining means. Assembly is quick and easy because the process requires no hand tools.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the preferred tree stand, in accordance with the present invention;
FIG. 2 is a top plan view of the tree stand;
FIG. 3 is a bottom view showing the geometrical relationship between the supporting leg members as they fit into the grooves and apertures that retain them;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3;
FIG. 5 shows a sectional view taken along line 5--5 of FIG. 2;
FIG. 6 shows the bottom of the tree stand container as a leg member is just being inserted;
FIGS. 7, 8, and 9 show an exemplary sequence of events during the insertion of the leg subsequently to the step that is depicted in FIG. 6;
FIG. 10 shows four legs of the preferred support base interlocked in a self-supporting geometric pattern.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-4, tree stand 10 broadly includes a multi-legged support base 12, a tree-receiving container 14 on top of base 12, threaded fasteners 16 for retaining the tree by its trunk within container 14, and water level indicator 18.
FIG. 10 shows support base 12 assembled in a square structural brace overlap type of interlocking geometric pattern. Legs 20-26 are substantially identical, and they are formed from 3/8" diameter high strength steel rods. Each of legs 20-26 has a respective end segment 28-34 and a respective main body 36-42. As seen in the example of leg 26, line 44 represents a projected central axis of symmetry in the main body 42 of leg 26. Similarly, projected line 46 represents a central axis of symmetry in end segment 34 of leg 26. The angle α measures the angle between lines 44 and 46. The projected lines 44, 46 show that segment 34 exists in an angularly skewed and downwardly curved relationship with main body 42. This relationship exists because end segment 34 incorporates a curved section to produce angle α. Although each of the legs 20-26 has been illustrated in its preferred form as having an end segment 34 of some significant length that extends beyond the downturned curve or crook in the leg, it will be appreciated that each leg could dispense with the end segment 34 and terminate immediately after the hump or curve presented by the crook.
Legs 20-26 each include a respective end cap 48-54. Note that number 56 represents the floor of a structure or building and that angle β, which measures between line 44 and floor 56, represents the rise of leg 26 from leg end cap 54 to leg end segments 34. A similar angle β exists for all legs 20-26, and the most preferred angle β ranges between 2° and 5° to yield a slightly positive rise along legs 20-26. The magnitude of angle β, however, is not critical to the invention as long as legs 20-26 can reasonably resist against forces that could overturn the base. In particularly preferred forms, the angle α ranges between 15° and 40°.
FIG. 3 shows a bottom view of container 14 with legs 20-26 installed for retention in the structural brace overlap type of interlocking geometric pattern of FIG. 10. Container 14 is formed with four channel grooves 58-64, with each channel groove corresponding to a given leg 20-26. As seen in FIG. 6, channel groove 60 includes sidewalls 66, aperture 68, cross piece 70, bottom surface 72, and snap lock 74. Snap lock 74 is of rounded dimensions and includes flexible lip 76 for retaining leg 22 in place. Channel groove 60 forms an example for the other grooves 58,62,64, because all channel grooves 58-64 have a similar construction, and they act to retain legs 20-26 in a self-supporting interlocked manner.
As can be seen primarily in FIGS. 1, 2, and 5, container 14 has additional features that function well in the preferred tree stand, including water aperture 78 near the bottom of the container, nipple 80 (FIG. 3) associated with aperture 78, upright spike 82 in the center of the floor of the container, rim 84 around the top of the container, hose aperture 86 (FIG. 5) in rim 84, horizontally extending threaded apertures 88 in the side of rim 84, bottom wall 90, and container side wall 92. Water aperture extends through bottom 90 from the interior side 94 to the exterior side 96 (FIG. 6), and nipple 80 forms structure around the aperture 78 as it passes through to the exterior side 96 of bottom wall 90. Spike 82 extends upwardly from the approximate midpoint of interior side 94 along an approximate central axis of symmetry 83 in platform 14. Exterior side 96 incorporates central cross-brace system 98 (FIG. 6) to support the portion of spike 82 that protrudes through bottom 90. Hose aperture 86 extends through rim 84 which depends from the top of side wall 92. Rim 84 incorporates threaded apertures 88, which extend through rim 84 and include structure for mounting a standard threaded metal nut 99 (FIG. 3) for accommodating the threads of threaded fasteners 16 as they pass through apertures 88. Note that threaded fasteners 16 are ordinary eye bolts. Side wall 92 conically tapers inwardly and downwardly to present a lesser diameter at bottom joint 100 (where bottom 90 meets side wall 92) than at the top of container 14.
Water level indicator 18 includes transparent hose 102 and retainer 104 (FIG. 5). Hose 102 fits around nipple 80, and it may be bound there around its circumference by means of a metal band or clip (not depicted) to prevent fluid leaks. As seen in FIG. 5, retainer 104 has a head 106 and body 108, and it is otherwise known as a commercially available type of automotive fastener. Body 108 has a series of protrusions 110 that slightly exceed the diameter of hose 102. These protrusions 110 do not extend around the entire circumference of body 108, but they are formed in semi-spherical shapes extending radially and outwardly with vertically oriented gaps between the shapes. This configuration allows air to flow in and out of hose 102 through the end of hose 102 that is connected to retainer 104. The head 106 of retainer rests against the outer, upper face of rim 84 to hold the tube 102 up in its position within the aperture 86 in the rim 84.
A consumer may assemble tree stand 10 by inserting threaded fasteners 16 into threaded apertures 88 and also inserting legs 20-26 into respective channel grooves 58-64. Advantageously, hand tools are not required. As an example of the required leg insertion procedure, FIGS. 6-9 depict the sequence of steps that result in the insertion of leg 22 into groove 60. Arrows 112 to 118 depict the general directions of movement as the consumer inserts leg 22. Arrow 112 shows that end 30 of leg 22 is placed in groove 60 to face aperture 68. Arrows 114, 116 show that end 30 travels toward and then through aperture 68. Arrow 118 shows that leg 22 is pressed downwardly through lip 76 of snap lock 74 where it is removable held in place. All of legs 20-26 are assembled in this manner until they rest in grooves 58-64 and in such a way that the square structural brace overlap interlocking geometric pattern of FIG. 10 is preserved.
In use, tree stand 10 holds a cut tree (not depicted) in a vertical orientation with the cut end down and impaled by spike 82. Threaded fasteners 16 serve to adjustably support the tree from the sides. The legs of support base 12 extend outwardly to prevent stand 10 from tipping over on its side. The consumer may desire to keep the tree fresh by placing water (not depicted) inside container 14, which forms a sort of watertight bucket. The water will flow through aperture 78 and into transparent hose 102 where the water level will be visible from the outside.
It will be appreciated that although the snap locks 74 securely 20-26 in place on the bottom of the container 14, there is little or no weight transferred from the container to the legs at that location. Instead, the main load-bearing contact between the container 14 and the brace 12 occurs at the "humps defined by the intersection of each downturned end segment 28-34 with its main leg section 36-42 (see FIG. 4 for example). Thus, creep and wear of the plastic at locks 74 is minimized.
Of course, the invention as described herein is given by way of example and not by way of limitation. Most particularly, the disclosure includes a tree stand, but this should not be seen as a necessary limitation on the structural brace itself. Any number of different types of objects and devices could be supported on the brace.
Additionally, support base 12 may incorporate a variety of geometric patterns, e.g., triangular, square, pentagonal, and octagonal. These patterns are all produced in a similar manner in that leg end portions overlap the main bodies of other legs to produce a support base. The minimum practical number of legs is three, and all of these variations fall within the spirit of the invention.
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of his invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims. | A self-supporting base having legs that overlap to geometrically interlock in a structural brace can advantageously support such articles as a plastic tree stand container without creating undue stress in the plastic. The resultant tree stand additionally contains a water level indicator having a transparent hose that is retained at its upper end by a special fastener. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a surface treating method of a granular material formed by polishing a rice, a barley, a Japanese millet, a foxtail millet, an adlay, or the other grains, or kneading and solidifying a starch such as a tapioca.
2. Description of the Prior Art
In the rice, the barley, the Japanese millet, the foxtail millet, the adlay, or the other grains, a “bran” or the like attached to a surface thereof or forming a part of the surface is removed by polishing prior to being served as a food. Further, a miscellaneous grain crop, a corm or the like is once formed into fine particles so as to be made a dry starch, and thereafter is kneaded and solidified, thereby being processed to a granular material having a fixed size such as the tapioca.
Since the polished grains or the processed granular materials mentioned above mainly contain a starch, an entrained component such as a fat and an oil or the like oozes out and an oxygen, a moisture or the like enters into an internal portion, whereby the polished grains or the processed granular materials change in quality. Accordingly, these materials are not proper to be kept or stored for a long time.
For example, with respect to the rice, there is performed a method of removing a bran component on the surface and an aleurone layer by polishing a brown rice so as to obtain a polished rice and further removing a skin bran by brushing it so as to obtain a milled rice.
Since the polished rice has less bran component and aleurone layer in comparison with the brown rice, the polished rice less changes in quality, so that the taste thereof is deteriorated at a lower degree during the storage within a given period.
However, on the contrary, since the polished rice is not covered with the bran component or the aleurone layer, the oil and fat easily oozes out to the surface at that degree and the oxygen, the moisture or the like easily enters into the internal portion, so that there is a problem the polished rice is easily oxidized and changes in quality, thereby being improper to be kept or stored for a long period.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a treating method of forming a protection layer having strong abrasion resistance and oxidation resistance and having a thickness of micron order of a surface of a polished grain or a processed granular material so as to make it hard to be changed in quality, thereby improving a storage capacity for a long time.
Further, another object of the present invention is to provide a treating method of forming fine particulate starches attached to the grain or the granular material into a paste state so as to combine with the protection layer.
The prevent invention solves the problems mentioned above by means of applying a high humidity hot wind to a polished grain or a processed granular material so as to heat a surface layer portion, forming a starch in the heated portion into a paste state, making the starch into an alpha state, cooling the portion and forming a fine layer of the alpha starch.
The method in accordance with the present invention is to apply the high humidity hot wind to the granular material such as the polished grain or the like so as to form the starch in the portion between some microns and some hundreds microns of the surface of the granular material into a paste state due to the heat and the moisture, further to make the starch into an alpha state so as to form the alpha starch layer having a fine density and a high abrasion resistance, and to cool the alpha starch layer.
A temperature and a humidity (moisture containing amount) of the high humidity hot wind and a heating time of the granular material are determined on the basis of a quality of the raw material granular material and a thickness (between some microns and some hundreds microns) of the alpha starch layer required for the product granular material.
That is, when applying the high humidity hot wind to the granular material, the starch of the surface portion is at first formed into a paste state, and next it is made into an alpha state.
In this case, the fine-powder-shaped starch attached to the surface of the granular material is also simultaneously formed into a paste state so as to be attached to the granular material, thereby being integral with the granular material.
The raw material granular material has a tendency that the surface portion is easily formed into a paste state as the contained moisture becomes higher, and the paste state and the alpha state of the starch of the surface portion of the granular material can be securely promoted as the heating time becomes longer, whereby the thickness of the alpha starch layer is increased.
In this case, when the temperature of the high humidity hot wind is over a fixed temperature, for example, 250° C., a speed at which the portion is dried becomes greater than a speed at which the starch is made into a paste state in accordance that the temperature becomes higher, whereby the alpha starch layer becomes thin.
Further, when the heating operation is continued after the alpha starch layer is generated, the alpha starch layer is dried, the density fineness is reduced to weaken the layer, and a crack is going to be generated on the surface of the granular material. In this case, when the heating operation is further continued, the heat is transmitted to an inner side of the alpha starch layer, the starch at this portion is made into an alpha state and the contained moisture is reduced, whereby the granular material becomes not “a raw rice”.
Accordingly, in view of this point, the high humidity hot wind is to be properly set such that a temperature is about 85 to 300° C., a humidity is about 50% or more, and a heating time is about 1 to 10 seconds, and in the case that a temperature is about 200 to 300° C., the heating time is to be properly set to about 1 to 5 seconds.
After applying a predetermined heat treatment to the granular material, the treated granular material is cooled. This cooling operation is applied for the reason of preventing the alpha starch layer being weakened due to the continuous heat application after the pasted starch is made into an alpha state and preventing the granular material from being changed in quality due to the temperature transmission to the inner portion of the granular material. The cooling operation is performed by changing the temperature to a temperature (about 40 to 50° C. or less) at which the weakening and the change in quality are not generated before the weakening and the change in quality are generated (within about 1 to 10 seconds after the heating). The purpose can be achieved by bringing the alpha starch layer into contact with the air at a room temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view schematically showing an embodiment of a surface treating apparatus of a granular material to which a method in accordance with the present invention is applied; and
FIG. 2 is a partly cutaway vertical cross sectional view showing another embodiment of a high humidity hot wind generating furnace.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A description will be particularly given below of a surface treating method of a granular material in accordance with the present invention on the basis of an illustrated surface treating apparatus.
In this embodiment, the surface treating apparatus of the granular material is constituted by a heating tank 1 and a cooling conveyor 2 .
In the heating tank 1 , an inlet port 11 for a raw material granular material is mounted at an upper portion and a discharge port 12 is mounted at a lower portion. Further, a sliding surface 13 formed by a metal net or a punched metal is provided between the both ports. Further, although an illustration is omitted, a fixed amount inputting apparatus of the raw material granular material is connected to the inlet port 11 so as to input the fixed amount of the raw material granular material into the heating tank 1 , whereby the input raw material granular material is slid down while rolling along the sliding surface 13 and is discharged from the discharge port 12 . A ventilating port 14 for a high humidity hot wind is mounted to a lower portion of the heating tank 1 , an exhaust port 15 is mounted to the upper portion thereof, and a high humidity hot wind generating apparatus is connected to the ventilating port 14 , whereby the structure is made such as to supply the high humidity hot wind having a predetermined temperature to the heating tank 1 . The supplied high humidity hot wind passes through the sliding surface 13 within the heating tank 1 so as to be in contact with the granular material sliding thereon and heat the granular material, and thereafter is discharged from the discharge port 15 . In other words, the granular material sliding on the sliding surface 13 is in contact with the high humidity hot wind so as to be heated, and thereafter is discharged from the discharge port 12 .
The heating tank 1 is structured such that an angle of incline can be freely adjusted, whereby a time required for the granular material sliding on the sliding surface 13 , that is, a time required for being heated and treated by the high humidity hot wind can be adjusted by adjusting the angle of incline of the heating tank 1 so as to adjust the angle of incline of the sliding surface 13 .
In accordance with the embodiment shown in FIG. 1, the high humidity hot wind generating apparatus is of a type of supplying a combustion gas of a burner as one component of the high humidity hot wind to the heating tank 1 , and is constituted by a mixing tank 3 , a burner 4 and a spray nozzle 5 . The spray nozzle 5 is provided at a position at which the flame injected from the burner 4 is not directly brought into contact with the spray nozzle 5 and a spray-like water injected therefrom is easily mixed with the flame of the burner 4 , the spray-like water is mixed with the flame and the hot gas within the mixing tank 3 so as to be gasified and the inner portion of the tank is filled with the air having high humidity and high temperature.
In this case, the mixing tank 3 is structured such that an inner surface is covered by a heat resisting material so as to be protected and a part being in contact with the surface among the spray-like water injected from the spray nozzle 5 is easily gasified.
An air supply port 31 is formed at one end of the mixing tank 3 , and a temperature, a humidity and a generating amount of the high humidity hot wind are adjusted by suitably adjusting a strength of the flame injected from the burner 4 , an amount of air supplied to the mixing tank 3 from the air supply port 31 and an amount of water injected from the spray nozzle 5 . In this case, the illustrated high humidity hot wind generating apparatus is structured such that an excessive water can be blown out from the spray nozzle 5 so as to make it easy to adjust the generating amount of steam within the mixing tank 3 , and a service tank 8 is attached to the mixing tank 3 so as to receive an excessive high temperature moisture which is not gasified within the tank 3 and mix the moisture with a fresh water, thereby supplying to the spray nozzle 5 . Accordingly, it is intended to efficiently utilize a thermal energy.
Further, an outlet duct 32 is connected to a proper portion in the mixing tank 3 , the outlet duct 32 is connected to the inlet port 14 of the heating tank 1 , and a heat resisting blower 33 is mounted in the middle thereof, whereby the high humidity air generated within the tank 3 is supplied to the heating tank 1 as the high humidity hot wind. In this case, in the illustrated embodiment, the structure is made such that a raw material water is stored in the service tank 8 , a water supply pump 9 , a flow amount meter 92 and the like are interposed between the service tank 8 and the spray nozzle 5 , and a predetermined amount of water is injected from the nozzle 5 at a fixed pressure. A level sensor 82 is mounted to the service tank 8 , and a control valve 81 is mounted to a water intake pipe 83 , whereby a water level within the service tank 8 is kept at a fixed range by connecting the both members.
As the cooling conveyor 2 , a net conveyor is used in this embodiment and provided below the discharge port 12 of the heating tank 1 , so that the granular material treated in the heating tank 1 is dropped on the cooling conveyor 2 immediately after being discharged from the discharge port 12 , and is in contact with the air within the room so as to be cooled. A suction duct 21 is mounted to a lower surface of the feeding surface of the cooling conveyor 2 , and a suction blower 22 is connected to the suction duct 21 , thereby generating an air stream from an upper surface of the feeding surface of the cooling conveyor 2 toward a lower portion so as to increased a cooling effect of the granular material and remove fine particles mixed in the granular material.
When supplying the raw material granular material to the heating tank 1 , the granular material is at first brought into contact with the high humidity hot wind at an upper portion of the sliding surface 13 . Since the granular material has a temperature lower than that of the high humidity hot wind, the temperature of the high humidity hot wind at first brought into contact with the granular material is slightly reduced, and the relative humidity thereof is increased at that degree. Accordingly, the granular material is in a state of being covered with the air rich in the contained moisture. Then, in the granular material, the starch on the surface layer portion is formed into a paste state due to the moisture of the air, the moisture contained in the granular material itself and the temperature while sliding on the sliding surface 13 , and next the pasted starch is continuously made into an alpha state. At this time, the particulate starch closely attached to the raw material granular material is also formed into a paste state so as to be attached to the granular material, thereby being integral therewith so as to constitute a part of the granular material.
In the surface layer portion of the granular material, the starch is formed into a paste state and the dried state is promoted. Since the dried state is promoted faster as the temperature of the high humidity hot wind is higher, the moisture required for forming into a paste state is faster lost as the temperature of the high humidity hot wind is higher, whereby the promotion of the paste state is restricted and the pasted layer tends to be thin. Further, when the passing time within the heating tank 1 is long and the heating operation is further continued after being formed into a paste state, the pasted starch layer is dried so as to become porous and be weakened. A part inside the alpha starch layer of the granular material itself is made into an alpha state, is dried and generates a crack.
The granular material in which the starch on the surface portion is formed into a paste state so as to be made into an alpha state is temperature reduced immediately after being dropped on the cooling conveyor 2 , and the starch layer is solidified, so that the alpha starch layer is formed.
FIG. 2 shows a high humidity hot wind generating furnace in another type. The high humidity hot wind generating furnace is structured such as to indirectly heat an air due to a heat generated from the burner, thereby preventing a combustion gas of the burner from being supplied to the heating tank 1 .
In FIG. 2, the high humidity hot wind generating furnace is provided with a combustion chamber 7 in a bottom portion within a main body 6 , and the burner 4 is mounted thereto, thereby injecting the flame thereto. Further, a plurality of chimney pipes 71 are provided at a suitable interval, each of them is connected to the combustion chamber 7 , and a hot gas generated in the combustion chamber 7 passes within the chimney pipes 71 , ascends while exchanging heat with the air within the main body 6 and is discharged to the open air through a chimney 72 later. In this case, in the illustrated embodiment, the combustion chamber 7 is formed by using heat resisting bricks so as to resist against a high temperature.
An air supply port 61 is formed at a proper portion of the main body 6 , and a hot wind supply duct 62 is mounted at another proper portion thereof. Further, a heat resisting blower 63 is connected to the hot wind supply duct 62 . The air is sucked into the main body 6 from the supply port 61 by driving the heat resisting blower 63 , and the sucked air is heated by the heat in the chimney pipes 71 so as to become a high temperature air and be taken out from the hot wind supply duct 62 .
The spray nozzle 5 is mounted in the main body 6 , and is structured such as to inject a suitable amount of water in a spray state into the main body therefrom. The water is mixed with the high temperature air flowing within the main body so as to be gasified, and the air becomes an air having a high humidity and a high temperature. In this case, in the illustrated embodiment, the structure is made such that the raw material water is stored in the service tank 8 , and a predetermined amount of water is injected at a fixed pressure from the nozzle 5 through the water supply pump 9 , a flow amount adjusting valve 91 , a flow amount meter 92 and the like interposed between the service tank 8 and the spray nozzle 5 . Further, it is intended to effectively utilize the heat by introducing a high temperature drain water discharged from the main body 6 to the service tank 8 . A level sensor 82 is mounted to the service tank 8 , and a control valve 81 is mounted to a water intake pipe 83 , so that a water level within the service tank 8 is kept in a fixed range by communicating both the members.
When generating the air having a high humidity and a high temperature, the burner 5 is driven so as to inject the flame to the combustion chamber 7 , thereby setting the chimney pipes 71 to a heated state. Then, the water supply pump 9 is driven as well as the heat resisting blower 63 is driven. Then, the air stream from the supply port 61 to the hot wind supply duct 62 is generated within the main body 6 , is brought into contact with the chimney pipes 71 so as to be heated and become a high temperature air, and at the same time, a predetermined amount of water is injected from the spray nozzle 5 in a spray state and is mixed with the high temperature air so as to be gasified. Accordingly, the air becomes the air having a high humidity and a high temperature, and is fed to the heating tank 1 via the heat resisting blower 63 from the hot wind supply duct 62 .
As mentioned above, the surface treating method of the granular material in accordance with the present invention is structured such as to apply the high humidity hot wind to the granular material so as to heat the portion in the thickness between some microns and some hundreds microns of the surface, thereby forming the starch into a paste state and further making it into an alpha state and cool the portion, so that the alpha starch layer having a fine density and a high abrasion resistance is formed in the surface portion of the granular material.
As a result, since no fine particles exist on the surface of the granular material and no fine pieces due to the abrasion during the treatment is generated, there is an advantage that these particles and pieces are not required to be washed at a time of cooking the rice. Further, since the surface portion of the granular material is constituted by the alpha starch layer, the oil and fat are prevented from being oozed out of the inner portion and the oxygen is prevented from being entered into the inner portion, so that the change in quality due to the oxidation of the oil and fat is not generated. Accordingly, it is possible to storage for a long time. | The invention provides a treating method of forming a protection layer having strong abrasion resistance and oxidation resistance and having a thickness of micron order of a surface of a polished grain or a processed granular material obtained by kneading and solidifying a starch so as to make it hard to be changed in quality, thereby improving a storage capacity for a long time. Further, the invention provides a treating method of forming a fine particulate starch attached to the grain or the granular material into a paste state so as to combine with the protection layer. The surface treating method has a step of applying a high humidity hot wind to the polished grain or the granular material so as to heat a surface layer portion, a step of forming a starch in the heated portion into a paste state and further making the starch into an alpha state, and a step of cooling and forming a fine layer of the alpha starch on the surface portion. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Statement of the Technical Field
[0002] The present invention relates to the field of call processing systems, and more particularly to processing menu changes in a telephone prompting system.
[0003] 2. Description of the Related Art
[0004] Telephone prompting systems are increasing employed to provide an interface to voicemail systems and to provide an interface for interactive voice response systems (IVR), such as airline reservations, bank customer account lines, and other institutional lines such those of government, utilities, credit card companies and the like. Many systems, such as those used for banking or stock trading, may be frequently accessed by individual users, often several times a day. In such systems, users are presented with hierarchical levels of prompts that the customer can respond to by depressing buttons on the telephone keypad or through spoken words. The resulting dual tone multifrequency (DTMF) signals or audio are received by the prompting system and used to access a different level in the hierarchy or to access a specified function.
[0005] Prompting system technologies do not require human interaction over the telephone as the user's interaction with the database is predetermined by what the prompting system will permit the user to access. For example, banks and credit card companies use prompting systems so that their customers can receive up-to-date account information instantly and easily without having to speak directly to a person. Prompting system technology, such as that found in IVR systems also can be used to gather information, as in the case of telephone surveys in which the user is prompted to answer questions by pushing the numbers on a touch-tone telephone.
[0006] Sometimes, the menu structures of a telephone prompting system must be changed due to changing levels of service such as when a new service option has been added or when existing service options have been removed. Other circumstances can include the re-organization of a menu resulting from caller complaints, business rule changes or priorities, usability testing, and the like. When menu structure changes are made, it is important to inform the calling parties of such menu changes in order to minimize navigational errors, as well as erroneous transfers to unwanted agents. This can be helpful when a calling party attempts to “key ahead” to reach a known destination or menu in a prompting system but unwittingly ends up in a menu or accessing a service that is unwanted. However, after a while, repeated messages or announcements of menu changes may frustrate and annoy certain calling parties who are frequent users of the prompting system.
SUMMARY OF THE INVENTION
[0007] The present invention addresses the deficiencies of the art in respect to telephone prompting systems and provides a non-obvious method, system and apparatus for dynamically alerting calling parties of menu structure changes in a telephone prompting system. In a telephone prompting system, a menu structure change alert method can include determining whether a menu structure change has occurred for the telephone prompting system in response to the receipt of an incoming call from a calling party. Subsequently, the calling party can be selectively alerted of the menu structure change. In this regard, an alert message can be played to the calling party.
[0008] In a particular aspect of the invention, the step of selectively alerting the calling party can include identifying the calling party and retrieving a set of call statistics for the identified calling party. Subsequently, an alert can be provided to the calling party only if permitted by the call statistics. Otherwise, the alert can be withheld if an alert is not permitted by the call statistics.
[0009] In another aspect of the present invention, a call processing system can include a telephone prompting system having a menu structure. The system further can include call statistics storage configured to store call statistics for callers. Finally, the system yet further can include dynamic alerting logic configured for coupling to the telephone prompting system and the call statistics storage in order to selectively alert callers of changes to the menu structure based upon call statistics for the callers stored in the call statistics storage.
[0010] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
[0012] FIG. 1 is a schematic illustration of a system, method and apparatus for dynamically alerting calling parties of menu structure changes in a call processing system; and,
[0013] FIG. 2 is a flow chart illustrating a process for dynamically alerting calling parties of menu structure changes in the call processing system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention is a method, system and apparatus for dynamically alerting calling parties of changes to menu structures in call processing systems. In accordance with the present invention, a dynamic alerting process can detect when changes are made to the menu structure of a call processing system. Responsive to detecting a change to the menu structure, a message can be presented telephonically in order to alert the calling party of the menu changes. Additionally, it automatically can be determined when to stop the presentation of the menu change message so as to not irritate the caller with repetitive information.
[0015] In operation, a query can be received in the call processing system and processed by dynamic alerting logic. The dynamic alerting logic can access call statistics for the calling party in order to determine whether a menu change message or alert can be presented to the calling party. Consequently, the dynamic alerting process provides a message to alert a calling party of menu changes while restricting the alerting feature based upon pre-determined criteria.
[0016] In further illustration of the foregoing inventive arrangements, FIG. 1 is a schematic illustration of a system, method and apparatus for dynamically alerting calling parties of changes to menu structures in call processing systems. The call processing system 130 can be configured for communicative linkage to one or more calling parties 110 over the communication network 120 . In this regard, the communications network can be a PSTN, a data communications network configured to carry telephonic data, or any combination thereof. The call processing system 130 can include a telephone prompting sub-system 160 programmed to prompt calling parties 110 with information based upon a menu structure 170 . Importantly, dynamic alerting logic 140 can be coupled to the telephone prompting sub-system 160 as well as data storage of caller statistics 150 .
[0017] In accordance with the present invention, the dynamic alerting logic 140 can determine for an incoming call from a caller 10 whether or not the underlying menu structure 170 for the call processing system 130 has changed. If so, the dynamic alerting logic 140 can access caller statistics 150 to determine whether or not it is permissible to issue an alert to the caller 110 that the menu structure 170 has changed. If permitted, an alert can be issued to the caller 110 . Otherwise, no alert can be issued.
[0018] In more particular illustration of the process of the invention, FIG. 2 is a flow chart illustrating a method for processing calls based upon the dynamic alerting process in the system of FIG. 1 . Beginning in block 205 , a call is received by the system. The call can be received telephonically over a telephone network from an external or internal telephone calling party, or over an external or internal data communications network.
[0019] In further explanation, FIG. 2 is a flow chart illustrating a process for alerting a calling party when the menu is updated or changed. Beginning in decision block 210 , the system determines if there have been any changes to the system menu. If there are no menu changes, the call can continue as normal as indicated in block 215 . Otherwise, if there is a menu change, the system will ascertain the identity of the calling party and whether the calling party has previously accessed the system in decision block 220 . If the calling party is identified, then in block 225 the “call statistics” for this specific calling party are retrieved from the storage and updated. The “call statistics” can include various calling party information such as the ID or PIN number for the calling part, the number of times the party has heard a particular alert message, and the like. If the caller does not have an identity stored in the system, a general set of call statistics can be used for this particular call as shown in block 230 . Naturally, going forward, a specific identity for this calling party can be generated and the appropriate call statistics assigned and updated.
[0020] The call statistics of blocks 225 or 230 are then passed to decision block 235 . In decision block 235 , the call statistics are evaluated and it can be determined whether the alert message should be played or not. As mentioned previously, various criteria may be used to determine when an alert message should no longer been provided to a calling party. A system administer can specify which call statistics (e.g., elapsed time, number of calls, some combination of these, or the like) are used to make the play or no play alert message decision. If the message should be played, the process will continue through block 245 . If not, the process can continue to block 240 . In either event, the process will continue through to block 215 where the call can be continued in a normal manner.
[0021] The present invention can be realized in hardware, software, or a combination of hardware and software. An implementation of the method and system of the present invention can be realized in a centralized fashion in one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system, or other apparatus adapted for carrying out the methods described herein, is suited to perform the functions described herein.
[0022] A typical combination of hardware and software could be a general-purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein. The present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which, when loaded in a computer system is able to carry out these methods.
[0023] Computer program or application in the present context means any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following a) conversion to another language, code or notation; b) reproduction in a different material form. Significantly, this invention can be embodied in other specific forms without departing from the spirit or essential attributes thereof, and accordingly, reference should be had to the following claims, rather than to the foregoing specification, as indicating the scope of the invention. | A method, system and apparatus for dynamically alerting calling parties of menu structure changes in a telephone prompting system. In a telephone prompting system, a menu structure change alert method can include determining whether a menu structure change has occurred for the telephone prompting system in response to the receipt of an incoming call from a calling party. Subsequently, the calling party can be selectively alerted of the menu structure change. In this regard, an alert message can be played to the calling party. | 7 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to an electrophotographic apparatus, such as a laser beam printer and a copying machine, whose toner hoppers and developers can be replaced by its user or a maintenance engineer.
[0002] Referring to FIG. 7, the general configuration of a laser printer whose toner hopper 1 and a developer 2 can be replaced by its user will be explained. For example, an electrophotographic apparatus is typically equipped with one or more printing sections comprising a photoreceptor 8 , a charger 9 that electrically charges the surface of the photoreceptor 8 , an optical scanning section 10 that optically scans the surface of the charged photoreceptor 8 with a laser beam, a developer 2 that develops image areas that are scanned optically, a toner hopper 1 that supplies toner 11 to said developer 2 , and an image transfer unit 13 that transfers the developed image to a recording member 12 . With such an arrangement, it is possible to print multi-color images on a single laser printer by replacing the set of elements consisting of the toner hopper 1 and the developer 2 . This is also applicable to MICR toner (toner for magnetic ink character recognition).
[0003] In the above-described laser printer, a user or a maintenance engineer replaces the toner hopper 1 and the developer 2 . At the time of this replacement, the toner hopper 1 (for example, containing red toner) may be combined with the wrong developer 2 (for example, containing a blue toner), so that the image printing may fail. To prevent this, various contrivances have been proposed.
[0004] Referring to FIG. 8, one of the conventional techniques used in full-color laser printers will be explained. This example is comprised of a slit disk 16 that is mounted on the shaft of a rotating means 15 disposed in a toner cartridge 14 , which disk 16 has some equally-spaced slits on its circumference; a photo sensor that is provided opposite to the slit disk 16 to detect the presence of respective slits of the disk 16 as the disk rotates; a pulse signal generator 18 that generates a pulse signal responsive to detection of each slit of the disk 16 as the disk rotates; and a detector 3 that detects the kind of a toner cartridge 14 from the pulse signal. Generally, a full-color laser printer contains four printing sections which provide for use of four kinds of toner (yellow, magenta, cyan, and black) to form color images. Therefore, the laser printer requires four toner cartridges 14 . Similarly, the pulse signal generator 18 must have four slit disks 16 that have different slit intervals to distinguish the toner cartridges 14 properly. (For example, see Japanese Application Patent Laid-Open Publication No. 2001-255728 (Page 3-7, FIG. 3))
[0005] Referring to FIG. 9, a general technique for effecting proper combination of a toner hopper and a developer will be explained. FIG. 9A shows a means to prevent a wrong combination of toner hoppers and developers. FIG. 9B shows examples of a key configuration used for this purpose. In FIG. 9A, plural keys 19 are provided in the part where the toner hopper 1 is connected to the developer 2 to prevent wrong hopper-developer combinations. FIG. 9B-(i a) shows the shape of a key 20 for a toner hopper containing red toner and the shape of a key 21 of the developer 2 containing red toner. The projection and recess of these keys are formed to fit each other. Similarly, FIG. 9B-( b ) shows the shape of a key 22 for a toner hopper containing blue toner and the shape of a key 23 of the developer 2 containing blue toner. The projection and recess of these keys are formed to fit each other. However, in FIG. 9B-( c ), it can be seen that the key 22 of the toner hopper containing blue toner does not fit to the key 21 of the developer 2 containing red toner.
[0006] Generally, a full-color laser printer uses four kinds of toner (yellow, magenta, cyan, and black) to form full color images. In other words, the printer requires four toner hoppers and four developers. Therefore, a spot color printer that has at least one printing section and forms images without mixing toners must prepare some dozens of toner colors to meet a user's requests.
SUMMARY OF THE INVENTION
[0007] Usually, a laser printer generally stores information concerning the quantity of consumption to indicate the timing to replace expendables and specific control values in a non-volatile memory. This procedure is also applicable to the toner hoppers and developers. In the case of a printer which has a toner hopper and a developer that cannot be replaced, the printer stores information concerning the quantity of toner consumption related to the toner hopper and the developer and specific control values in a non-volatile memory on a control board in the printer. On the other hand, in the case where the toner hopper and the developer are replaceable, such information and specific control values before and after replacement may be mixed up after the toner hopper and the developer are replaced, if the printer stores such information and values at an address of the non-volatile memory on the control board. To avoid this, conventional printers use a method of providing a non-volatile memory in their toner hoppers or developers. When a developer has a non-volatile memory, the data in the non-volatile memory contains information concerning a corresponding toner hopper. For example, when a printer has two sets of a toner hopper and a developer for red toner, information of one of the red toner hoppers is stored in the non-volatile memory of the corresponding developer only. If this red toner hopper is connected to the other developer, different control may result from wrong information. In other words, when a spot color printer or the like has at least one printing section and does not mix toners to form color mages, only providing means to distinguish toner hoppers and developers for respective colors is not enough. If the user requires some dozens of toner colors, the printer must provide further means to distinguish them.
[0008] However, the above-described conventional technology must provide very complicated slit disks and many hopper-developer engagement keys. This technology makes the printer product very expensive (because of the costs to make the slit disks and key dies).
[0009] An object of this invention is to provide an electrophotographic apparatus that can detect hopper-developer correspondences by use of electric signals of the toner hoppers and the developers without using many complicated and expensive parts to detect such correspondences.
[0010] The above-stated object can be attained by providing a means such as a DIP switch or non-volatile memory to output electric signals on each of the toner hoppers and the developers, assigning codes corresponding to toner colors to electric signals, and detecting the correspondences of toner hoppers and developers by use of the electric signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a block diagram which shows an embodiment of this invention, in which a toner hopper and a developer respectively contains a DIP switch.
[0012] [0012]FIG. 2 is a block diagram which shows an embodiment of this invention, in which a toner hopper contains a DIP switch and a developer contains a non-volatile memory.
[0013] [0013]FIG. 3 is a block diagram which shows an embodiment of this invention, in which a toner hopper and a developer respectively contain a non-volatile memory.
[0014] [0014]FIGS. 4A and 4B are diagrams which show an example of assignment of 8-bit data codes to a toner hopper and a developer according to toner colors.
[0015] [0015]FIGS. 5A and 5B are diagrams which show an example of assignment of 4-bit data codes to toner hoppers and developers according to toner colors and assignment of set codes to toner hoppers and developers of the same color, if any.
[0016] [0016]FIG. 6 is a schematic diagram which shows an example of the configuration of a DIP switch circuit whose bits represent a code of a toner hopper in accordance with the embodiment of this invention.
[0017] [0017]FIG. 7 is a schematic diagram of an electrophotographic processing apparatus.
[0018] [0018]FIG. 8 is a diagram which shows a configuration of a conventional means to detect the correspondence of a toner cartridge using a slit disk.
[0019] [0019]FIGS. 9A and 9B are diagrams which show conventional means to mechanically prevent a wrong combination of a toner hopper and a developer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to FIG. 1, an embodiment concerning first and second aspects of this invention will be explained. The toner hopper 1 and the developer 2 , respectively, have a DIP switch 4 which is connected to a detecting section comprising a CPU, a memory, and a logical circuit. For example, when the DIP switches are respectively 8 bits long, a hexadecimal code “01h” is assigned to a black toner hopper 1 and a developer 2 that contains black toner. Similarly, a hexadecimal code “02h” is assigned to a red toner hopper 1 and a developer 2 that contains red toner. The DIP switches are respectively set to “01h” and “02h.”
[0021] When the black toner hopper 1 is engaged with the developer 2 containing black toner, the DIP switch 4 in the black toner hopper 2 outputs code “01h” and the DIP switch 4 in the developer 2 containing a black toner outputs code “01h,” too. These codes “01h” are output to the detector 3 . When the same codes “01h” are received from the toner hopper 1 and the developer 2 , the detector judges that the toner hopper 1 and the developer 2 are correspond to each other and permits the laser printer to start printing without outputting an error message.
[0022] However, when the black toner hoper 1 is combined with the developer 2 containing red toner, the DIP switch 4 in the black toner hopper 1 outputs code “01h” and the DIP switch 4 in the developer 2 containing red toner outputs code “02h.” These codes “01h” and “02h” are output to the detector 3 . When these different codes “01h” and “02h” are received from the toner hopper 1 and the developer 2 , the detector judges that the toner hopper 1 (including black toner) and the developer 2 (including red toner) do not correspond with each other, and so an error message is outputted, and the laser printer is not allowed to start printing.
[0023] In accordance with the third and fourth aspects of this invention, at least either the toner hopper 1 or the developer 2 has a non-volatile memory. First, with reference to FIG. 2, a case in which only the developer 2 has a non-volatile memory 5 will be explained. The toner hopper 1 has a DIP switch 4 and the developer 2 has a non-volatile memory 5 . The DIP switch 4 and the non-volatile memory 5 are respectively connected to a detector 3 comprising a CPU, memory, and a logic circuit. For example, when the DIP switch 4 and the non-volatile memory 5 are respectively 8 bits long, a hexadecimal code “01h” is assigned to a black toner hopper 1 and to a developer 2 that contain a black toner. Similarly, a hexadecimal code “02h” is assigned to a red toner hopper 1 and to a developer 2 that contains red toner. The DIP switch 4 in the toner hopper 1 is set to code “01h” and data at a preset address in the non-volatile memory in the developer 2 is set to “02h.” To check the hopper-developer correspondence, the detector checks the codes sent as electric signals from the toner hopper and the developer 2 in a similar way and permits the printer to start printing when the codes are identical or does not allow the printer to start printing when the codes are different. This is applicable also when only the toner hopper 1 has a non-volatile memory.
[0024] [0024]FIG. 3 shows a case in which both the toner hopper 1 and the developer 2 have a non-volatile memory 5 . These non-volatile memories are respectively connected to a detector comprising a CPU, memory, and a logic circuit.
[0025] For example, when the data lengths of the non-volatile memories 5 are each 8 bits long, a hexadecimal code “01h” is assigned to a black toner hopper 1 and to a developer 2 that contains black toner. Similarly, a hexadecimal code “02h” is assigned to a red toner hopper 1 and to a developer 2 that contains red toner. The contents at preset addresses in the non-volatile memories of the toner hopper 1 and the developer 2 are respectively set to “01h” and “02h.” To check the hopper-developer correspondence, the detector checks the codes sent as electric signals from the toner hopper and the developer 2 in a similar way and permits the laser printer to start printing when the codes are identical or does not allow the printer to start printing when the codes are different. Further, when the toner hopper 1 or the developer 2 has both a DIP switch 4 and a non-volatile memory 5 , a code can be assigned to any of them.
[0026] A fifth aspect of this invention is related to the assignment of said codes. FIGS. 4A and 4B show examples of an 8-bit code assignment to a toner hopper 1 and to a developer 2 . In FIG. 4A, each toner color is assigned to each data bit. For example, black, red, and blue are assigned to bit 0 , bit 1 , and bit 2 in that order. Other toner colors can be assigned to the other data bits in a similar manner. This enables recognition of toner hoppers 1 and developers 2 for toners of eight colors.
[0027] In FIG. 4B, color codes are assigned to combinations of data bits instead of by bit-by-bit assignment. You can assign 256 colors by assigning each color to a respective hexadecimal value, for example, black to “01h,” red to “02h,” blue to “03h,” and so on including “00h” and “FFh”, or 254 colors not including “00h” and “FFh.”
[0028] A sixth aspect of this invention uses set codes in the assignment of color codes when the printer has a plurality of toner hoppers and a plurality of developers that contain toners of identical colors. FIGS. 5A and 5B show examples of the assignment of color codes of four data bits long and set codes of four data bits long to the toner hoppers 1 and the developers 2 . In FIG. 5A, toners of respective colors are assigned in bits, and, further, it is possible to recognize toner hoppers 1 and developers 2 for four toner colors and four sets of toner hoppers 1 and developers 2 of the same color by assigning bit 4 to the first set of a toner hopper 1 and a developer 2 of the same color, bit 1 to the second set, bit 2 to the third set and so on. For example, when the first set of the yellow toner hopper 1 and the developer 2 for yellow toner are used, bits 3 and 4 are selected and code “18h” is output. When the second set of the yellow toner hopper 1 and the developer 2 for a yellow toner are used, bits 3 and 5 are selected and code “28h” is output. In this way, it is possible to distinguish the toner hopper 1 and the developer 2 from those of the same color.
[0029] In FIG. 5B, toner colors are assigned to combinations of data bits, and further, it is possible to assign toner hoppers 1 and developers 2 for 16 toner colors and 16 sets of toner hoppers 1 and developers 2 of the same color, for example, by assigning “10h” to the first set of a toner hopper 1 and a developer 2 of the same color, “20h” to the second set, and so on, including “00h” and “FFh”, or toner hoppers 1 and developers 2 for 16 toner colors and 16 sets of toner hoppers 1 and developers 2 of the same color and the like, not including “00h” and “FFh.” For example, when the first set of a red toner hopper 1 and a developer 2 for red toner is selected, a code “12h” is output. When the second set of a red toner hopper 1 and a developer 2 for red toner is selected, a code “22h” is output. In this way, it is possible to distinguish the toner hopper 1 and the developer 2 from those of the same color.
[0030] In accordance with a seventh aspect of this invention, codes to toner hoppers 1 and developers 2 are assigned independently of toner colors. When data of the DIP switches 4 or non-volatile memory 5 in the toner hoppers 1 and the developers 2 are respectively 8 bits long, it is possible to distinguish toner hoppers 1 and developers 2 of the same colors. For example, assuming a purchase has been made of toner hoppers 1 and developers 2 for a blue toner, a red toner, a black toner, and again a red toner in this order, it is possible to distinguish them by assigning “01h” to those for a blue toner, “02h” to those for a red toner, “03h” to those for a black toner, and “04h” to the second set of a toner hopper and a developer for a red toner.
[0031] According to an eighth aspect of this invention, codes that generate electric signals of all zeros or all ones are not assigned to toner hoppers 1 and developers 2 . In other words, when data of the DIP switches 4 or non-volatile memory 5 in the toner hoppers 1 and the developers 2 are respectively 8 bits long, only codes “01h” to “FEh” are available. The reason for this will be explained below with reference to FIG. 6. FIG. 6 shows an example of a circuit containing a DIP switch of 8 bits long to determine the code of a toner hopper 1 . One end of each data bit of the DIP switch is grounded and the other end of each bit is connected to a detector 3 through a connector 6 . Each signal is pulled up to Vcc through a resistor 7 . In this circuit configuration, each bit becomes “0” when its micro-switch of the DIP switch 4 is turned on or becomes “1” when its micro-switch of the DIP switch 4 is turned off. If you assign a code “FFh” that generates an electric signal of all ones to a black toner hopper 1 , you cannot tell it from another signal pattern “FFh” that represents a disconnection of the connector 6 . When a code that generates an electric signal of all zeros or all ones is not assigned, it is possible to easily recognize a disconnection of the connector 6 (that is a disconnection of the toner hopper).
[0032] As explained above, this invention enables detection of correspondences of toner hoppers 1 and developers 2 by use of electric signals generated by the toner hoppers 1 and the developers 2 , instead of using a lot of complicated parts to detect correspondences of toner hoppers 1 and developers 2 .
[0033] In accordance with this invention, an electrophotographic apparatus can detect correspondences of toner hoppers and developers by providing a means, such as a DIP switch or non-volatile memory, to output electric signals that are coded according to toner colors or the like on respective toner hoppers and by developers and using the electric signals instead of using a lot of complicated parts. | An electrophotographic apparatus is equipped with one or more printing sections including a photoreceptor, a charger that electrically charges the surface of the photoreceptor, an optical scanning section that optically scans the surface of the charged photoreceptor with a laser beam, a developer that develops image areas formed by optical scanning, a toner hopper that supplies toner to the developer, and an image transfer unit that transfers the developed image to a recording member. In this apparatus, the developer and toner hopper can be mounted and demounted separately and a plurality of toner hoppers and developers are changeable according to the kinds of toner colors to be used. Thus, each of the developers and toner hoppers is equipped with a device that outputs electric signals to detect the correspondences of the toner hoppers and the developers. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a chain-control device for solar road studs, which is capable of setting road studs into an interactive chain-control state for presenting a simultaneous or fancy flash, as well as a solar energy flash device.
2. The Prior Arts
Solar road studs are usually disposed on the shoulders and the median of a highway, which, particularly in our local areas, would rather flash randomly than synchronously or interactively.
As the shoulders and the median of road can be viewed more clearly, to flash the road studs synchronously or interactively is preferred. Taking the local solar road studs for instance, the flash period of each road stud is 0.5 seconds approximately. However, there is no time interval regulated between one stud to the next, which could be any value from 0.3 seconds to 1 second according to different tolerances of different components and charged electricity quantity of batteries. To our opinion, a good timing sequential flash of chain-control mechanism would be preferred, which could be done usually by triggering one after another in sequence.
A solar flash system is basically a wireless system needing no wiring job or city power. For achieving the chain control purpose, the control signals could be carried by IR (Infra-Red) ray or RF (Radio Frequency) signals.
The appearance of a shoulder's road stud 21 is shown in FIG. 1 , in which an IR receiver commonly applied in a generic electric home appliance, such as a remote controller for TV set or video recorder, is adopted on account of its cost, noise resistivity, and power consumption. An example is TSOP1838SS3V of VI_SHAY, which has a working voltage of 3V, an IR carrier signal at 38 KHz, and a high enough sensitivity to IR for receiving a signal radiated from as distant as 35 m away, and a fast response ability for receiving a signal in 1 msec.
SUMMARY OF THE INVENTION
The present invention relates to a chain-control device for solar road studs, in which solar cells are employed to convert solar energy into electric energy in daytime and stored in a battery unit, so that those road studs can flash in nighttime for traffic security purpose or gardening deposition. The present invention needs no wiring job or city power, and it can well conform with environment protective conditions. Unfortunately, however, the existing flash devices flash randomly, they do not provide a chain control flash style.
Therefore, the primary object of the present invention is to provide a chain-control device for solar road studs, which requires no wiring job and flashes interactively in a chain-control operation.
Another object of the present invention is to provide a free-of-wiring-job chain-control device for solar road studs, in which the chain control signals are transmitted by IR or RF carrier waves, and the encoded digital control signal may comprise control instructions, flash instructions, color-control instructions, remote control setting instructions, and sovereignty transfer instructions.
Yet, another object of the present invention is to provide a chain-control device for solar road studs, in which a flash device, when it starts to flash, will trigger a next road stud and so on such that a chain-control flash could be made to show a lighting point sliding along the median and shoulders distinctly.
A further object of the present invention is to provide a solar energy flash device.
For more detailed information regarding advantages or features of the present invention, at least an example of preferred embodiment will be described below with reference to the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The related drawings in connection with the detailed description of the present invention to be made later are described briefly as follows, in which:
FIG. 1 shows the appearance of a solar road stud on road shoulder;
FIG. 2 shows the internal configuration of the solar road stud of the present invention;
FIG. 3 shows a linearly disposed IR-control detailed circuit;
FIG. 4 shows the key distribution of a remote controller;
FIG. 5 is a linear distribution diagram; and
FIG. 6 is a two-dimensional distribution diagram.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to a chain-control device for solar road studs, as well as a solar energy flash device. In a road stud system related to the present invention, a plurality of road studs is driven and controlled to flash synchronously or in fancy styles by a chain control technology. Each road stud shown in FIG. 2 comprises an input device 130 for receiving IR or radio encoded digital flash control signals; a processing device 150 for receiving the flash control signals delivered from the input device 130 , controlling flash, and executing commands according to different encoded control instructions; and an output device 170 for receiving flash style from the processing device and outputting a flash control signal by means of RF or IR carrier.
The road studs are supposed, under a linear or two-dimensional disposition, to present a synchronous flash or a fancy flash performance regularly, in which the fancy flash is mostly applied for gardening creative purposes in two dimensions, in which each road stud is provided with an ordinal number and a predetermined time interval between flashes and flash colors to present different flash effects by a sovereignty transfer instruction.
Moreover, the input device 130 in an interactive chain control device for solar road studs is substantially a front-end signal receiver 131 for receiving IR or radio carrier frequencies.
Yet, the processing device 150 further comprises a power supply unit 153 for supplying electric power to the processing device, a microprocessor unit 155 for determination of the flash style by availing the power supplied by the power supply unit, a memory unit 157 for the microprocessor unit 155 to fetch data of a specified flash style.
Yet, the power supply unit 153 further comprises a solar cell-board unit 156 for transferring solar energy into electric energy, and a battery unit 158 for storing the electric energy delivered from the solar cell-board unit 156 and outputting a first control signal for judging whether it is now in daytime or nighttime. The memory unit 157 could be an EEPROM (Electrically Erasable Programmable Read-Only Memory) employed to store the parameters of working manners of the road stud, flash intervals, fancy flash styles, ordinal numbers, and colors.
Yet, the output device 170 for transmitting flash control signals by means of RF or IR carrier further comprises a rear-end signal transmitter 171 , which could be an IR emission diode or RF transmitter, for outputting the flash control signals; and a light-emitting diode 179 , in which a monochrome diode is applied for a generic road stud and a RBG diode unit is applied to gardening arts for offering people with a splendid and color-enriched impression.
Yet, the input device 130 , which is a front-end signal receiver 131 , could be a TSOP1830SS3V of VISHAY to be worked at 3 V.
Yet, the microprocessor unit 155 is substantially a microprocessor, and in this case, a PIC12CE518 of MICROCHIP having a built-in EEPROM and SLEEP MODE function for energy saving is adopted.
FIG. 3 shows a linearly disposed IR-control detailed circuit. The circuit is comprised of a solar cell-board unit 330 for transferring received solar energy into electric energy, and a battery unit 333 . In this circuit, the solar cell-board unit 330 is supposed to charge the battery through a diode D 1 ; after pin GP 1 of the microprocessor PIC12CE518 outputs LOW to have a capacitor C 1 discharged, the pin GP 1 is turned to be an input end with a high impedance to detect the solar cells through a resistor R 1 ; then, the microprocessor shall go judging whether it is now in daytime or not by detecting the charging state of the capacitor C 1 , if positive, C 1 is charged gradually, otherwise the microprocessor should prepare to flash.
By the way, an auxiliary IC MCP809 of Microchip is also provided to inspect the power voltage to keep the microprocessor working smoothly. A second pin GND of the IR receiver TSOP18X of VISHAY is connected with pin GP 2 of the microprocessor. In the duration between two flashes, the microprocessor would enter a SLEEP MODE to consume current in 2 μA only to lower down the power consumption, and the receiver might be shut down then and there and reopened at the moment the microprocessor is supposed to receive a flash trigger signal so that more power consumption can be saved. Also, in the microprocessor, pin GP 5 outputs LOW to lighten an LED D 3 , while GP 4 outputs LOW to lighten an IR LED D 2 .
The related flash parameters are stored in the EEPROM of the microprocessor. The operating highlights are summarized as the following:
(1) A flash period may be set at 0.5 seconds for example. The microprocessor is requested to flash repeatedly by this period on it's own before a flash control signal is detected and received.
(2) A detection time for detecting a flash control signal may be set at 0.4 seconds for example. It is meant to detect for the next flash control signal by the end of an elapsed 0.4 seconds after a previous flash is finished, while the microprocessor would enter the SLEEP MODE before the critical 0.4 seconds for saving power consumption.
(3) An ending time for receiving a flash control signal may be set at 0.55 seconds for example. As mentioned above, the microprocessor is requested to flash on it's own by the period of 0.5 seconds if no flash control signal is available, and after a predetermined times to have no flash control signal received, the receiving function is opened once more continuously to obtain the synchronism. Hence, every flash device may serve for an initial flash device to perform a synchronous control and maintain the power-consumption saving function.
(4) A serial number is offered to every flash device. Therefore, it is possible to effect a flash style made by the odd-numbered flash devices and the even-numbered flash devices alternately.
(5) The flash device works either in a chain flash style or a synchronous flash style, in which, under the chain flash style, a flash device flashes upon receipt of a chain-control signal and meanwhile forwards a chain-control signal to the next flash device to perform the same; while, under the synchronous flash style, upon receipt of a flash control signal, a flash device would transmit the same immediately to the next flash device in recursion (plus 1), then the microprocessors will calculate and compensate the time delayed to therefore perform a synchronous flash.
(6) If desired, there can be other parameters.
In regard to the setting procedure of the flash device parameters, detailed description is made below.
In every road stud, the flash style parameters could be preset in the EEPROM by maker or set on site. Because an IP or RF receiver is arranged in each road stud, therefore, it is possible to set the parameters with a remote controller shown in FIG. 4 , without increasing the cost.
For setting a single one or all the road studs with a remote controller, the interaction between the remote controller and every corresponding road stud is described below.
First, a user has to make sure that a road stud to be set is in the stand-by state; then, depress a key “calling a flash device”. The road stud starts to flash in a time interval of 0.5 seconds for example, upon receipt of the signal “calling a flash device” sent from the remote controller. The road stud would return to the stand-by state again in the event that no “Yes” signal is received from the remote controller within 5 seconds afterwards, or the road stud would flash repeatedly with the time interval of 0.5 seconds if the “Yes” signal is received within 5 seconds as expected.
In the next step, the user may choose to set all the road studs or a single one.
If setting all the road studs is desired, the user has to first depress in sequence a key “Set all”, “Parameter”, parameter value “nnn”, then “Confirmation (Yes)”. The remote controller will send all the parameters out, and this time each the road stud will flash rapidly with a time interval shorter than 0.5 seconds. This action continuous until all the data is stored, and then, the road studs begin to flash with the time interval of 0.5 seconds.
On the contrary, if setting a single road stud is desired, the user needs to depress in sequence a key “Set single”, “serial number of stud”, “Parameter”, parameter value “nnn”, then “Confirmation (Yes)”. A road stud to be set having a serial number corresponding to code sent by the remote controller will receive and update the parameter value (nnn). At this time, this road stud will flash rapidly with a time interval shorter than 0.5 seconds, which is then changed into 0.5 seconds after the data received is stored.
In addition, the depositing and mounting method of the interactive chain-control devices of solar road studs is suggested to perform according to the following steps:
The first step is a step for deciding a linear or a two-dimensional deposition.
The second step is a step for installing a plurality of road studs according to the chosen deposition.
The third step is a step for deciding the flash style.
The fourth step is a step for setting the working parameters to the road studs with a remote controller.
First Example for Road Security Studs
The system is controlled by IR in unidirectional receiving and unidirectional transmitting.
In the linear deposition shown in FIG. 5 , two dotted lines rep resent the roadsides 490 (the shoulders); a string of road studs is mounted in the median and defined as the median studs, which are divided into odd-numbered and even-numbered median studs and interpolated intermittently, in which the even-numbered studs 410 are arranged to receive the flash control signals from the right to the left 430 , while the odd-numbered studs 470 are arranged to receive the flash control signals from the left to the right 450 .
The foregoing arrangement of the odd-numbered and the even-numbered median studs may be inversely arranged.
The intermittently interpolated median studs could be fully viewed by the wagon flow from the right to the left and vice versa to show meaningful directions and paths for signal transmission.
Besides, there is a string of road studs aligned on a top end of the road, which is defined as shoulder studs, in which the shoulder studs on the top end will receive the flash control signals in the same direction with the wagon flow, which directs to the left from the right. Also, there is another string of road studs aligned on a bottom end of the road, which is defined as shoulder studs too, in which the shoulder studs on the bottom end will receive the flash control signals in the same direction with the wagon flow, which directs to the right from the left.
Second Example for Gardening Deposition
A plurality of flash devices in accordance with the present invention is installed in two dimensions as shown in FIG. 6 .
As illustrated in FIG. 6 , a circular center space is a landscape-viewing section, which is provided on two sides with respective aisles and a plurality of flash marking devices 601 interspersed in a substantially two-dimensional distribution, in which two asterisk symbols 603 represent the flash markings radiating flash control signals.
In gardening arts, the direction-indiscriminating RF control signal is more effective in a larger scope than that of IR. Therefore, it is possible to locate a RF transmitter in a center position of a garden for controlling all flash devices mounted therein.
In the above described, at least one preferred embodiment has been described in detail with reference to the drawings annexed, and it is apparent that numerous changes or modifications may be made without departing from the true spirit and scope thereof, as set forth in the claims below. | A chain-control device for solar road studs is provided to work by using a plurality of solar cells to convert solar energy into electric energy during daytime and store it in a battery unit, so that they can flash in nighttime for traffic security purpose or gardening deposition. The primary merit of the present invention is, first of all, free of wiring job, no need of city power, good conformity with environment protective conditions. Because of a successful chain control function, the existing random flash performance could be substituted with an interactive chain control flash or a synchronous flash performance, which is also applicable to gardening for fancy flash performance. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Japanese Patent Application No. 2001-164278 , filed on May. 31, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to method and an apparatus for cutting sheet or plate-shaped members to form parts of a desired configuration.
[0004] 2. Description of Background Art
[0005] It has been usually carried out that a plurality of sheet members for example of aluminum are laid in a stacked manner on a table of a cutting apparatus and then are cut into a desired configuration using an end mill movable in three dimensions above the table in order to simultaneously have a plurality of parts of a same configuration. That is, it is possible to simultaneously obtain a plurality of parts of the desired configuration through one operation by driving the end mill until it arrives at the bottom one of the stacked sheet members.
[0006] However, it has been often caused that the cut out part or parts would be fly apart immediately after the cutting operation by the end mill had been completed. This sometimes causes damages on the parts and thus exerts an adverse effect on the yield. In a conventional manner, all the sheet members are fastened by screws in order to prevent the parts from flying apart from the sheet members on completion of the cutting operation.
[0007] However, the conventional manner requiring previous screw fastening operation of the sheet members is cumbersome and the operability would be further made worse particularly in forming a plurality of parts from one sheet member since the screw fastening operation should be made on every parts.
SUMMARY OF THE INVENTION
[0008] It is, therefore, an object of the present invention to provide method and an apparatus for cutting plate-shaped or sheet members to form parts therefrom which do not require any screw fastening operation and thus enable to obtain an improved operability in manufacturing parts of a desired configuration from the sheet member.
[0009] According to the present invention, a method of cutting sheet or plate-shaped members to form parts of a desired configuration from the sheet members by cutting them with pressing them down from above comprises: a first cutting step for cutting a substantial portion of the outline of the desired configuration leaving a small portion of the outline uncut with weakly pressing the sheet members down from above around a portion to be cut, and a second cutting step for cutting the parts out from the sheet members of the desired configuration by cutting the small portion left uncut with strongly pressing down therearound.
[0010] According to the present invention, since the sheet members are weakly pressed down from above in the first cutting step, it is possible to prevent cut chips from incoming between sheet members as well as since the parts of the desired configuration are strongly pressed down around the small portion left uncut in the second cutting step, it is possible to prevent the parts from being flied apart from the sheet members.
[0011] Also according to the invention, it is possible to eliminate the screw fastening operation of the sheet members in the prior art and thus to improve the operability in cutting parts out from the sheet members.
[0012] Further according to the present invention, an apparatus for cutting sheet members to form parts of a desired configuration from the sheet members by cutting them with pressing them down from above comprises: a table on which the sheet members are laid and positioned, cutting means movable in three dimensions for cutting the sheet members on the table into the desired configuration, and presser means for pressing the sheet members down around a portion to be cut, the sheet members are weakly pressed down by the presser means when a substantial portion of the outline of the desired configuration is cut by the cutting means with leaving a small portion of the outline uncut, and the sheet members are strongly pressed down around the small portion left uncut when it is cut by the cutting means to form parts of desired configuration.
[0013] Further, it is possible to eliminate the screw fastening operation of the sheet members in the prior art and thus to improve the operability in cutting parts out from the sheet members.
[0014] It is preferable, that the presser means is separably connected to driving portion of the cutting means, and that it is connected to the driving portion of the cutting means when the cutting means cuts the substantial portion of the outline of the desired configuration leaving the small portion of the outline uncut so as to be interlocked with the cutting means and is separated from the driving portion of the cutting means when the small portion left uncut is cut by the cutting means to form parts of the desired configuration so as to be made independent from the motion of the cutting means.
[0015] The presser means is interlocked with the driving portion of the cutting means and weakly presses the sheet members down and slides on the top surface of the sheet members together with the cutting means. It is possible to prevent the incoming of the cut chip between the sheet members during the cutting operation. Since the sheet members are strongly pressed down against the table, it is possible to prevent the flying of the finished parts apart from the sheet members.
[0016] It is preferable, that the table is movable in two directions orthogonally crossing with each other in a plane parallel to a floor surface, the presser means can be separably connected to the driving portion of the cutting means in one direction of said two directions and can be connected to the driving portion of the cutting means via extensible elastic members in the other direction of said two directions.
[0017] The presser means can be separably connected to the driving portion of the cutting means in one direction. The motion of the presser means in the other directions can be permitted by the extension and compression of the springs. Thus, it is possible to manufacture the cutting apparatus at low cost and to achieve easy maintenance.
[0018] It is also preferable that the elastic members are coil springs connecting between the presser means and the driving portion of the cutting means. The elastic members are formed by common coil springs. Also, it is possible to manufacture the cutting apparatus at low cost and to achieve easy maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Preferred embodiments of the present invention will be described with reference to the accompanied drawings in which;
[0020] [0020]FIG. 1 is a schematic view of the cutting apparatus according to one preferred embodiment of the present invention,
[0021] [0021]FIG. 2 is a plan view of the presser means of the cutting apparatus of FIG. 1,
[0022] [0022]FIG. 3 is a cross-sectional view taken along a line III-III of FIG. 2,
[0023] [0023]FIG. 4 is a schematic view of one sheet member and examples of outline of parts cut by the cutting apparatus,
[0024] [0024]FIG. 5 is a flow chart showing the cutting steps of the cutting apparatus of the present invention,
[0025] [0025]FIG. 6 is a plan view of the sheet member after completion of the first cutting step performed by the cutting apparatus of the present invention, and
[0026] [0026]FIG. 7 is a plan view of the presser means of the cutting apparatus according to another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The cutting apparatus of the present invention is intended to form parts of the desired configuration by cutting them out from sheet members stacked on a table of the cutting apparatus with pressing the sheet members down from above against the table and generally comprises, as shown in FIG. 1, a table 1 , an end mill 2 as a cutting means, and a presser means 3 .
[0028] The table 1 on which the sheet members are laid and positioned is arranged on a bed 9 of the cutting apparatus and is provided with a plate of bakelite. A plurality of sheet member e.g. aluminum are laid on the table 1 in a stacked condition and secured thereon by a suitable clamping means such as a vice. The table 1 is reciprocally driven by a driving mechanism (not shown) arranged under the table 1 in left and right directions shown by an arrow “Y” in FIG. 1.
[0029] The end mill 2 is mounted via its shank on a holder 4 a of a driving means 4 such as a motor and can be driven in three dimensions (“X” , “Y” and “Z” directions) above the table 1 to form parts of a desired configuration from the sheet members stacked on the table 1 by cutting the outline of the parts out from the sheet members. It is possible to use any other tool suitable for the outline cutting in place of the end mill 2 .
[0030] Secured on the bed 9 is an annular column 7 on which two guiding rails 7 a for slidably supporting a horizontal slider 6 are horizontally arranged. Thus the end mill 2 can be driven in three dimensions by the horizontal movement of the slider 6 , the vertical movement of a vertical slider 5 and the reciprocal movement of the table 1 .
[0031] The presser means 3 is intended to press the sheet members down at a position around a place to be cut i.e. the end mill 2 and comprises, as shown in FIGS. 2 and 3, generally a main frame 8 and a sub frame 10 which are connected with each other via two coil springs 11 extending in the “Y” direction. One side of the main frame 8 is provided with a cylinder 12 having an extendable rod 12 a to releasably lock the main frame 8 with the sub frame 10 .
[0032] The base end of the main frame 8 is provided with first and second gripping means 3 a and 3 b actuated by hydraulic or pneumatic driving power. The first gripping means 3 a is adapted to grip a stay 7 b mounted on the annular column 7 and the second gripping means 3 b is adapted to grip a stay 6 a mounted on the horizontal slider 6 . When the second gripping means 3 b grips the stay 6 a of the horizontal slider 6 acting as one of the driving portion of the end mill 2 , the presser means 3 is connected to the horizontal slider 6 and thus is interlocked with the motion of the end mill 2 so that it can move in the direction “X”. Of course, under this situation it is necessary to keep the first gripping means 3 a free from stay 7 b and thus not to interfere the motion of the presser means 3 in the direction “X”.
[0033] On the contrary, when releasing the second gripping means 3 b from the stay 6 a and making the first gripping means 3 a grip the stay 7 b , the presser means 3 is freed from the end mill 2 in the direction “X” and is secured at the position. The connection and separation of the presser means 3 to and from the end mill 2 may be achieved by providing any projected members engageable with apertures formed in the slider 6 and the column 7 .
[0034] The sub frame 10 is formed with a tool aperture 13 substantially at the center thereof through which the end mill 2 passes to cut the sheet members stacked on the table 1 along a predetermined outline. Mounted on the under surface of the presser means 3 around the periphery of the tool aperture 13 is a plastic pad 14 which is adapted to contact the top surface of the stacked sheet members on the table 1 .
[0035] As previously described, since the sub frame 10 is connected to the main frame 8 via coil springs 11 , it can be moved in the direction “Y” relative to the main frame 8 if it is not secured to the main frame 8 by the cylinder 12 . Accordingly, the motion of the sub frame 10 in the direction “Y” is independent from the motion of the end mill 2 , since the motion of the sub frame 10 in the direction “Y” is absorbed by expansion and compression of the coil springs 11 and thus is not transmitted to the main frame 8 .
[0036] The sub frame 10 is provided with presser cylinders 15 . The stacked sheet members are pressed down against the table 1 by the plastic pad 14 by extending piston rods 15 a of the presser cylinders 15 . The pressing force can be adjusted by controlling the amount of extension of the piston rods 15 a.
[0037] The cutting operation will be hereinafter described.
[0038] Firstly a predetermined number of the sheet members “A” such as aluminum sheets are laid on the table 1 in a stacked manner and secured to the table 1 by the vice. Several kinds of parts “P” each having a desired outline e.g. shown in FIG. 4 are cut out from the stacked sheet members “A” by moving the end mill 2 along the outline. The motion of the end mill 2 in the direction “X” is performed by the horizontal slider 6 , the motion thereof in the direction “Y” is performed by moving the table 1 in the direction “Y” relative to the end mill 2 , and the motion thereof in the direction “Z” is performed by the vertical slider 5 .
[0039] The cutting operation is controlled in accordance with a manner shown in a flow chart of FIG. 5. In the first cutting step S 1 , the cutting along the desired outline is carried out by moving the end mill 2 along the outline with weakly pressing the stacked sheet members “A” down at a position around the cutting place i.e. around the end mill 2 . In this first step S 1 , the first gripping means 3 a is released from the stay 7 b and the second gripping means 3 b is connected to the stay 6 a . Also in this first step S 1 , the main frame 8 and the sub frame 10 are united by causing the piston rod 12 a of the cylinder 12 to be projected.
[0040] In the first cutting step S 1 , the cutting is carried out so that a portion of the desired outline is remained uncut as shown in FIG. 6. That is, the outline is cut along a portion P 2 and remained uncut at a portion P 1 to keep the parts “P” united with the sheet members “A”.
[0041] During the cutting operation in the first cutting step S 1 , since the presser means can slide on the top surface of the stacked sheet members and the portion P 1 is kept uncut, it is possible to prevent the parts P 1 from flying apart from the sheet members “A” as well as to prevent the cut chips from incoming between the sheet members. Several portions more than one may be kept uncut.
[0042] After the completion of the first cutting step SI and thus the cutting of the portion P 2 of all the parts P, the second cutting step S 2 starts. In this second cutting step S 2 , the uncut portion P 1 is cut by the end mill 2 to form the final parts “P” of the desired configuration with strongly pressing the stacked sheet members “A” down around the uncut portion P 1 . In this second step S 1 , the first gripping means 3 a is connected to the stay 7 b and the second gripping means 3 b is released from the stay 6 a.
[0043] In this second cutting step S 2 , since the presser means 3 is freed from the motion of the end mill 2 , it is not necessary to slide the presser means 3 on the top surface of the stacked sheet members. This enables the presser means 3 to strongly press the stacked sheet members “A” down against the table 1 and thus the cut parts “P” can be prevented from flying apart from the sheet members and from being damaged by impact. Since the end mill 2 operates within the aperture 13 also in the second cutting step S 2 , the presser means 3 should be positioned so that the uncut portion P 1 is positioned within the aperture 13 of the presser means 3 . Also in the second cutting step S 2 , the first gripping means 3 a is arranged to grip the stay 7 b and the second gripping means 3 b is freed from the stay 6 a as well as piston rod 12 a of the cylinder 12 is retracted to release the sub frame 10 from the main frame 8 .
[0044] In the second cutting step S 2 , the presser means 3 is separated from the horizontal slider 6 forming the driving portion of the end mill 2 and thus is independent from the end mill 2 in the direction “X”. On the other hand, when the sub frame 10 of the presser means 3 is moved in the direction “Y” together with the sheet members due to the strong pressing force acting on the sheet members, the motion of the sub frame 10 in the direction “Y” is absorbed by the compression and extension of the springs 11 and is not transmitted to the main frame 8 . Thus, the motion of the presser means 3 is also independent from that of the end mill 2 in the direction
[0045] When cutting of all parts “P” is completed, the vice is released from clamping of the sheet member and thus the finished parts “P” can be removed from the sheet members “A”. Although it has been described to cut a plurality of sheet members, it should be noted that the cutting of the present invention can be carried out on one sheet member.
[0046] According to the present invention, since the sheet members are weakly pressed down in the first cutting step S 1 , it is possible to prevent the cut chips from incoming between the sheet members, and since the sheet members are strongly pressed down in the second cutting step S 2 , it is possible to prevent the cut parts “P” from flying apart from the sheet members. In addition, since the presser means 3 is separably connected to the driving portion of the end mill (i.e. the horizontal slider 6 ) via the second gripping means 3 b , it is possible to interlock the presser means 3 with the end mill 2 in the first cutting step and to make the presser means 3 independent from the end mill 2 in the second cutting step S 2 .
[0047] Although the preferable embodiment of the present invention has been described above, the present invention is not limited to such an illustrated embodiment and it is possible to provide another cutting apparatus comprising a presser means 3 ′ having a following structure. That is, the presser means 3 ′ may have coil springs 11 ′ extending in the direction “X” in addition to the coil springs 11 extending in the direction “Y”. This enables to eliminate both the first and second gripping means 3 a and 3 b of the presser means 3 .
[0048] In this embodiment, since the motion of the sub frame 10 in the direction “Y” is absorbed by the coil spring 11 and the motion thereof in the direction “X” is absorbed by the coil spring 11 ′, it is possible to simplify the mechanism for separating the presser means 3 from the end mill 2 in the second cutting step S 2 . The coil springs 11 and 11 ′ may be replaced by any other types of elastic members e.g. leaf springs etc.
[0049] Furthermore, the presser means 3 may be driven by any other driving means and the connection and separation of the motion of the presser means 3 to and from the end mill 2 may be carried out by that driving means. In this case, it is necessary to control the driving means so that the presser means 3 follows the motion of the end mill 2 in the first cutting step S 1 and the presser means 3 is secured independent from the motion of the end mill 2 in the second cutting step S 2 . This structure using the driving means for the presser means 3 enables to achieve the reliable control of the motion of the presser means 3 . | A method and an apparatus for cutting plate-shaped or sheet members to form parts that do not require a screwing operation and thus improve the operability in manufacturing parts of a desired configuration from the sheet member. The method for cutting sheet or plate-shaped members to form parts of a desired configuration from the sheet members includes cutting them by pressing them down from above. A first cutting step cuts a substantial portion of the outline of the desired configuration leaving a small portion of the outline uncut by weakly pressing the sheet members down from above around a portion to be cut. A second cutting step cuts the parts out from the sheet members of the desired configuration by cutting the small uncut portion by strongly pressing down around the desired configurations. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the priority date of U.S. provisional application Ser. No. 60/670,459, filed Apr. 11, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a system and apparatus for dispensing flowable products. More particularly, the present invention relates to consumer-suspended, fluid product dispensing containers for dispensing consumer quantities of fluids ranging from liquid to granular solid powder.
BACKGROUND OF THE INVENTION
[0003] Many consumer products such as dishwashing detergent, hand soap, shampoo, hair conditioner, toothpaste, condiments including mustard, ketchup, mayonnaise, syrup, honey and viscous food fluids such as jams, jellies, peanut butter, and the like, are packaged in containers that are often recloseable and have a capacity anywhere from an individual portion to 64 fluid ounces or more. The containers are typically made from molded materials (PE, PETE, PP, ABS, polycarbonate, etc.) and generally have a structure which includes a lower end adapted to maintain them in a standing position on a flat surface and an upper end having an outlet for dispensing the fluid. Covers for outlets range in complexity from simple twist-off caps, and lift-up nozzles to compressible pumps and squeezable bottles having integrated pre-measured dose cups. Additionally, some containers are specially shaped for a specific purpose, such as sculpted or narrowed near the middle to improve grip.
[0004] The known methods and structures for dispensing such consumer-directed fluid products commonly rely on a combination of picking up the dispenser container, opening its outlet, positioning it over the dispensing area (food, sponge, hand, etc.), and either inverting and pouring, or by applying pressure directly or via some pump mechanism to the contents in the container to get the fluid through the outlet onto the intended target. One might dispense product into one's cupped hand either at the work area or at a distance from where it will be used (assuming one has two hands available) and then bringing the dispensed product to its intended destination, for example, in or over a countertop, table surface, sink or tub. The operation differs little if the container is equipped with a pump. In any case, most known dispensing containers must be opened, positioned, manipulated and restored to their former position and condition, or by applying pressure to a pump.
[0005] Many instances of dispensing operations require two free hands for any combination or permutation of the following operations to be performed either sequentially or contemporaneously: to manipulate an outlet to a dispensing position, to hold the dispenser in place while a pump is actuated, to invert rotate or otherwise change the resting position of the entire container in order to move viscous fluids to the dispensing outlet, to restore the container to a non-dispensing position or state. Frequently, fluids are dispensed directly into a user's hand, while the other hand is occupied with the manipulating the container.
[0006] With respect to cost, providing a dispensing fluid container with a pump- or siphon-action fluid outlet is relatively significantly more expensive than providing a fluid container with a gravity-dependent fluid outlet. Moreover, a pump can suffer from mechanical failure and be inefficient in that most are unable to extract some significant portion of fluid from a nearly-emptied container, especially if the fluid is very viscous.
[0007] When viscous fluids such as gels, jams, hair conditioner, mayonnaise, honey, mustard, glues and the like are sold or kept in pouring-type dispensers having a flat bottom resting area and a recloseable dispensing fluid outlet at or near the opposing top end, the time it takes to perform each successive dispensing operation increases as the distance between the surface level of the fluid and the outlet increases. Furthermore, waste of product is practically inevitable as the contents are gradually used since some product often clings to the bottom lower sides of the container interior. Related to this, between dispensing operations, gravity causes viscous fluid to accumulate at the lowest point of the fluid container, i.e. usually the end farthest away from the dispensing opening. In an effort to reduce time to pour and to reduce waste, strategies must be employed to keep the bulk of the remaining viscous fluid accumulating closer to the dispensing opening. For example, toothpaste tubes and bottles, shampoos, conditioners, body washes, ointments and a wide variety of flowable personal hygiene, cosmetics and cleaning products are supplied in dispensing bottles or tubes with flat covers over the dispensing openings so they may be stored standing on their head, so to speak, between uses. Unfortunately, that requires that the tube be rested on a flat surface, usually a kitchen, sink or bath countertop, tabletop or ledge, thus adding to clutter, increasing potential for spills and residual drips, soiling and using some of the most valuable and heavily used real estate in any home or work environment. Some containers are made squeezable to allow consumers to squeeze the product up and out, but as anyone who has ever squeezed a tube of toothpaste knows, the squeezing operation can become a chore. In the alternative, product is wasted by those not desirous of employing economizing strategies.
[0008] Work surface areas, including tabletops and countertops in most environments, domestic or commercial, are often at a premium. For example, counter-top space in the vicinity of water outlets, e.g. sink faucets, bath and shower outlets, in even the largest household kitchens and bathrooms is usually precious and domestic engineers agree that reduction of kitchen and bathroom counter clutter, and increasing counter availability, is important for achieving and maintaining efficiency and tranquility. The same is true for many culinary, commercial and industrial settings.
[0009] In situations where a fluid dispenser will get heavy use, such as in a public restroom or dining hall, the risk of passing infection increases where other people must handle the container at its dispensing point and along its outer side surfaces of the dispenser sufficiently firmly to maintain a grip and invert the dispenser. A dispenser that requires less contact to dispense its contacts is more hygienic.
[0010] References show mechanisms for hanging fluid dispensers in inverted positions from housings which are fixed to the wall. These are typically fitted with push-up valves. Unfortunately, such devices often have flow-rate control and leakage issues, resulting almost inevitably in spillage on the counter or articles below the dispenser. Additionally, users will often soil the area around a sink by dripping product or water onto the counter in the process of moving their hands from the spout end of the faucet to the dispenser and back to a position over the sink.
[0011] With reference to food service establishments, many provide condiments such as ketchup, barbecue sauce, salad dressing, and the like from pump-equipped containers. Frequently the containers can't be pumped dry as they can't get the last bit at the bottom. Furthermore, pumps are often difficult to control and users often spill condiment on the countertop instead of on the food, adding to maintenance.
[0012] U.S. Pat. No. 5,857,594 discloses a device which comprises a soap dispenser that is attached to the end of a faucet and further comprises a valve mechanism. Unfortunately, most sinks have only one or two faucet ends, substantially limiting the potential locations and space-saving potential for the device. Additionally, placing anything at the end of the faucet affects the usage of both faucet and sink, as well as increasing likelihood of accidental discharge of soap into water used for food preparation.
[0013] Similarly, PCT Publication No. WO 00/41608, of International Application PCT/AU00/00015 discloses a device for positioning solid soap in the water stream by suspending the device from the end of the water-dispensing faucet.
[0014] The combination liquid soap dispenser and protective cover for water fixtures disclosed in U.S. Pat. No. 5,125,577 similarly positions a device having a soap container directly in contact with a faucet end, therefore negatively affecting normal sink usage, access to which should be as unimpeded as possible at all times.
SUMMARY OF THE INVENTION
[0015] Exemplary embodiments of fluid dispensers for end users useful in the system of the present invention [a] make use of often-underutilized space; [b] conserve product; [c] conserve work environment space and normalcy of operation while still permitting easy use of the fixture; [d] permit pre-positioning of the dispenser directly over its intended use environment, such as the sink/tub drain, so that should normal and excess product dispensing or spillage occur, clean-up effort and time are reduced, [e] may be easily adapted to suit attachment to a wide variety of fixtures; [f] dispense viscous fluids easily, quickly and with greater efficiency, without interfering with the normal operation of the fixture where attached and its environment; and [h] permit truly one-handed operation so simple that even a toddler can use it, among other advantages.
[0016] Fluid dispenser apparatus of the exemplary embodiments also provide exceptional advertising value, by improving conspicuity of the container brand, being in daily view whether or not in use, and even adding visible surface area for advertising/marketing.
[0017] Embodiments of the present invention provide a solution for storing and dispensing powders and viscous fluid products used by consumers in closest proximity to their area of actual use, with minimal impact on the normal use of the space, thereby reducing time, clutter, spillage, clean up, and reducing the risk of non-food chemicals accidentally dripping onto the sink, tub, food-preparation area, table surface or even food itself.
[0018] Furthermore, embodiments of the present invention overcome the difficulty of finding an attachment system which is able to engage a large number of the great variety of fixtures with respect to being able to adapt to their sometimes complex and varied cross-sectional conformation, size and space restrictions presented by the area in consideration.
[0019] Moreover exemplary embodiments of the present invention permit the marketing and use of fluid containers that are disposable/replaceable. Additionally, the fluid containers of some exemplary embodiments, by being relieved of the constraints of having to have a flat resting surface substantially opposite the dispensing end, allow for a vast new variety of design options with distinctive and attractive shapes and other physical characteristics as well as production methods which are not now possible in the case of known containers constructed to stand independently upright on a counter top.
[0020] These and other advantages and characteristics are achieved by providing a coupler that is attached or attachable to a fluid dispensing container and is also attachable to the external surface of a fixture. Either the fluid container is rotatable with respect to the coupler, the coupler is rotatable relative to the fixture, or both. By rotatable, it is meant that the height of the outlet of the fluid dispensing container relative to the fluid of the level within can be changed in small user-determined incremental movements, in at least one plane that has a vertical component. Attachment between the coupler and fluid dispensing container can be accomplished in any of a number of different ways. As an example, a coupler may be able to be incrementally rotated by hand around the longitudinal axis of fixtures having a wide range of shapes and sizes, of the kind that be attached or found adjacent to and/or overhanging a work surface, such as a countertop or tabletop, sink fixture such as a faucet or an adjacent sprayhead, suspended rod, tension rod, column, or countertop dishwashing machine vent, as examples.
[0021] A rotating coupler can comprise a mechanism as mechanically simple as an elastic arranged in a harness-type arrangement on a fluid container, which is attached to a fixture, preferably suspended above or protruding out over the desired zone of use, in such a way and in such a position as to allow orientation of the fluent level with respect to the outlet as desired. Preferably, the fluid container can be rotated in a controllable, incremental manner in at least one plane having a vertical component such that the rotation elevates or lowers the fluid outlet with respect to the level of the fluid contained therein. By controllable manner, it is meant that a user can selectively and deliberately choose the vertical position the fluid dispensing outlet relative to the surface of the fluid in the container. By simply rotating the coupler or the container, or both, a user can easily control liquid flow-rate and fluid level in the container relative to the fluid outlet, i.e., such that, between dispensing operations, the fluid accumulates in the area of or directly adjacent to the fluid outlet or accumulates well away from the dispensing opening to prevent accidental discharge, or anywhere in between. This is especially advantageous when dispensing viscous fluids or controllably dispensing fluid, even with one hand unavailable.
[0022] Furthermore, a user should preferably be able to choose the position of the rotating coupler along substantially the entire length of an elongated horizontal and vertical fixture and be accommodative of a broad range of widths, and cross-sectional conformations with which fixtures such as those commonly found in kitchens and bathrooms are found. Other exemplary embodiments may be suitable for attachment at an edge or on a vertical or horizontal surface.
[0023] Exemplary embodiments of the present invention facilitate one-handed operation by even the youngest user with little or no training, and eliminate the need for picking up a potentially large, but slippery surfaced bottle.
[0024] Exemplary embodiments of the invention include those comprising a fluid container or reservoir and a coupler adapted for rotatably coupling the fluid reservoir container to an exterior surface, an edge, or a fixture having at least some longitudinal aspect such as a closet rod, a column, a sink faucet, bath fixture, towel bar, or sprayhead.
[0025] Additional exemplary embodiments of the invention include those comprising a dispensing container and coupler for coupling the dispensing container to an exterior surface of a sink faucet or bath fixture, wherein the coupler comprises an axle for rotation in a plane having some vertical component of the dispensing container relative to the sink faucet or bath fixture.
[0026] Yet other exemplary embodiments of the invention comprise a dispensing container and coupler for coupling the dispensing container to a suspended rod, a vertical shaft or column, an edge or an exterior surface, wherein the exterior surface might be that of a sink faucet, bath fixture, or a neck affixed to a surface at or adjacent to a target site, intended environment of use.
[0027] And still other exemplary embodiments of the invention comprise a dispensing container and coupler for coupling the dispensing container to an exterior surface of a fixture, wherein the dispensing container holds and dispenses a fluid, which may be a liquid, particulate, gel, foam, paste, or any other flowing material normally dispensed from a bottle.
[0028] Another exemplary embodiment of the invention comprises a dispensing container and coupler for coupling the dispensing container to an exterior surface of a neck, sink faucet shaft, vegetable spray head base or bath fixture, wherein the coupler is rotatable in a plane around the faucet, i.e. perpendicular to the longitudinal axis of the neck.
[0029] Another exemplary embodiment of the invention comprises a dispensing container and coupler for coupling the rotatable dispensing container to or around an exterior surface fixture having a longitudinal portion, wherein the direction of rotation of the dispensing container is in a plane having a vertical component and preferably parallel to the longitudinal portion of the faucet.
[0030] A further exemplary embodiment of the invention comprises a dispensing container and coupler for coupling the dispensing container to or around an exterior surface of a fixture, wherein the coupler is selected from the group comprising a clamp, a cuff, a bracelet, an elastic band, a strap, or hook and loop strap.
[0031] Still a further exemplary embodiment of the invention comprises a dispensing container and coupler for coupling the dispensing container to an exterior surface of a sink faucet or bath fixture, wherein the coupler comprises an adapter, the adapter comprises a cooperative lockable mechanism further comprising cooperative locking components attached to or integrally formed on the container and the adapter.
[0032] In yet a further exemplary embodiment of the present invention, the container and adapter are each provided with one of a pair of interlocking members.
[0033] In still a further exemplary embodiment, one interlocking member has a male configuration and the other has an interlocking female configuration. The male interlocking member and female configuration interlocking member have complementary shapes and sizes designed to permit manual incremental rotation of one relative to the other, thereby translating rotational motion to the dispensing container relative to the fixture. The male interlocking member may be attached to or integrally formed on the dispensing container and the female interlocking member.
[0034] An exemplary embodiment of a dispensing container and coupler according to the present invention has a coupler that comprises a faucet adapter, attached to the faucet adapter is at least one male protuberance, and the container has a female receptacle; the male protuberance and female receptacle are complementarily shaped and sized relative to one another to permit the male protuberance to be securely, yet removeably, received and retained into female receptacle.
[0035] In many exemplary embodiments, the dispensing container or containers can be rotated relative to the coupler.
[0036] Many of the exemplary embodiments include a dispensing container which is capped with a recloseable cap. Exemplary embodiments of the dispenser container of the present invention could have collapsible flexible walls. Some exemplary embodiments of the dispenser container may have all rigid walls.
[0037] Other exemplary embodiments will have at least one shape-maintaining wall and at least one collapsible wall.
[0038] A dispensing container of the present invention could have at least one surface adaptation for securely being attached to a sink fixture with an elastic coupler. The dispensing container can have grooves formed at or near each end for securely receiving an elastic coupler for attachment to a sink fixture.
[0039] One exemplary embodiment of a dispensing container has at least one groove formed on an outer surface thereof, the groove having a shape and being positioned to cooperate with the outer surface of a fixture to stabilize the position of the dispensing container against the fixture outer surface.
[0040] An exemplary embodiment of a coupler for rotatably attaching at least one fluid dispensing container to an external surface of a sink fixture has surfaces to provide resistance to rotational force to increase the force required to move the dispensing container and thereby reduce accidental dislocation of the dispensing container from a desired position relative to the sink or bath fixture.
[0041] The coupler could comprise a hook and loop (Velcro®) strap, a spring-loaded band, a notched rubber strap or a cradle.
[0042] In yet another exemplary embodiment, the fixture adapter portion of the coupler could have one or more surfaces contoured to reduce unintentional movement with respect to the fixture.
[0043] As an example, the dispensing container can have guide grooves which can help container be seated against faucet in various positions.
[0044] The exemplary embodiments of fluid containers of the present invention could dispense at least one fluid selected from the group consisting of liquid toiletry, dishwashing detergent, flowable cosmetics, soaps, shampoos, hair conditioner, body wash, skin creams, moisturizers, soap bubbles, bath salts and crystals, bubble bath, shaving cream/lotion, toothpaste, hair gels, hair mousse, pastes, adhesives, sealants, caulks and anything flowable that is used near/in conjunction with a kitchen, dining room, kitchen sink, bathroom/washroom sink, bathing facility, workshop or classroom.
[0045] Additional exemplary embodiments of fluid containers taught by the present invention could quickly and cleanly dispense viscous fluid comestibles, such as ketchup, mustard, honey, maple syrup, chocolate topping and other condiments.
[0046] Even powder fluids, such as laundry detergent powder, sugar, salt, spices, could easily be dispensed from containers embodying the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIGS. 1-3 are perspective views of a translucent, mostly-filled dispensing device constructed in accordance with an exemplary embodiment of the teachings of the disclosure and in pre-dispensing, dispensing and post-dispensing positions, respectively;
[0048] FIGS. 4 a - 4 a are perspective views of exemplary embodiments of anchoring straps for use with exemplary embodiments of couplers such as those shown in FIGS. 5 a - d and FIGS. 7 a - g , respectively;
[0049] FIG. 5 a is a partial cross-section view of a container's attachment to a coupler to form a fluid dispenser having a rotational axis in accordance with teachings of the disclosure;
[0050] FIG. 5 b is an exploded partial cross-section view of the container and coupler shown in FIG. 5 a;
[0051] FIG. 5 c is a partial detailed cross-section view showing attachment of a container-coupler combination, i.e. fluid dispenser, using a strap of the kind shown in FIGS. 4 a - e , to a fixture in accordance with teachings of the disclosure;
[0052] FIG. 5 d is a front elevation view of an exemplary female embodiment of a coupler constructed in accordance with teachings of the disclosure and shown in FIGS. 5 a , 5 b and 5 c;
[0053] FIG. 6 a is an exploded front elevation view of an exemplary embodiment of a fluid dispenser constructed in accordance with teachings of the disclosure;
[0054] FIG. 6 b is a front elevation view of the exemplary embodiment in FIG. 6 a with the fluid dispenser having a separately formed male coupler attachment member attached in accordance with teachings of the disclosure;
[0055] FIG. 6 c is a left side elevation view of the exemplary embodiment of the fluid container with attached male coupler attachment member shown in FIGS. 6 a and 6 b;
[0056] FIG. 7 a is a front perspective view of an exemplary embodiment of a coupler constructed in accordance with teachings of the disclosure taken from below;
[0057] FIG. 7 b is a rear perspective view of the exemplary embodiment of the coupler in FIG. 7 a , taken from above the left side;
[0058] FIG. 7 c is a top plan view of the exemplary embodiment of the coupler in FIG. 7 a;
[0059] FIG. 7 d is a rear elevation view of the exemplary embodiment of the coupler in FIG. 7 a;
[0060] FIG. 7 e is a left side inverted elevation view of the exemplary embodiment of the coupler in FIG. 7 a;
[0061] FIG. 7 f is a detailed perspective view of a gripping portion of the exemplary embodiment of the coupler in FIG. 7 a;
[0062] FIG. 7 g is a detailed cross-section view of the exemplary embodiment of the coupler in FIG. 7 a , installed against and anchored to a longitudinal fixture with the strap in FIG. 4 b;
[0063] FIG. 8 is a cross-sectional view of another exemplary embodiment of a fluid container having an integrally and internally formed female coupler attachment housing and a complementary male coupler in accordance with the teachings of the disclosure;
[0064] FIG. 9 is a front elevation view of another exemplary embodiment of a fluid container constructed in accordance with the teachings of the disclosure;
[0065] FIG. 10 is a cross-sectional exploded view of an exemplary embodiment of a fluid container as shown in FIG. 9 taken along line X-X and looking in the direction of the arrows, and a male coupler installed on a fixture in accordance with the teachings of the disclosure;
[0066] FIG. 11 is a front elevation view of an exemplary embodiment of a fluid container;
[0067] FIGS. 12 a - b are front and rear perspective views of an exemplary female embodiment of a coupler constructed in accordance with teachings of the disclosure, open and unlatched, respectively;
[0068] FIG. 12 c is a perspective view, taken from below, of the female coupler shown in FIGS. 12 a - b , closed and latched and constructed in accordance with teachings of the disclosure;
[0069] FIG. 12 d is a bottom plan view of the closed female coupler shown in FIGS. 12 a - c;
[0070] FIG. 12 e is a top plan view of the female coupler shown in FIGS. 12 a - d;
[0071] FIG. 12 f is a side elevation view of the female coupler shown in FIGS. 1 a - e;
[0072] FIG. 13 a is an inverted top perspective view from above and behind an exemplary embodiment of a female coupler constructed in accordance with teachings of the disclosure;
[0073] FIG. 13 b is a top plan view of the female coupler shown in FIG. 13 a;
[0074] FIG. 13 c is a rear elevation view of the inverted female coupler shown in FIGS. 13 a and b;
[0075] FIG. 13 d is a side elevation view of the female coupler shown in FIGS. 13 a - c;
[0076] FIG. 14 a is a front elevation view of one exemplary embodiment of a female coupler for attaching a fluid container to a fixture according to teachings of the disclosure;
[0077] FIG. 14 b is a top plan view of the coupler shown in FIG. 14 a;
[0078] FIG. 14 c is a front side elevation view of a variant of the exemplary embodiment of the female coupler shown in FIGS. 14 a and b , constructed according to teachings of the disclosure;
[0079] FIG. 15 a is a cross-section view, of an exemplary embodiment of a male coupler, in accordance with teachings of the disclosure;
[0080] FIGS. 15 b - 15 f are top plan views, in partial cross-section, of exemplary embodiments of couplers, in accordance with teachings of the disclosure;
[0081] FIG. 16 is a top plan view, in partial cross-section, of an exemplary female embodiment of coupler, in accordance with teachings of the disclosure;
[0082] FIG. 17 is a front elevation view of an alternate construction of a female coupler in accordance with teachings of disclosure;
[0083] FIG. 18 is a front elevation view of a variant construction of a female coupler in accordance with teachings of the disclosure;
[0084] FIG. 19 is a perspective view of an exemplary embodiment of a coupler adapted for extending the fluid dispenser a desired distance from a fixture;
[0085] FIGS. 20 a - c are cross-sectional views of an exemplary embodiment of a partly fluid-filled dispenser and integrally formed coupler constructed and installed on a fixture, rotated to various positions, in accordance with teachings of the disclosure;
[0086] FIG. 21 is an exploded view of an exemplary female embodiment of a dual container coupler adapted for attachment to a vegetable sprayer fixture in accordance with teachings of the disclosure;
[0087] FIG. 22 is an exploded view of an exemplary female embodiment of a dual container coupler adapted for attachment to a vegetable sprayer fixture in accordance with teachings of the disclosure;
[0088] FIG. 23 is a side elevation view of an exemplary embodiment of a columnar female coupler mounted to a fixture comprising the upper rim of a sink;
[0089] FIG. 24 is a side elevation view of an exemplary embodiment of a translucent male fluid dispensing container with female coupler mounted on a fixture comprising a countertop;
[0090] FIG. 24 a is a side elevation view of an exemplary embodiment of a translucent male fluid dispensing container with female coupler mounted on a fixture comprising a countertop;
[0091] FIG. 25 a is a top plan view of an exemplary embodiment of an elastic coupler constructed in accordance with teachings of the disclosure;
[0092] FIG. 25 b is a side elevation view of the elastic coupler in FIG. 25 a connected to a fluid container in accordance with teachings of the disclosure;
[0093] FIG. 25 c is a top plan view of an exemplary embodiment of an elastic coupler constructed in accordance with teachings of the disclosure;
[0094] FIG. 25 d is a perspective view from above and in front of the elastic coupler in FIG. 25 c connected to a fluid container in accordance with teachings of the disclosure;
[0095] FIG. 26 a is a front elevation view of a fluid dispenser constructed in accordance with teachings of the disclosure;
[0096] FIG. 26 b is a rear elevation view of the fluid dispenser in FIG. 26 a;
[0097] FIG. 26 c is a front elevation view of the fluid dispenser in FIGS. 26 a and 26 b coupled to a fixture in accordance with teachings of the disclosure;
[0098] FIG. 26 d is a front elevation view of the fluid dispenser in FIGS. 26 a - c coupled to a fixture in shown rotated in accordance with teachings of the disclosure;
[0099] FIG. 26 e is a side elevation view of the fluid dispenser in FIGS. 26 a - d coupled to a fixture in accordance with teachings of the disclosure;
[0100] FIG. 27 a is a front elevation view of a fluid dispenser constructed in accordance with teachings of the disclosure;
[0101] FIG. 27 b is a cross-section view of the fluid dispenser in FIG. 27 a taken at line XXXI-XXXI and looking in the direction of the arrows;
[0102] FIG. 28 a is a top plan view of a pair of fluid containers coupled to a longitudinal fixture by a single coupler constructed in accordance with teachings of the disclosure;
[0103] FIG. 28 b is an exploded partial longitudinal cross-section view, taken from below, of the pair of containers and coupler shown in FIG. 28 a ; and
[0104] FIG. 28 c is a partial sagittal cross-section taken from the front elevation of the pair of containers and coupler shown in FIGS. 28 a - b.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0105] The present invention comprises novel apparatus for fluid dispensers targeted at consumers or end users, and a novel system and method of merchandising that is enabled by the novel apparatus. The apparatus comprises mechanisms and methods for allowing a consumer to suspend one or more fluid dispensers in a strategic location in the vicinity where the fluid will actually be used. The suspension mechanism must be simple to make and use yet highly adaptable to enable to accommodate the range of potential fixtures from which consumers may wish to suspend the dispensers. Furthermore, the exemplary embodiments comprise apparatus for adapting a fluid reservoir or container, often provided in advance with an outlet, to be attached to a fixture via a coupler. The structural relationship between either the coupler and fixture, or the coupler and coupled fluid container, is such that a user can manually, controllably and incrementally rotate the fluid container such that its outlet travels in a path having a vertical component. The outlet is thereby movable by each user between a storage position, i.e. where the fluid surface is below or at the bottom of the outlet, and a dispensing position, where the fluid surface level is above the bottom of the outlet, and vice versa.
[0106] Preferably, the more the user is able to control the position of the outlet via rotation, the better. Thus, there is a corresponding need for the coupling to be securely attached to the fixture; enough to resist the torque applied by a user in repositioning the outlet. A balance needs to be struck between the mechanisms that facilitate rotation and position maintenance of the container relative to the coupler and of the coupler relative to the fixture. A satisfactory balance produces a container and coupler which in use are stable relative to the fixture and yet sufficiently sensitive to permit fine, or even infinite, degrees of adjustment of the container relative to the fixture by a user repositioning the dispenser between a dispensing and nondispensing storage position, usually by rotation.
[0107] In typical use, it is contemplated that after dispensing, the user relocates the outlet, stopping rotation with the top surface of the remaining fluid just below the outlet, sufficiently to prevent dripping, yet closely enough so that when the next user has to dispense the fluid, the fluid will already be accumulated in the area immediately adjacent to or just below the outlet, by the force of gravity alone, and readily available for dispensing. Subsequent dispensing operations thus require less time and relatively little effort to get the fluid level to rise above the outlet level and pour out, a mere couple of degrees of rotation. A simple and minimal upward twist of the container stops the fluid from dripping and readies the dispenser for the next user.
[0108] The containers of the exemplary embodiments described hereinbelow are preferably made from molded or cast materials commonly used in packaging fluids for resale. Useful materials include thermoplastics such as polycarbonate, polypropylene, polyethylene, vinyl, PETE, etc. as well as traditional materials such as glass, ceramic and light metals. While the invention is scalable over a wide range and containers can have a fluid storage capacity of from fractions of a fluid ounce to several gallons, most consumer applications will only require fluid storage containers having capacity of from ¼ fluid ounce to about 128 ounces. Variable factors such as size, weight, shape, volume, materials, etc. are somewhat interdependent and the degree of variation is well within the skill of the ordinary person in the art of packaging design. The combination of the factors and two relevant resultant torsional values (force to twist container and attachment force for coupler to resist twisting around fixture), will help determine how the artisan will design the overall apparatus, given the particular product's anticipated uses and target environment. For instance, gently squeezing the sides of a container which is somewhat flexible, could assist a user in the dispensing operation. If the container is expected to be fairly heavy, then the thickness of the walls will be of some importance with respect to preventing undesired shape distortion. A floppy container may be undesirable or aesthetically displeasing.
[0109] The system is particularly well-suited for dispensing particulate fluids and viscous fluids, such as liquid soap, toothpaste, detergents, syrups, honey, condiments, cleaning powders, laundry powders, gels, sealants, adhesives, pastes and the like.
[0110] Exemplary embodiments of the present invention further comprise a product and system adapted for attachment to a variety of fixtures. Examples of fixtures with which the fluid dispensers are adapted to be used include: kitchen and bath plumbing fixtures including faucets, spigots, taps, spray heads, shelving and cabinetry; as well as work surfaces, countertop, tabletop and wash basin rim surfaces via couplers that are specifically designed for receiving the fluid containers of the present invention, and permitting the manual rotation thereof, while resisting dislocation of the coupler after installation and during and between dispensing operations.
[0111] Since the attachment site fixture can take so many shapes and sizes, to give the consumer the greatest degree of freedom, it is important to use attachment mechanisms which are easily and suitably (i.e. tightly attached or rotatable under appropriate manual force) adaptable to fit many, if not most, of the fixtures most closely associated with and proximate to the environment where the fluid would be likely dispensed. Generally the categories of fixtures can be summed by those that have some longitudinal dimension and cross-section around which a coupler can be attached, those with angled edges and those presenting flat surfaces. For example, fixtures (found in and around washing installations, e.g. a kitchen sink, a laundry room sink, a washroom sink, a bathtub, etc. as well as surrounding or adjacent work surfaces such as countertops, islands, tabletops) including faucets, spray nozzle housings, and spigots can be roughly cylindrical, rectangular, elliptical, etc., but nearly all have some portion that is somewhat elongated, though their sizes, terminal conformations and cross-sections can vary greatly. Therefore products like toothpastes, soaps, conditioners, toiletries, etc. would be suitably packaged and marketed in containers adapted for coupling to plumbing fixtures or countertops. Exemplary embodiments of the present invention are thus generally adaptable for one or more of fixtures having some longitudinal conformation, an edge such as of a shelf or window sill, or a flat surface, i.e., planar or not planar.
[0112] In the following exemplary embodiments, like parts in different embodiments will be designated by like reference numerals increased in increments of hundreds.
[0113] With reference to FIG. 1 , an exemplary embodiment of fluid dispenser 12 is rotatably coupled via coupler 22 (shown and described hereinbelow) to fixture 10 , which in this instance comprises a sink faucet spout. Fluid dispenser 12 comprises a container 14 having an outlet 16 . Container 14 , shown here as translucent for clarity of discussion, is made from any material or materials normally used for the purpose, and preferably light molded materials such as thermoplastics like PET, PVC, polycarbonate, polypropylene, polyethylene, glass, ceramic, etc. Additionally, flexible pouches, for example of the disposable type, may be adapted for use in the invention as long as provision, for example an exoskeletal frame, is made for providing some rigidity to at least one wall of the pouch, preferably the wall to which a pivot button or female housing is or would be attached or formed. The outlet for a pouch or puncturable container can be created by the consumer.
[0114] The present invention provides bottle designers with new degrees of freedom in designing a fluid container which can be shaped without regard to adaptations for maintaining it in a standing position when placed on a surface, for example a flattened area, legs, and dimples. Thus container 14 is shown in FIGS. 5 a - c as having a substantially elliptical periphery in profile, everywhere but the outlet 16 , with little or no regard to their ability to stand on a horizontal surface.
[0115] Referring again to FIGS. 1-3 , translucent container 14 contains translucent fluid 18 and has an outlet 16 on its periphery. Outlet 16 will often have an outlet cover 17 , such as a twist off or threaded on cap, a lift-up hinged flap lid, pop/pull up extending nozzle, and the like. Due to the unique character of the fluid dispenser 12 , outlet cover 17 can be replaceable, recloseable, disposable or not present at all. Due to the stable nature of the containers of the present invention, many products may be packaged and marketed in fluid containers that do not have caps at all, for example where the outlet is purchased sealed and is subsequently unsealed, punctured or cut open by the consumer. Coupler 22 , visible through fluid 18 in FIGS. 2 and 3 , has a receptacle chamber 29 which is provided on an outer surface with pivot slot 30 shaped somewhat like an inverted skeleton-key hole for receiving the pivot button 20 of container 14 .
[0116] Referring to FIGS. 1, 2 and 3 in sequence, one notes that container 14 is rotated, changing the height of outlet 16 from a non-dispensing position at about ten degrees from vertical to a dispensing position at roughly 250 degrees rotation (as measured clockwise, though rotation may be counterclockwise or fully bidirectional). A non-dispensing position is one where outlet 16 is above the surface of fluid 18 and a dispensing position is one where outlet 16 is below the fluid surface. FIG. 2 shows fluid 18 , with surface level now above outlet 16 , beginning to drain due to the repositioning through open outlet 16 out of container 14 under the force of gravity alone or possibly assisted with a manual squeeze. It should be noted that full 360 degree rotation is not necessarily required. Container configurations are contemplated which may require as little as a 60 degree to 90 degree arc of rotation to move the outlet from non-dispensing when substantially full to dispensing substantially completely. For instance, a square container having the outlet at one corner merely needs a total rotation range of 90 degrees to cover at least one of each possible dispensing/non-dispensing elevation. A triangular container can be rotated through a complete range of needed elevations in as little as 120 degrees. An elliptical container could be nearly completely drained with as little declination of outlet 16 as 40 degrees below horizontal.
[0117] It should be kept in mind that each dispensing operation (as well as refilling) changes the fluid level and hence the dynamics of the dispenser. For example, the center of gravity shifts ever lower, as does the point between dispensing and non-dispensing positions. In prior art pouring dispensers, the outlet position does not adjust to fluid level change as the fluid level drops. Therefore, those known containers must be manipulated more and longer in subsequent dispensing operations to allow for viscous fluids to “catch up” to the changed outlet elevation. The present invention permits easy priming of the
[0118] With reference to FIG. 2 , if left in a dispensing position, gravity causes fluid 18 to drain from container 14 as long as the fluid surface is above the edge of the opening of outlet 16 and then stops on its own once as in FIG. 3 when the fluid surface level is below the opening 16 . In actual use, this feature helps to prevent complete loss of contents caused by, for example, a child forgetting to reposition or recap the container 14 . Furthermore, since the difference between the dispensing position and non-dispensing position can be finely controlled, a user can position the container between dispensing operations such that viscous contents can accumulate directly adjacent to but slightly below the outlet, ready for immediate dispensing upon demand by the next user. Incidentally, where a container is provided with a resealable cap, a user can choose to simply cap the container, rather than reposition it upwards, allowing fluid to accumulate right at the outlet, primed for the next use.
[0119] Referring to FIGS. 4 a , 4 c - 4 a and 5 a - 5 d , coupler 22 is positioned with its rear gripping surface 27 against the fixture 10 . At its upper ends, coupler 22 has strap-retaining members 28 , for example, hooks, pegs or barb slits and is maintained in place by slipping one perforation 61 of elastic strap 25 over one strap-retaining member 28 , stretching strap 25 tautly around fixture 10 and slipping another distal perforation 62 , chosen to retain the tautness, over the other strap-retaining member 28 . Container 14 is attached to fixture 10 by coupler 22 which is shown having on its front side a skeleton-keyhole shaped pivot slot 30 in the outer wall of a receiving chamber 29 . Container 14 and coupler 22 are rotatably joined by a pivot button 20 comprising a flange 26 -topped neck (or shaft) 19 extending axially from container's 14 rear wall 21 roughly perpendicular to outlet 16 . Flange 26 -topped neck 19 and face 44 are complementary in shape and dimension to pivot slot 30 and inner and outer surfaces of receiving chamber 29 . Tight tolerances between the interfacing surfaces of pivot button 20 and receiving chamber 29 permit flange 19 to be slid somewhat forcibly down into pivot slot 30 past retaining constriction 31 and or restraining beads 32 until seated in the closed circular bottom well 33 of pivot slot 30 . In another exemplary embodiment (seen for example in FIGS. 6 a - 6 c ), flange 226 may be frusto-conical and pushed through an appropriately smaller sized hole provided in the outer wall of receiving chamber. Finally, referring to FIGS. 27 a - b and 28 a - c , it can be seen that the length of slot 230 may be quite extensive, and that a plug 397 may be inserted to prevent pivot button 20 from sliding out towards the slot's open end when container 10 is inverted. Both structure types result in a secure pivoting relationship established between the container and the coupler at one or more surface interfaces, for example between button neck 19 and the bottom round portion of pivot slot 30 , among others.
[0120] In order to ensure that container 14 is manually and incrementally rotatable while installed in coupler 22 , at least some portion of the interfacing surfaces between container 14 and coupler 22 should be designed to have sufficient friction between contacting surface areas to be able to withstand the torsional forces exerted by a gravity on a partially filled container. Torsional forces that must be counteracted will vary depending on several factors including the position on rear wall 21 of pivot button 20 and the density of the fluid contents. Although pivot button 20 is shown centered on rear wall 21 , to reduce the friction required to keep container 14 from moving on its own, positioning it off-center may have advantages in certain applications, depending on how the shifting center of gravity of the fluid in the container affects the frictional force required to keep coupler 22 from twisting about fixture 10 . As described above, preferred balance of friction is achieved for a container having any given size and shape when the outlet 16 of the fluid container 18 can easily be vertically displaced about the axis formed by the pivot button of the container in the coupler 22 by an adult's and/or child's manual rotation, yet remains where positioned until acted upon again by the user, regardless of how filled or empty it is. Thus, once positioned with the outlet below the surface level of the fluid contained therein, the fluid should flow out until the surface drops to just below the level of outlet opening 16 or until it is repositioned to a non-dispensing position by the user, preferably just enough to be primed and ready to be used by the next user with minimal time lag.
[0121] As mentioned hereinabove, coupler 22 has a structure which provides the dual functions of [1] facilitating manual repositioning of outlet 16 relative to fluid 18 in a plane having a vertical component between dispensing and non-dispensing positions and [2] attaching fluid container 14 to a fixture 10 causing it to be suspended. Thus there are two attachment sites per coupler 22 and either one, or both, of the attachment sites of an exemplary embodiment of a coupler can provide the rotational repositioning function. In other words, in one form (see FIGS. 20 a - c ), the coupler may be stationery with respect to the container to which it is attached and the entire fluid dispenser is rotated around the fixture, or the coupler may be stationery with respect to the fixture, as in the above-described embodiments. Finally, forms of the container and coupler may be movable with respect to both the fixture and one another. Ultimately what matters is that the container is generally suspended from the fixture in a desirable place and is manually displaceable in a plane having at least some vertical component.
[0122] Referring particularly to FIGS. 7 a - g , fixture attachment mechanism 523 provides the attachment required between coupler 22 and fixture 10 . The illustrated exemplary embodiment of a fixture attachment mechanism 523 further comprises a fixture gripping surface 527 on the somewhat U- or V-shaped concave inner surface created between fixture engaging members 524 , extending outward from the side of coupler 22 opposite slot 530 . Fixture gripping surface comprises a modification of the surface provided to enhance the stability of coupler 22 on fixture 10 and may comprise surface coating, texturing, stepped profiling, dimples, ridges, grooves and could even be molded from a different, stickier material than the rest of coupler 22 , such as rubber, silicone, vinyl, etc. Fixture engaging members 524 are distanced apart to provide the fixture gripping surface 527 and are shown terminating distally in strap retaining members, here shown as slot 541 and button-receiving slot 530 . For examples of additional embodiments of fixture gripping surfaces, reference should be had to FIGS. 4 e , 15 a - f , 16 and 17 showing possible different profiles.
[0123] Referring to FIG. 7 g , when positioned with fixture gripping surface 527 pressed against the surface of a fixture 10 , one or more retainer straps or bands 25 is hooked and stretched between strap retaining members 28 , passing over fixture 10 . Referring to FIG. 4 b , fixture retaining strap 525 has an anchor 560 at one end sized so it will not pass through slot 541 , and the elongated portion having at least one and preferably more molded protuberances 561 is threaded through slot 541 , from inside of receiving chamber 529 and out and around fixture 10 and in through pivot button receiving slot 530 . When pivot button 520 is inserted into receiving chamber 529 , strap 525 is trapped between button flange 526 and fixture 10 . Generally speaking, the environment within which the product is expected to be used will have a bearing on choosing the characteristics of the fixture retaining mechanism. Many cylindrical or other longitudinal shaft-type fixtures can be accounted for by a single retaining strap which can be trimmed to size by the installer. Other exemplary embodiments of fixture attachment mechanisms are described with reference to the remaining drawings further hereinbelow.
[0124] The exemplary embodiment of container 14 in FIGS. 5 a and 5 b has pivot button 20 integrally formed. Often, a 90 degree angle relationship is provided between the axis described by pivot button neck 19 and the long axis running between outlet 16 and the bottom 21 of container 14 . The angle between pivot axis and container outlet can range very widely in other exemplary embodiments. Retaining beads 32 are formed into the inner walls of the main slot 40 of receiving chamber 29 and positioned between the open top of main slot 40 and the closed bottom thereof such that when an edge of flange 26 is aligned with main slot 40 and with neck 19 traversing pivot slot 30 and neck is depressed completely into pivot slot 30 , flange 26 is pushed down and past retaining beads 32 to be firmly but rotatably seated in receiving chamber 29 . Coupler 22 is thus shown in FIG. 5 b cooperating with container's 14 pivot button 20 to provide an axle that rotates in a plane having a vertical component that is easily actuated, preferably incrementally, as desired. As an alternative to a relatively two-dimensional button flange 526 , a ball-shaped pivot button can be seated in a complementary semi-spherical shaped joint socket-type receiving chamber formed on a coupler. Design considerations would include clearance between outlet 16 and fixture 10 , as well as outlet 16 and intended target work area of the fluid being dispensed.
[0125] Referring now to FIGS. 6 a - 6 b , an elliptical fluid container 314 is shown having pivot button 320 as a separately formed component, attached to the outer surface of fluid container 314 and extending axially outward from the outer surface 323 thereof at approximately a 90° angle with outlet 316 . Outlet 316 should preferably be situated at or near container's 314 periphery, permitting it to be rotated to positions where it is near or at the highest and/or lowest points of the container as it is rotated, regardless of the overall shape. This design feature bears on how completely a container will drain when inverted and will also determine the real capacity of a filled container. Practically, the outlet opening's distance from the outer edge will affect the maximum volume of fluid within.
[0126] It bears repeating here that in order to promote control of the rotation and positioning of container 14 , it is preferable that inner and outer surfaces of receiving chamber 29 and slot 13 and corresponding outer surfaces of pivot button 22 and the bearing surface area 44 of container 14 immediately surrounding the base of neck 19 , collectively the container-coupler interfaces, are complementarily shaped to provide a stabilizing, friction-maintained, contact interface when pivot button 20 is completely inserted into receiving chamber 29 . Interface surfaces may be further provided with textural features such as bumps, grooves, ridges, etc. or be surfaced with friction modifying materials, such as rubber, silicone rubber and nylon.
[0127] Pivot button disc 320 can be formed or molded separately from the container 314 and affixed thereto by welding, adhesive, cohesion, or even suction alone given the right combination of materials, fluid product volume and taking into account the force needed to rotate the fluid dispenser 312 in normal use. Pivot button disc 320 comprises a base disc 340 having an inner surface 342 contoured to conform as much as possible with the intended attachment site on the outer surface 346 of container 314 . Pivot button disc 320 is further provided with an interface bearing plateau 344 , shown here as flat and preferably textured, on its outer surface in the area immediately surrounding the base of shaft 319 . Base disc 340 is also an example of one kind of reinforcement that may be applied to container wall 321 to resist flexing or distortion caused by its own weight and the twisting forces, as well as increasing the area of contact at the interface between base disc 340 and the outer surface of receiving chamber 29 when pivot button 420 is seated therein. The remainder of pivot button 320 is constructed according to the same principles enunciated hereinabove, i.e. with a shape intended to firmly, but rotatably engage a receiving chamber in a coupler 22 .
[0128] Referring to FIGS. 8-10 , two exemplary embodiments of fluid dispensers and couplers constructed according to the principles taught by the invention are shown. FIG. 8 shows the cross section of a fluid dispenser 612 which has a female pivot receiving chamber 629 integrally formed into an exterior side surface of container 614 . Fluid dispenser 612 is paired with a coupler 622 having a complementary male pivot button 620 formed on or attached thereto. Assembly requires insertion of the pivot button 620 into receiving chamber 629 until seated and rotatable.
[0129] The exemplary embodiment of fluid dispenser 712 shown in FIGS. 9 and 10 comprises a female receiving chamber 729 attached or integrally formed on the exterior surface of container 714 . Coupler 722 comprises a male pivot button 720 integrally formed or attached to an outer surface thereof. The area of surface surrounding the base of neck 719 is similarly provided with an interface plateau 744 , shown here as flat, that is complementary to the front face 743 of receiving chamber 729 and is preferably rubberized or otherwise textured to increase friction between the plateau and its complementary surfaces with which it interfaces. If desired, any of the embodiments described herein can be provided with texturing over any or all of the complementary interfacing surfaces to enhance friction. Coupler 722 has fixture attachment members 724 designed to engage cylindrical portions of fixtures, within a pre-defined size range determined by the flexibility and elasticity of the members 724 and the distance between their tips 745 . Coupler 722 is in the shape of a cuff describing a fixture receiver 747 in its interior. Manufacturing coupler 722 from a firm but flexible material, such as nylon, polyethylene, Delrin®, hard rubber, silicon, and the like permits sufficient spreading of its tips to permit a fixture 10 to be inserted into fixture receiver 747 as seen in FIG. 10 .
[0130] Referring to FIG. 11 , flange 126 of pivot button 20 is shown having a non-circular shape, in this case an octagon. Other shapes are also contemplated as capable of providing the controlled rotation preferred by the present invention, for example, as mentioned above, a pivot button could terminate in a round or faceted ball which is received into a receiving chamber complementarily shaped like a ball socket.
[0131] FIGS. 12 a - 12 f show a coupler 222 having fixture attaching members 123 and 124 comprising flexible straps extending from opposite sides of receiving chamber housing. Strap 123 is provided with perforations 152 and strap 124 is provided with a catch 150 . Any excess strap 123 can either be trimmed or inserted into a slot 131 below and behind chamber housing 119 into the back of pivot slot 130 where it can provide additional frictional pressure to help maintain the position of a pivot flange.
[0132] FIGS. 13 a - 13 d show coupler 422 having a relatively rigid, disc-shaped receiving chamber 419 which has a keyhole shaped pivot button receiving slot 430 and the fixture attachment mechanism is an elasticized strap 424 integrally formed so that the strap may be stretched over a longitudinal fixture's terminal end (often significantly larger in diameter than the longitudinal portion or shaft) and then released into a stable tightened position around the fixture where desired, adapting itself to the fixture's cross-sectional profile.
[0133] Similar to the embodiment of FIGS. 12 a - 12 f , the couplers shown in FIGS. 14 a - 14 c also have a disc-shaped receiving chamber 529 having a pivot slot 530 therein and having an attached (or integrally formed) retaining strap 525 extending outwardly from opposite sides the disc. The locking mechanism for tightening the strap 525 . Incorporated or attached to, or extending out from, rear edge 554 opposite rear edge 550 , a strap receiving slot 556 has an associated lock mechanism 558 . Strap 525 is provided with lock engaging features 552 comprising, for example, parallel ridges across along its length. Lock engaging features 552 are shaped to interact with lock mechanism 558 when strap 525 is inserted into strap receiving slot 556 thereby locking strap 525 in position once the end thereof is wrapped around a fixture 510 , inserted therein and pulled until a snug fit is achieved and maintained by the interaction of lock engaging features 552 and lock mechanism 558 . Examples of similar lock mechanisms and lock engaging features are commonly known for securing cable ties, watch straps (see FIG. 4 a ), scuba goggle straps (see FIG. 4 b ) and the like, wherein the end of a notched, ridged or perforated strap is inserted through a slot and the notches ridges or perforations-are engaged by a latch mechanism.
[0134] FIGS. 15 a - f show exemplary embodiments of male couplers 722 and female couplers 822 all having fixture engaging surfaces 727 shaped or otherwise enhanced to reduce unintended movement of couplers 722 and 822 when installed around a fixture 10 having angular cross-section features (corners and other abrupt changes). In one exemplary embodiment ( FIG. 15 a ), fixture surface engagement enhancement is provided by texturing with ridges. Fixture engagement surfaces 727 having one of the profiles with multiple or compound curves such as those shown in FIGS. 15 b - 15 f , could be particularly useful. Other surface adaptations may be used to modify the characteristics of fixture engaging surfaces depending on the desired effect. For example, if the fluid dispenser design requires that the coupler remain immobile even when wet yet still be controllably rotatable around the fixture, then the fixture engaging surface may benefit from having a hydrophobic coating layer or, as seen in FIG. 7 g , a piece of such material between the surface and fixture 10 . Providing a coupler that has regions with different properties may prove desirable, different materials can be used and either formed separately and attached to one another, or methods such as co-extrusion could be used. It is anticipated that flexible or elastic and rigid combinations of materials such as rubber, nylon, silicone, PETE, polypropylene, polyethylene, polyvinyl chloride, polycarbonate and ABS can be used, and the selection thereof is well within ability of one of ordinary skill in the art to select based on the properties desired, within the parameters of the teachings herein.
[0135] FIG. 16 shows a coupler having slender fixture retaining members 424 that are inclined towards one another at an acute angle to change how it grips fixtures. FIG. 17 shows a coupler having contact adhesive pads 453 on the fixture engaging surface 427 to permit positioning and installing a coupler independent of any retaining straps or bands. This exemplary embodiment may be particularly suitable for installation on fixtures such as shelf edges, counter top edges, table edges or window sills. FIG. 18 shows a coupler having fixture retaining members 524 that are wider than the receiving chamber housing 419 to better resist the torsional stress caused by rotating the fluid dispenser 412 .
[0136] Referring now to FIG. 19 , a coupler 922 is shown having fixture retaining members 924 which are elongated, parallel and have parallel opposing fixture gripping zones shaped, textured or otherwise adapted to grip a fixture at varying distances from the receiving chamber 929 . This feature addresses situations where the fixture may be somewhat farther from the target area than in others.
[0137] Referring to FIGS. 20 a to 20 c , a fluid dispenser 712 comprises a container 714 having coupler 722 attached in an immobile manner on an outer surface thereof. In this case, changing the elevation of outlet 716 requires rotating the entire assembly of fluid dispenser 712 in either direction around (perpendicular to) a horizontal portion of a fixture 10 .
[0138] A coupler may be adapted to couple more than one container to a fixture. Referring to FIGS. 21, 22 , and 28 a - c , two containers each 614 and 814 are rotatably attached to coupler 822 , which straddles, or encircles, a fixture 10 . Actually, in the case of FIG. 22 , two single couplers, are designed to mate and interlock when brought back-to-back. Further, they are each provided with a fixture engaging surface 627 between which a spray hose passes. An outer fixture engaging surface 527 is designed to be inserted into the grommet surrounding the spray house at the level of a counter top. The coupler 622 is one example of a columnar coupler. Additional examples are illustrated in FIGS. 23 and 24 a - b . FIG. 23 shows a coupler comprising a column adapted on a lower portion thereof to be attached along the upper vertical side wall of a basin. Attachment of the coupler can be accomplished by a number of methods, including for example suction cups, magnets or adhesive pads located between attachment member 326 and a surface of fixture 10 . FIGS. 24 a - b shows a suspended fluid dispenser 520 attached to a horizontal work surface, in this instance a countertop surrounding a wash basin, and example of a planar surface.
[0139] With reference to FIGS. 25 a through 25 d and 26 a - 26 e , there are shown exemplary embodiments of fluid containers which are adapted to be coupled to a faucet whereby as few as one or more elastic band 622 functions as the coupler and the band/s and fixture serve as an axle for the rotation of the fluid container 620 . Fluid container 620 is provided on its outer surface with a strap end button 621 and strap 622 is adapted to have at least one outlet engaging member, in this case a loop 623 , and one or more end button holes 624 for receiving strap end button 621 . The zone between loop 623 and end button holes 624 is elastic and stretched taut as it is wrapped about a longitudinal fixture 10 , thereby rotatably coupling container 614 to the fixture. The exemplary embodiments of FIGS. 26 a - e comprise containers sculpted on one side with attachment or retention channels 650 , then one or more elastic straps 628 , such as rubber bands, can serve as a coupler to attach the fluid container to a faucet neck and provide elasticity to permit rotation of the fluid container in relation to the faucet. The rotation in that case might be made incremental by molding stop depressions or guide channels 652 in an outer surface of the fluid container, opposite retention sites 650 , into which the faucet surface 29 could seat sufficiently to resist the memory or elastic response of the bands 628 and to prevent lateral displacement along the faucet neck. Together, the grooves and band cooperate to satisfy some of the most basic requirements of a suitable coupler.
[0140] Referring to FIGS. 27 a - b , a container 314 is provided with a long receiving chamber having a slot which runs about half the length of the container. Referring to FIGS. 28 a - c , the containers 314 and 14 are coupled to the straddling coupler previously described hereinabove. A retention plug is inserted to prevent receiving chamber 919 from slipping along pivot button. Although pivot buttons 820 are shown as engaging substantially the center of containers' 814 outer surface, thus forming an axle, it should be noted that eccentric arrangements of pivot buttons and complementary receiving chambers can be used for making containers 814 rotatable relative to coupler 822 .
[0141] A fluid container suitable for use in exemplary embodiments of the present invention can hold anywhere from less than a cubic centimeter of fluid to several liters. More commonly, the fluid container will hold between about 2 mls and 4 liters of fluid.
[0142] Exceptional advertising value is provided by the fluid containers of the exemplary embodiments, by improving conspicuity of the container brand, for example, spending more time in open view whether or not in use, and even adding visible surface area for advertising/marketing over the whole outside surface of the container and coupler, rather than just the container sides. For example, FIG. 4 c shows a strap marked with indicia and making the strap broader serves the double purpose of increasing advertising space as well as increasing stability of the installed coupler's position.
[0143] It should be noted that exemplary embodiments of the present invention could be automated or semi-automated with the addition of appropriate circuitry including proximity and fluid level sensors, power supply, motor and controller. For example, the proximity sensor could sense when a user's hand is near the outlet, activating a motor integrated into the coupler which repositions the container, lowering the height of the outlet to below the sensed level of the fluid. After fluid has been dispensed, the motor can be reversed until the outlet is just above the sensed new surface level of the fluid and then deactivated. This arrangement results in a completely hands-free dispensing operation.
[0144] The above exemplary embodiments should be taken as non-limiting examples intended to demonstrate many of the capabilities, but not necessarily the boundaries, of what applicants consider the invention. Alterations, modifications and additions may be made to the examples and the claimed invention by one of ordinary skill in the art without departing from the spirit and scope of the invention as defined in the appended claims. | A fluid dispenser comprises a container or fluid reservoir and a coupler. The container is adapted to be suspended from, and rotationally coupled to, a mounting point selected by a consumer. The container has at least one outlet at a first position in an outer surface thereof and further has the coupler located at a second position on the outer surface and attachable by a consumer to the selected mounting point in a repositionable relationship. The fluid dispenser further comprises position stabilization for maintaining the user-determined position of the container when not being acted upon, whereby a consumer controls fluid dispensing from the container by re-orienting the height of the outlet between any non-dispensing position and any dispensing position, without decoupling the container from the mounting point. | 0 |
RELATED APPLICATIONS
This application claims the benefit of U. S. Provisional Application No. 60/139,563 filed Jun. 16, 1999.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention generally relates to a lawn cutting apparatus. More particularly, the present invention pertains to a mechanism for positioning a cutter assembly for a riding lawn mower.
2. Discussion
Operators of lawn cutting equipment often have a need to adjust the position of the cutter assembly relative to the ground over which the lawn mower is driven. The cutter assembly is typically retracted when the mower is driven from one cutting area to another to avoid hitting obstacles such as curbs and stones.
Many riding lawn mowers are equipped with mechanisms for positioning the cutter assembly to a desired cutting height. Most of these mechanisms consist of linkage interconnecting the cutter assembly and a lever which is directly controlled by the operator's hand or foot to engage a series of holes which correspond to specific cutting heights. Although the effort required to lift the cutter assembly is reduced by using leverage, these mechanisms require strength and coordination.
Other cutter assembly lift mechanisms exist that are actuated by an electric motor or a hydraulic cylinder. However, many of these devices have certain undesirable features. Firstly, the operator of the lawn cutting equipment is unable to easily position the cutter assembly at a desired height because the device lacks a positive height setting device. While some of the aforementioned mechanisms include a fine adjustment capability that is facilitated by using a slow actuation means, use of this design sacrifices productivity by making the operator wait. Secondly, many riding mowers are controlled by a steering mechanism that requires the use of both of the operator's hands. Accordingly, operation of the aforementioned lift mechanisms requires the operator to stop the mower in order to take one hand off of the steering mechanism and adjust the cutting height.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved positioning mechanism and control for a riding lawn mower.
It is another object of the present invention to optimize the speed and accuracy of positioning the cutter assembly in the desired position.
It is yet another object of the present invention to allow the operator to raise and lower the cutter assembly without sacrificing control of the mower.
According to the present invention, a cutter assembly positioning mechanism for a riding lawn mower having a frame includes an actuator adapted to be coupled to the frame, a cutter assembly adapted to be movable relative to the frame for adjusting a cutting height and a first flexible member interconnecting the actuator and the cutter assembly. The actuator is operable to extend and retract thereby raising and lowering the cutter assembly.
Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from a reading of the subsequent description of the preferred embodiment and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a riding lawn mower constructed in accordance with the teachings of the present invention;
FIG. 2 is a partial side view of the cutter assembly positioning mechanism of the present invention;
FIG. 2A is a magnified view of the mechanism of FIG. 2;
FIG. 3 is a perspective view of an embodiment of the cutter assembly positioning mechanism of the present invention;
FIG. 4 is a side view of the secondary and tertiary sprockets of the cutter assembly positioning mechanism of the present invention;
FIG. 5 is a partial perspective view of the cutter assembly positioning mechanism constructed in accordance with the teachings of the present invention;
FIG. 6 is a side view of the cutter assembly positioning mechanism depicting the cutting height memory mechanism in an operable position; and
FIG. 7 is an electrical schematic of the control system for the cutter assembly positioning mechanism of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, a cutter assembly positioning mechanism and control for a riding lawn mower constructed in accordance with the teachings of an embodiment to the present invention is generally identified at reference numeral 10 . The cutter assembly positioning mechanism 10 is shown operatively associated with an exemplary riding lawn mower 12 . In the preferred embodiment, the riding lawn mower 12 is a zero turning mower capable of performing zero radius turns. The riding lawn mower 12 includes a left steering control lever 14 for controlling a left drive wheel 16 and a right steering control lever 18 for controlling a right drive wheel 20 . Accordingly, proper operation of the riding lawn mower 12 requires the use of both of the hands of an operator at all times. The riding lawn mower 12 further includes a pair of front wheels 22 mounted on pivots 24 to facilitate zero radius turns. One skilled in the art will appreciate that the riding lawn mower depicted in the drawings and described in detail is merely exemplary and that the cutter assembly positioning mechanism of the present invention may be utilized in a variety of applications such as riding lawn tractors and walk-behind mowers.
Referring to FIGS. 1 and 2, the riding lawn mower 12 further includes a frame 26 having a seat 28 , a floor pan 30 and the pivots 24 mounted thereto. The riding lawn mower 12 also includes a cutter assembly 32 pivotally interconnected to the frame 26 via links 34 . One skilled in the art will appreciate that the frame 26 , the cutter assembly 32 and the links 34 form a four-bar linkage such that the cutter assembly 32 remains in a generally horizontal plane as it is raised and lowered.
As shown in FIG. 3, the cutter assembly 32 is raised and lowered by an actuator 36 interconnected to a roller chain 38 . The roller chain 38 is coupled to a first sprocket 40 which is drivingly engaged to a primary shaft 42 . Depending on the geometry of the cutter assembly 32 , a number of secondary sprockets 44 and 46 may be drivingly engaged with and positioned along the length of the primary shaft 42 . The secondary sprockets 44 and 46 are utilized to distribute the lifting effort supplied by the actuator 36 across the surface of the cutter assembly 32 . In this manner, a large cutter assembly 32 such as the one depicted in FIG. 3, may be smoothly raised and lowered without binding the links 34 during operation. However, one skilled in the art will appreciate that some cutter assemblies may require only one lift point and that the roller chain 38 may be directly interconnected to the cutter assembly 32 without the need for secondary sprockets. It should also be appreciated that the roller chain 38 is merely an exemplary device and that a variety of flexible members such as wires, cables or belts may be used without departing from the scope of the present invention. In similar fashion, it should be appreciated that other rotary power transfer devices such as gears, pulleys, cogs, bearings, cams and shafts may be implemented instead of sprockets without departing from the scope of the appended claims.
In the preferred embodiment, an inner secondary sprocket 44 and two outer secondary sprockets 46 drivingly interconnect with the primary shaft 42 . Each of the secondary sprockets 44 and 46 are interconnected to the cutter assembly 32 via a flexible member 48 . As earlier described, the flexible member 48 may comprise devices such as a chain, a wire, a cable or a belt. As shown in FIGS. 2 and 2A, the flexible members 48 associated with the outer secondary sprockets 46 are directly interconnected to the cutter assembly 32 via an attachment mechanism 50 .
The attachment mechanism 50 includes a lift pin 52 mounted to an upper surface 54 of the cutter assembly 32 , an “L” shaped bracket 56 also mounted to the upper surface 54 of the cutter assembly 32 and a deck lift stud 58 for interconnecting the flexible member 48 and the “L” bracket 56 . Specifically, the “L” bracket 56 includes a first leg 60 coupled to the cutter assembly 32 and a second leg 62 having an aperture 64 extending therethrough. The deck lift stud 58 is a generally cylindrical rod 66 having an external thread extending along a substantial portion of its length. The deck lift stud 58 includes a transverse aperture 68 extending through the rod 66 near one of its ends for receipt of the flexible member 48 . Specifically, the flexible member 48 is coupled to the deck lift stud 58 in a manner commonly known in the art such as pinning. In addition, a pair of adjustment nuts 70 cooperate with the external thread of the deck lift stud 58 and the second leg 62 of the “L” bracket 56 to provide an initial adjustment feature whereby the operator may level the cutter assembly if more than one secondary sprocket is used.
Referring to FIG. 3, the inner secondary sprocket 44 and its corresponding flexible member 48 act in cooperation with a tertiary sprocket 72 drivingly engaged with a secondary shaft 74 rotatably coupled to the frame 26 . It will be appreciated that the flexible member 48 drivingly engages both the inner secondary sprocket 44 and the tertiary sprocket 74 and is coupled to the cutter assembly 32 via the attachment mechanism 50 as previously described in detail. In reference to FIGS. 3 and 4, as the actuator 36 is extended, the primary shaft 42 rotates in a clockwise direction as viewed from the left side of the riding lawn mower 12 . Accordingly, the secondary sprockets 44 and 46 also rotate in a clockwise manner. Based on the routing of the flexible member 48 , the tertiary sprocket 72 rotates in a counter-clockwise fashion thereby lowering the cutter assembly 32 . Conversely, when the actuator 36 is retracted, the primary shaft 42 rotates in a counter-clockwise direction while the secondary shaft 74 rotates in a clockwise direction thereby raising the cutter assembly 32 .
Referring to FIG. 5, the cutter assembly positioning mechanism 10 of the present invention also includes a cutting height memory mechanism 76 . The memory mechanism 76 includes a stop 78 extending from the frame 26 . Preferably, the stop 78 defines a passage 80 for guiding the roller chain 38 therethrough. The cutting height memory mechanism 76 also includes a sleeve 82 defining a passage 84 with the roller chain 38 disposed therein. The sleeve 82 includes a first aperture 86 and a second aperture 88 for receipt of a pin 90 . The pin 90 is sized to cooperate with the roller chain 38 and the first and second apertures 86 and 88 . Specifically, the pin 90 has a diameter less than the minimum spacing between a pair of adjacent rollers 92 of the roller chain 38 .
In order to provide the cutting height memory mechanism 76 with a relatively fine adjustment increment, the first aperture 86 is spaced apart from the second aperture 88 a distance approximately equal to one and a half times the distance between adjacent roller chain links. Accordingly, when the operator of the riding lawn mower 12 wishes to establish a fixed cutting height, the operator translates the sleeve 82 along the roller chain 38 to abut with the stop 78 as shown in FIG. 6 . At this time, the pin 90 is disposed within the aperture best aligned with the space between the rollers 92 to set the memory mechanism 76 . Accordingly, the operator may raise the cutter assembly 32 for transport over rough terrain such as rocks or curbs and subsequently lower the cutter assembly 32 until the sleeve 82 engages the stop 78 thereby returning the cutter assembly 32 to exactly the same cutting height previously set. One skilled in the art will further appreciate that the cutting height memory mechanism 76 does not interfere with an anti-scalp lawn protection system 94 .
As best seen in FIG. 1, the anti-scalp system 94 includes a plurality of rollers 96 mounted at the forward edge 98 of the cutter assembly 32 to prevent the mower blades from damaging or scalping the turf when traversing uneven terrain. During operation, the anti-scalp system 94 operates to raise the cutter assembly 32 when the rollers 96 are contacted by an obstacle or rapidly changing ground elevation. The cutting height memory mechanism 76 cooperates with the anti-scalp system 94 by allowing the cutter assembly 32 to be lifted by the rollers 96 without operator intervention. Specifically, once the memory mechanism 76 has been set, the sleeve 82 is forced against the stop 78 thereby placing the roller chain 38 in a tensile mode. When in tension, the roller chain 38 limits the downward travel of the cutter assembly 32 . However, when an obstacle is encountered, the cutter assembly 32 is free to move in an upward direction because the roller chain 38 becomes slack and the sleeve 82 is no longer loaded against the stop 78 . As the riding lawn mower 12 enters smooth terrain, the rollers 96 will no longer be loaded and the cutter assembly 32 will lower until the sleeve 82 once again contacts the stop 78 thereby returning the cutter assembly to the height initially set.
Referring to FIG. 1, the actuator 36 is controlled by the operator's foot or feet. In the preferred embodiment, a first switch 100 and a second switch 102 are located on the floor pan 30 of the riding lawn mower 12 . The first switch 100 is preferably located near the operator's left foot and second switch 102 is preferably located near the operator's right foot. Depressing the first switch 100 causes the cutter assembly 32 to lower while depressing the second switch 102 causes the cutter assembly 32 to be raised relative to the ground. One skilled in the art will appreciate that a single switch system may also be implemented to raise and lower the cutter assembly without departing from the scope of the present invention. In addition, it should be appreciated that the actuator 36 may be of an electrical or a hydraulic type.
Referring to FIG. 7, the preferred embodiment utilizes an electrical control system 104 with the actuator 36 as depicted in the electrical schematic. The control system 104 functions to position the cutter assembly 32 by extending or retracting the actuator 36 . Specifically, the control system 104 includes a portable power source 106 preferably mounted to the frame 26 of the riding lawn mower 12 . The control system 104 also includes a circuit 108 including the first switch 100 , the second switch 102 , a first relay 110 and a second relay 112 . Each of the relays 110 and 112 are preferably of the dual position, dual throw type having a dual position switch and a coil operable to selectively change positions of the switch. The relay 110 includes a normally closed first position input 114 , a normally open second position input 116 , an output 118 , and a coil 120 selectively energizable for switching the first position 114 to open and the second position 116 to closed. The second relay 112 includes a first normally closed input 122 , a second normally open input 124 , an output 126 , and a coil 128 .
Beginning with the portable power source 106 , a first battery terminal 130 is connected to ground. A second battery terminal 132 is connected to one side of each of the coils 120 and 128 , a first position 114 of first relay 110 , and a second position 124 of second relay 112 . A first lead 134 of actuator 36 is connected to an output 118 of first relay 110 . A second lead 136 of the actuator 36 is connected to an output 126 of second relay 112 . Connected to ground are the second position 116 of first relay 110 , the first position 122 of the second relay 112 and the second side of each of the coils 120 and 128 . The first switch 100 is normally open and positioned between the ground and the first position 122 of the second relay 112 while the second switch 102 is positioned between the coils and ground. Accordingly, when switch 100 is depressed, power is delivered directly to the actuator 36 causing it to extend thereby lowering the cutter assembly 32 . Upon release of the first switch 100 , the actuator 36 stops due to an open circuit condition. If an operator wishes to raise the cutter assembly 32 , the second switch 102 is depressed to close the circuit and energize coils 120 and 128 . Once the coils have been energized, each of the relays 110 and 112 switch such that the second position is now closed and the first position is open. In effect, depression of switch 102 reverses polarity to the electric actuator 36 thereby causing the actuator to retract.
An alternate means of controlling the actuator includes implementing a single, three-positioned multi-pole electrical switch that would extend the actuator when moved in a first direction and retract the actuator when moved in a second direction. The single three-positioned switch may also be foot operated.
Another alternate means of controlling the actuator is by way of a single spool, three-position hydraulic valve. The hydraulic valve controls a hydraulic cylinder instead of the electric actuator 36 presented in the drawings. In operation, fluid circulates throughout the system while the hydraulic valve is in the center position. Once the hydraulic valve is moved to one of the two engaging positions, hydraulic fluid is directed to one end of the hydraulic cylinder to extend the actuator. Conversely, once the hydraulic valve is switched to the opposite engaged position, the hydraulic fluid forces the cylinder to retract.
The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations may be made therein without departing from the spirit and scope of the invention as defined in the following claims. | A cutter assembly positioning mechanism provides an improved positioning mechanism and control for a riding lawn mower. Specifically, the mechanism optimizes the speed and accuracy of positioning the cutter assembly in the desired position and allows the operator to raise and lower the cutter assembly without sacrificing control of the mower. The lawn mower has a frame including an actuator adapted to be coupled to the frame, a cutter assembly adapted to be movable relative to the frame for adjusting a cutting height and a first flexible member interconnecting the actuator and the cutter assembly. The actuator is operable to extend and retract thereby raising and lowering the cutter assembly. | 0 |
BACKGROUND OF THE INVENTION
Present day sailcloth is made from a variety of materials, with one of the most common being a tightly woven cloth of polyester yarns. Sailcloth is the most tightly woven textile in the world and requires extensively modified heavy looms to generate the necessary forces to attain such a dense construction. Normally, polyester sailcloth is only woven in what is known as a plain weave, in which every warp yarn passes over and under each fill yarn, with the yarns being crimped over each other. After weaving, the cloth is impregnated with a resin and is heated, causing the resin to cure and also causing the polyester fabric to shrink.
The above described weaving method tends to impart certain characteristics to the cloth due to the nature of the operation itself. The warp yarns, which run in the machine on long direction tend to crimp more than the weft or fill yarns, which run in the cross machine direction. Sails of this nature are made up of a number of joined panels, and it is desirable to align the yarns with less crimp along directions of maximum stress or load in the sail. This, in turn, reduces stretch, which would otherwise cause the sail to lose its ideal or designed shape when subjected to increasing wind forces.
Fill oriented cloth imposes limitations on how panels can be cut and arranged in a sail while still making efficient use of the cloth. A common design using fill oriented cloth is a so-called cross cut design, in which the seams are substantially horizontal, and the fill yarns run from the top to the bottom of the sail.
Studies of the properties of sails have demonstrated that in triangular sails, especially genoas or jibs, the main forces radiate out of the corners of the sail. It becomes desirable to have sail panels which radiate out of the corners of the sail, and the most efficient way to accomplish this is with warp oriented cloth, e.g., cloth in which the warp yarns are relatively uncrimped.
One proposed solution to manufacture warp oriented polyester sailcloth is simply lower or reduce the fill yarn density by reducing or decreasing the fill yarn count per inch, thus increasing the spacing between the fill yarns. This approach is technically inferior for at least two reasons. The lower fill count significantly reduces the diagonal stability of the cloth, causing undesirable increased stretch along the bias. Also, lowering the fill count only partially reduces crimp in the warp yarns and also reduces the density of the weave. Thus, the cloth can still stretch in the warp direction and has a low service life.
In current fill oriented woven polyester fabrics, the natural tendency of the warp to crimp more than the fill is accentuated by using larger (heavier) fill yarns than warp yarns. The ratio of fill yarn weight to warp yarn weight is typically between 1.67 to 1 and 4.5 to 1. The density of these fabrics (as later defined herein) are in the order of 1,500 to 2,050 in the warp and from 1,000 to 1,330 in the fill.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel woven fabric of polyester or other heat shrinkable yarn is provided with yarn orientation in the warp direction, that is, crimp is imparted to the fill yarns while leaving the warp yarns relatively uncrimped, and also while producing the desired high fiber density fabric. This is accomplished by increasing the spacing between warp yarns to levels higher than current conventional fabrics and reversing the yarn weight ratios (fill vs. warp) to values between 1.0 to 1 and 0.22 to 1. This provides densities (as defined herein) in the warp of 970 to 1,500 and in the fill of greater than 1,400. The resulting cloth is then finished in a conventional fashion and is ready to be cut into panels.
DETAILED DESCRIPTION
In the present invention, the sailcloth is a plain weave and comprises 100% polyester or other heat shrinkable yarns, with a minimal value of shrinkage in the order of 10%, and with most polyester yarns shrinking greater than 15% when heated to temperatures in the order of 300 to 400° F. As envisioned, the fabrics of the present invention contemplate the use of warp yarns weighing from 100 to 2,000 denier and fill yarns having a denier of 30 to 1,000. In the alternative, the warp yarns may comprise monofilaments.
In addition to the above, the ratio of fill yarn weight to warp yarn weight is from 1.0 to 1 and 0.22 to 1. Surprisingly, this results in a woven cloth in which the warp yarns are relatively uncrimped.
As used herein, the term “density” of a fabric is determined by multiplying the square root of the yarn in denier which is a number proportional to the effective diameter of the yarn, by the yarns count per inch. Acceptable fabrics of the present invention are envisioned to have warp densities between 970 and 1,300 and concurrent fill densities greater than 1,400, or more generally, the warp density will be less than the fill density.
As an example of a specific fabric, the fabric would comprise 55 yarns per inch of 500 denier polyester in the warp and 135 yarns per inch of 200 denier in the fill. Using the above density calculation, this would result in a cloth having a warp density of 1,230 and a fill density of 2,002. When viewed at high magnification, the warp yarns are relatively uncrimped, and the densities are sufficient to provide a fabric having good stretch resistance along the bias.
Subsequent to weaving, the fabric is subjected to additional finishing operations. For example, the fabric is first cleaned to remove any sizings. Then the fabric is dipped into an aqueous bath of heat curable resin, such as melamine, which serves to lock the woven geometry and decrease stretch. The fabric is then dried and then heat-set by passing through an oven, causing the yarns to shrink, thereby increasing density. The fabric is then calendared by passing the fabric between a pair of rolls under high pressure, with one of the rolls being heated.
After the finishing operation, the cloth may be used as such to construct a sail made from panels. The panels are arranged such that the uncrimped warp yarns follow the major lines of stress in the sail when the sail is used. For example, the panels may radiate from the corners of a triangular sail. | A warp oriented woven sailcloth is provided in warp yarns are relatively uncrimped relative to the fill yarns. The yarn weight ratios (fill vs. warp) are 1.0 to 1 and 0.22 to 1. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an insulating apparatus for goods to be kept cool, such as frozen goods, chilled goods held at about 0° C., cooled goods held at about 10° C., etc., used in case of keeping the goods in containers and delivering the goods to stores or general households or temporarily stocking the goods in such a manner that the containers are individually maintained cool and insulated.
2. Description of the Prior Art
Goods to be cooled can be generally categorized to three types of frozen, chilled and cooled as described above. To deliver the goods, the goods have been heretofore contained in containers made of foamed polystyrene together with dry ice, cold storage reagent or ice.
According to the above method, an ordinary delivery vehicle can carry the goods to be cooled together with other types of goods, but since the insulation enabling time of the container is short, such as 5 to 10 hours, the above-described containers are not adequate when the delivery takes a long time, such as a long distance delivery or a delivery route (through branches and several delivery centers) like a general delivery. In such a case, a refrigerator or a special insulating vehicle must be employed. According to this method, the equipment is expensive, and since an exclusive insulation vehicle is used, general goods cannot be carried together with the goods required to be maintained cool. Further, since the vehicle must make the trip even if the quantity of the goods to be cooled is small, the delivery costs are increased. In addition, since the refrigerator in the insulating vehicle is maintained at uniform temperature, the goods to be frozen, chilled and cooled, each requiring different storage temperatures, cannot be contained together. Moreover, when the insulating vehicle or the refrigerator is employed, the door is opened whenever the goods are delivered, and chilled gas is readily leaked.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide an insulating apparatus which contains goods to be cooled in small containers and which can carry the goods in the containers together with general goods in a delivery vehicle.
Another object of the present invention is to provide an insulating apparatus which can maintain goods cool for a long time and set different insulating temperatures at every different containers therein.
Still another object of the invention is to provide an insulating apparatus which can contribute to the communication of the goods to be cooled.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferable embodiment of an insulating apparatus according to the present invention;
FIG. 2 is a perspective view showing an example of a container;
FIGS. 3A and 3B are longitudinal sectional views showing the internal structure of the container;
FIGS. 4 to 7 are views showing other examples of the structure of the container;
FIGS. 8A and 8B are views showing the displacing preventing method of the container;
FIG. 9 is a view showing the folded state of a cooling plate and racks;
FIG. 10 is a piping system diagram of a refrigerating system;
FIG. 11 is a schematic view of a refrigerating system controller;
FIG. 12 is a circuit diagram of a logic circuit for the controller;
FIG. 13 is a flowchart showing the operating flow;
FIG. 14 is a perspective view showing the case of supplying a cold air into a container in a cooling type of the container;
FIG. 15 is a view of the construction of a cooler of the case in FIG. 14;
FIGS. 16A and 16B are views showing a method of inserting a supply conduit and a recovery conduit in the container;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The most preferable embodiment of the present invention will be described in detail with reference to the accompanying drawings. The construction of a container used in the insulating apparatus of the invention will be first described. In FIGS. 1 through 3, a container 1 has a cover 2 and is made of foamed polystyrene. A shallow groove 3 is formed from the container 1 to the cover 2, and a rubber strip 4 is engaged in the groove 3. In FIG. 2, the strip 4 is not shown. The cover 2 is applied from above the upper surface of the container 1, and always pressed down by the strip 4. The front end 2a of the cover 2 is cut at both side corners in a square shape in the same width as an opening 5 formed by cutting the upper portion of the container 1 so that the cover 2 will fit in the opening 5. In FIG. 3A, a laterally long leg 2b is formed on the rear lower end of the cover 2. The leg 2b is placed together with the lower portion of the front end 2a of the cover 2 on laterally long stepped portions 1b and 1a formed on the upper inside and upper portions of the rear and front sides of the container 1. Thus, the cover 2 is pressed downwardly by the strip 4 engaged within the groove 3, to be usually tilted downwardly at the front side as shown in FIG. 3A. The lower side of the front end 2a of the cover 2 is obliquely cut to be formed with a claw inserting opening 2c to the upper end of the front portion of the container 1. A stopper 2d which is contacted with the upper edge 1c of the inside of the rear portion of the container 1 is formed as required at the front back surface side of the cover 2 inside the container 1.
The rubber strip 4 is laterally engaged around the entire periphery of the container 1. In this case, as shown in FIG. 4, lateral projections 6 and 6 may be protruded laterally from both lateral outsides of the container 1, and a rubber ring 7 may be engaged between the projections 6 and 6 through the groove 3 of the cover 2. Or, as shown in FIG. 5, other projections 2e and 2e may similarly protrude laterally from both lateral outsides of the cover 2 together with the projections 6 and 6, and a rubber ring 7 may be engaged between the projections 2e and 6. Further, in case of a hard container made of a hard plastic, as shown in FIG. 6, a spring 7a may be engaged between the cover 2 and the container 1. Moreover, the cover 2 may be retained by a hinged stopper 7b formed as shown in FIG. 7. Pressors 8, 9 and 10 are provided on the lower front surface of the container 1. For example, the pressors 8, 9 and 10 are corresponded to freezing, chilling and cooling zones of goods to be cooled. The pressors 8, 9 and 10 are respectively detachably installed in recesses 11 formed on the lower front surface of the container 1. To this end, the pressors 8, 9 and 10 are formed integrally with the container 1, for example, as clamped only at the upper portions of the pressors 8, 9 and 10. As another arrangement, it is considered that a plurality of recesses 8a are formed as shown in FIG. 5, fillers 8b are respectively inserted into the recesses 8a corresponding to the predetermined temperature zones (in the example in FIG. 5, the filler is inserted into the right side of the three recesses), or seals are bonded thereto. In case of the hard container, it is preferable that since the case is repeatedly used, a plurality of elevationally or laterally movable slide members 8c are provided in a slide type, and the slide members 8c corresponding to the predetermined temperature zone is moved in ON direction (FIG. 6). The number of the pressors is arbitrary, but one to five pressors are normally sufficient. A remote switch to be described later is operated by the pressors 8 to 10 to operate a refrigerating system. As shown in FIG. 3B, a recess 12 is formed on the bottom of the container 1, and a stopper 13 which extends laterally at the rear of the recess 12 is formed as required. The stopper 13 is used to retain a rack 18 to be described later.
In FIGS. 4 to 6, engaging grooves 14 are formed at the both lower outer corners of the container 1, and stoppers 14a (see FIGS. 8A and 8B) which extend from a cooling unit 15 are engaged with the grooves 14 to prevent the container from displacing due to the fluctuation of a transport vehicle. The shape of the stoppers 14a are arbitrary, and the positions and the shapes of the grooves 14 may be altered correspondingly to the stoppers 14a. FIGS. 8A and 8B show examples of the grooves 14 and the stoppers 14a. In FIG. 8A, the bottoms of the containers are formed with the grooves 14 with which the stoppers 14a engage, and in FIG. 8B, which is oriented 90° with respect to FIG. 8A, the sides of the containers are formed with the grooves 14 with which the stoppers 14a engage.
The cooling unit 15 is associated with an ordinary refrigerating system which has a compressor, a condenser and a heat exchanger installed as shown in a base 16 in FIG. 1. FIG. 10 shows an example of a piping system diagram of the cooling unit. The cooling unit has a compressor 30, a low pressure switch 31 for starting and stopping the compressor 30, a condenser 32, a liquid reservoir 33, a pressure switch 34 for starting and stopping a condenser fan, a drier 35, a heat exchanger 36, a sight window glass 37, and a distributor 38. Refrigerant gas is distributed from the distributor 38 to cooling plates 19. The cooling unit also has a solenoid valve 39, a capillary tube 40, an accumulator 41 and a capacity regulating valve 42. The refrigerating system may be disconnected from the cooling unit. For example, when the insulating apparatus of the invention is installed in a deck of a delivery vehicle, the refrigerating system is mounted on a vehicle body as a separate unit, and the operating power is produced from a prime mover of the vehicle or from another independent prime mover. The cooling unit also has supporting walls 17 (see FIG. 1) at the side ends of the base 16 for installing a number of racks 18 at the same interval as the height of each container 1. Each rack 18 is sufficiently formed by bending a rod as shown in FIG. 1, but may be of plate shape. Each rack 18 is normally maintained horizontally with respect to the walls 17. The rack 18 may be formed pivotally upwardly as shown in FIG. 9 by pivotally securing the both side ends of the rack 18 to the walls 17. The cooling plate 19 is installed to be horizontal above each rack 18. The plate 19 is formed in a convergent plane shape converged to the end, and formed with a wedge-shaped claw 20 over the entire width of the front end. The claw 20 of the plate 19 is readily inserted into the claw inserting opening 2c of the container formed as described above, thereby raising the front end of the cover 2 as shown comparing FIGS. 3A and 3B. The surface of the plate 19 may be perforated or made porous to enlarge the surface area and thereby improve the cooling efficiency, or a fin of suitable shape may be formed on the plate 19. To circulate cold air, a flat fan may be mounted on the upper side of the plate 19. A capillary tube is arranged on the back surface side of a cooling plate mount 21 for holding the plate 19, and an evaporator connected with the capillary tube is contained in the plate 19. The plate 19 is preferably rotatable upwardly similarly to the rack 18 by rotatably providing the cooling plate mount 21 with respect to the walls 18 (FIG. 9). When the racks 18 and the plates 19 are constructed in this manner, the racks 18 and the plates 19 may be folded upwardly at nonuse time. Thus, the racks 18 and the plates 19 do not take a large space nor disturb any. A container having a large height may be applied by retention at every other rack 18 and plate 19. Remote switches 22, 23, 24 for setting cooling temperatures are disposed on the lateral front frames of the walls 17. The switches 22, 23, 24 correspond to the abovementioned pressors 8, 9, 10, respectively, and, for example, permit one to select freezing (-20° to -18° C.), chilling (-3° to +2° C.) and cooling (+5° to +10° C.). As will be described, two of the switches 22, 23, 24 are pressed by the two of the pressors 8, 9, 10 to thereby operate the refrigerating system.
FIG. 11 schematically shows a controller of an insulating apparatus according to the invention. The controller has a control panel 49. A microprocessor 53 for variously controlling is contained in the panel 49. Power sources 51 and 52 of the panel 49 and the microprocessor 53 respectively have voltage converters for converting to DC 12 V, DC 24 V and AC 100 V available for both installed and portable types. A main/remote changeover switch 54 of illumination type can preferably confirm the operating modes of the insulating apparatus. A main temperature control dial 55 is provided to individually regulate the temperatures of the containers. An indicator 56 indicates the temperatures or set temperatures of the containers. A temperature zone monitor 57 indicates the temperature zones of foods to be cooled. A power switch 50 switches the power sources of the entire insulating apparatus and the controller. Temperature zone set remote switches 22 to 24 supply contact signals and temperature sensors 58 made of thermistors supply temperature signals to the panel 49. Although the sensors 58 are indicated in summary, the number of the sensors 58 is the same as that of settable containers. The sensors 58 are integrated with the cooling plates 19, respectively or inserted individually into the respective containers 1. Though the solenoid valves 39 are indicated in summary, the same number of the valves 39 as that of the containers are provided to control the containers at the different temperatures (FIG. 10). FIG. 12 shows an example of a logic circuit for describing the manner for processing signals in the panel 49 when the remote switches 22 to 24 are closed upon depression by the pressors 8 to 10, respectively. More specifically, when any two of the switches 22 to 24 are pressed and operated by the two pressors which are not removed by 3 AND gates 60 to 62 and an OR gate 63, the OR gate 63 generates an output. The desired container from which the sole pressor is removed can be cooled by the output of the OR gate 63 and the outputs fed through inverters 64 to 66. Further, since the containers can be cooled by the operations of the two remote switches, there is no possibility of causing an erroneous operation.
FIG. 13 is a flowchart showing the control flow of the insulating apparatus according to the invention. When the power switch 50 is turned ON in step S100, the indicator 56 is turned ON to indicate the power source ON. Then, the state of the switch 54 is confirmed in step S110, and when the switch 54 is set to the remote side, a control is advanced to step S120 to confirm the state of the remote switch. When the switch 54 is set to the main side, the set value by the main temperature control dial 55 is effected in step S130. When the insulating apparatus is controlled by the remote side of switch 54, a temperature zone monitor 57, displayed in colors in step S150, is turned ON by the operation of the sensor 58 in step S140, the temperature control output is generated in step S160, and the temperature is controlled by the operation of the solenoid valve 39. When the apparatus is controlled at the main side of the switch 54, the container can be cooled by the temperature set in step S130 irrespective of the state of the remote switch.
The insulating apparatus thus constructed of the invention is installed in a delivery center, a delivery branch store or a deck of a delivery vehicle, etc. To use the insulating apparatus, a delivery client places goods to be cooled in the container 1. In this case, dry ice and cold storage reagent are also contained together with the goods as required (ordinarily not required, but there might be the case that it takes a long time to deliver the goods to the branch store.) When the rubber strip 4 is engaged within the groove 3 after the cover 2 is applied on the container 1, the cover 2 is pressed downwardly by the strip 4, the front end 2a of the cover 2 is brought into contact with the step 1a of the container to close the front opening 5 of the container 1. The container 1 is brought into the branch store or the delivery center in this state, or delivered to the client. In this case, the cooling temperature is selected according to the type of the goods, i.e., freezing, chilling or cooling temperature is selected, and the corresponding pressor is removed (buried, and slid). Then, the client of the branch store or the delivery center sets the container 1 to the cooling unit 15 of the insulating apparatus. In this case, the rack 18 and the cooling plate 19 are tilted beforehand to a horizontal state (when the racks 18 and the cooling plates 19 are tiltably composed). Then, the front surface of the container 1 is directed toward the cooling unit 15 side, and pressed to slide on the rack 18. Thus, the claw 20 of the plate 19 is first introduced into the claw inserting opening 2c, the cover 2 is gradually pushed along the oblique surface of the claw 20 against the pushing force of the rubber strip 4, and the plate 19 itself is then introduced into the container 1 from the front opening 5. When the container 1 is pressed to the deepest position, either two of the pressors 8, 9, 10 collide with the corresponding remote switches to push them. Thus, the refrigerating system is operated, and the containers 1 start being cooled to the desired temperature range. When the temperatures of the containers 1 are regulated, the temperature controller is suitably operated. The containers 1 are ordinarily set from the rack 18 of the lowermost stage, but may be set at any stage. If the widths and the heights of the front openings 5 of the containers 1 are equalized, even if the lateral widths and the size are different, the containers 1 may be set in the same cooling unit 15. When the container 1 is drawn from the cooling unit to deliver the goods contained in the container 1, the pressing of the pressors 8, 9, 10 to the remote switches 22, 23, 24 is released to stop the operation of the refrigerating system of the cooling plate 19 which cools the container 1.
FIGS. 14 to 16A, 16B show the case that cooling air is supplied into the container from the cooling system in the container. In this case, a number of racks 73 which extend horizontally are provided in the cooling unit 71. A plurality of independent cooling units for individually cooling the containers 72 are contained in the cooling unit 71 as will be described later. Covering members 74 of wedge shape are provided at the right and left sides of the cooling unit 71 in the number corresponding to the number of the containers 72. The covering member 74 is introduced into the cutout 76 of wedge shape formed at the cover 75 of the container 72 when the container 72 is set on the rack 73 to raise upwardly the cover 75. A cooling air supply conduit 77 and a recovery conduit 78 are together projected from the cooling unit 71 toward the containers 72. The supply conduit 77 and the recovery conduit 78 are extended from the cooling system contained in the cooling unit 71 as shown in FIG. 15. Inserting openings 79 and 80, to which the conduits 77 and 78 are inserted, are opened at the sides of the container 72. The openings 79 and 80 are closed by blocking portions 81 formed integrally with the back surface side of the cover 75 when the cover 75 is closed, and opened by removing the blocking portions 81 from the conduits 77 and 78 when the cover 76 is opened to move the blocking portions 81 together with the cover 75 upwardly (in FIG. 16B). It is preferable to form the conduits 77 and 78 or the openings 79 and 80 in tapered shape to readily insert the conduits 77 and 78 into the openings 79 and 80. It is noted that caps may be mounted on the conduits 77 and 78 at nonusing time. FIG. 15 shows an example of the cooling system. The cooling system has an evaporator 82 and a fan 83 installed behind the evaporator 82. Cooling air generated by the evaporator 82 is forcibly supplied by the fan 83 into the supply conduit 77, and fed from the conduit 77 into the container 72. The recovery conduit 78 intakes the thermally exchanged cooling air in the container 72 by disposing the recovery conduit 78 behind the fan 83 to become negative pressure. More specifically, the cooling air is forcibly circulated in the cooling system and the container 72. Temperature sensors 84 are installed at the recovery conduit 78 side to detect the temperatures in the containers 72 and regulate the cooling degree. Referring back to FIG. 14, remote switches 85 to 87 and pressors 88 to 90 are provided to operate similarly to the remote switches 22 to 24 and the pressors 8 to 10 in the abovementioned previous embodiment.
Various modifications and alternations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention and the latter should not be restricted to that set forth herein for illustrative purposes. | An insulating apparatus for individually managing the temperatures of small containers to be delivered or stocked has containers and cooling units. The cooling unit has a rack for placing the container and cooling elements inserted into the containers. The cooling elements are operated by pressing selectively operable pressors of the container side by a remote switch of the cooling unit side. The cooling elements are independent at the respective containers to individually control the temperatures of the containers. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 08/246,536, filed May 20, 1994, now U.S. Pat. No. 5,438,571, which is a continuation-in-part of patent application Ser. No. 07/972,694, filed Nov. 6, 1992, now U.S. Pat. No. 5,550,836.
BACKGROUND
The present invention pertains to computer networks, and more particularly, to a method of transferring data at 100 Mb/s transfer rates over local area networks (LAN's) using unshielded twisted pair (UTP) wire media.
In the world of computers, pc and workstation users are requiring greater network bandwidths/higher speeds to carry more and more data over existing networks. The need for higher speed networks will grow even faster as desktop computers are equipped with the higher speed bus architectures that are being developed. Over the past ten years, desktop pc processing power has increased over a hundredfold. Over that same period, however, the data transmission speed of Ethernet LAN's has remained constant at 10 Mb/s. Network speeds are now a common bottleneck in a variety of key business application areas including database management, imaging, computer-aided design and network printing. On a typical 10 Mb/s Ethernet or Token-Ring network, it can take as long as 20 seconds to retrieve a single page of data depending upon network traffic. If 100 Mb/s networks were available, transfers would not be network limited and would take only one or two seconds for that same page of data.
Generally, for high speed data transfer in excess of 25 Mb/s over a LAN, data has been transferred using fiber optic media, coaxial cable, shielded wire or other specialized cable. For example, the fiber distributed data interface (FDDI) protocol is a common network protocol which operates using a fiber optic medium. FDDI has been available the longest of any high speed (100 Mb/s) network architecture, but it is still the costliest. Very few business users of computers have installed fiber optic cabling. In the United States it is estimated that approximately 80% of existing LAN users have "category 3" (voice grade) unshielded twisted pair wiring to interconnect desktop users. Such cables are usually configured in 25-pair bundles to accommodate future organizational growth.
The use of fiber optic media or shielded twisted pair (STP) wire for local area networking present various problems of their own. Most existing office buildings have an installed base of UTP wiring--not fiber optic cable or STP wire. Therefore, to utilize a fiber optic or STP network, assuming existing cable ducts have the space available, it would be necessary to specially install high quality cabling. This can be cost prohibitive. Yet if a LAN could be designed to operate at speeds of 100 Mb/s and work over Category 3 to Category 5 (data grade) UTP wire, users could easily switch to the higher speed network interface equipment using the existing cabling installation.
There has been some work done to increase the rate over which data can be transferred over installed twisted pair cabling. See for example U.S. Pat. No. 5,119,402 issued to Simon A. Ginzburg et al. for a Method and Apparatus for Transmission of Local Area Network Signals over Unshielded Twisted Pairs. However, in the prior art there has been no work which has sufficiently increased the speed of data transmission so that transmission over a four pair voice grade UTP wire network can rival the speed of data transmissions over fiber optic cabling. Some of the reasons for this are obvious. Unlike fiber optic cable or STP wire, UTP wire has greater radio-frequency (rf) emissions since it is unshielded. And, because the twist of the wire pairs does not provide perfect balance, there are also crosstalk and noise interference problems. And as speeds increase above 10 Mb/s these problems are exacerbated along with-high frequency rolloff causing signal distortion that increases with the length of the wire runs. Yet, given these problems there are various proposals for new network topologies to send data over UTP wire at transmission rates of 100 Mb/s; the present invention represents the heart of one of those proposals. And, although the present invention could easily be adapted to operate over higher quality cable, such as STP, it has its greatest utility (in terms of economy) for existing UTP wired facilities.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, a method is provided for transmitting data packets, grouped as data octets, over a LAN having a central hub linked to each of a plurality of network nodes via a physical medium consisting of four pairs of unshielded twisted pair (UTP) cable. The transmission method initially divides the data octets sequentially into 5-bit data quintets. The quintets are then sequentially distributed into four individual serial code streams. The four serial code streams are sequentially scrambled to produce four streams of randomized 5-bit quintets. The randomized data streams are sequentially block encoded into 6-bit symbol data which are then transmitted across the network by transmitting each data stream over one of said pairs of cable.
In the preferred embodiment, before the 6-bit symbol data is transmitted across the network, the data on two of the cable pairs is staggered (in time) by at least two data bits for various reasons including to increase the noise immunity of the transmission across the channel.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention as well as further features thereof, reference is made to the accompanying drawings wherein:
FIG. 1 shows a simplified block diagram of the interconnection of various networks.
FIG. 2 shows a simplified block diagram of a network in accordance with a preferred embodiment of the present invention.
FIG. 3 shows a simplified block diagram of a network device of the network shown in FIG. 2.
FIG. 3A is a block diagram which shows logical flow of information within the network device shown in FIG. 3.
FIG. 4 shows a simplified block diagram of the hub of the network shown in FIG. 2.
FIG. 5 shows a simplified block diagram of a transceiver within the hub shown in FIG. 4.
FIG. 6 shows a simplified block diagram of a repeater within the Mb shown in FIG. 4 in accordance with the preferred embodiment of the present invention.
FIG. 7 is a state diagram for a repeater state machine within the repeater shown in FIG. 6.
FIG. 8 is a state diagram for a training state machine within the repeater shown in FIG. 6.
FIG. 9 is a state diagram for a client state machine within the network device shown in FIG. 3A.
FIG. 10 is a state diagram for a client training state machine within the network device shown in FIG. 3A.
FIG. 11 is an example of a filter design which may be used the hub shown in FIG. 4 and the network device shown in FIG. 3.
FIG. 12 shows logic blocks within a network interface which prepare data to be forwarded to a hub in accordance with the preferred embodiment of the present invention.
FIG. 13 shows a diagram which explains data flow within the logic blocks shown in FIG. 12.
FIG. 14 is a timing diagram showing the timing of signals through a group of four twisted pair wires in accordance with a preferred embodiment of the present invention.
FIG. 15 is a block diagram of a circuit which facilitates collision detection in a network in accordance with a preferred embodiment of the present invention.
FIGS. 16 and 17 show potential frequency spectrums for signals sent across a twisted pair shown in FIG. 15.
FIG. 18 shows a block diagram of a circuit which provides common-mode collision signaling in a network.
FIG. 19 shows a block diagram of a circuit which provides in-band collision signaling in a network.
FIG. 20 is a block diagram which shows how the implementation circuit in FIG. 15 or the circuit shown in FIG. 18 may be used in a network where a network device sends data to a network device over four twisted wire pairs.
FIG. 21 shows a hub connected to network nodes through four twisted wire pairs.
FIG. 22 shows an example of signal timing within a network.
FIG. 23 shows an example of signal timing within a network.
FIG. 24 shows a hub connected to network nodes in a system where there is a collision window before each packet transmission.
DETAILED DESCRIPTION
FIG. 1 shows a simplified block diagram of a typical network structure. A LAN 11, a LAN 12 and a LAN 13 are connected, for example, through a bridge/router (not shown in FIG. 1) to network 10. Network 10 operates, for example, using the fiber distributed data interface (FDDI) protocol. LAN 11 and LAN 13, may operate, in accordance with any number of protocols. For example, if connected through a router, these LANs could operate in accordance with the IEEE 802.3 protocol, with the Token Ring protocol, with ISDN protocol or with a WAN protocol.
Various network devices, also referred to as end nodes, may be connected to the LANs. For example, a network device 14 and a network device 15 are shown connected to LAN 11. Network devices 16, 17 and 18 are shown connected to LAN 12. Network devices 19, 20 and 21 are shown connected to LAN 13. Network devices 14 through 21 may be, for example, a work station, a personal computer, a network server, or some other device.
FIG. 2 shows a block diagram of LAN 12 which includes a hub 30. Hub 30 is an intelligent central controller that manages data from the various network devices connected to the hub. Hub 30 is connected to network device 16 through four twisted-pairs of copper cable 31. Hub 30 is also connected to each network device 17 and 18 through four twisted pairs or copper cable 32 and 33 respectively.
FIG. 3 shows a simplified block diagram of a network interface 41, which is used by each of network devices 16, 17 and 18 to interface with hub 30. A backplane interface 42 provides an interface between computer system RAM and the network device. A random access memory (RAM) 43 is used to temporarily store data packets received from or to be transferred out on the network. A media access controller (MAC) 44 is used to control the flow of data within network interface 41. A transceiver 45 is used to send and receive through the network. A transformer and filter 46 is used to adjust voltage and provide noise filtering for signals transferred between transceiver 45 and a connector 47. A connector 47 is connected to the bundle of four UTP wires from hub 30.
FIG. 3A is a block diagram which shows logical flow of information within network interface (client) 41. A client-training-state machine 501 is used in initializing the connection between network device 41 and hub 30. (Although the function is explained below in greater detail, "training" is the initialization process that verifies the operation of the link and optimizes the circuitry for data transmission and reception.) A client-state machine 502 controls data transactions between network device 41 and hub 30. A DMA controller 503 controls DMA transfers between RAM 43 and a data buffer 504. Twisted pair transmit logic 505 forwards data to transceiver 45 via path 513. Twisted pair receive logic 506 receives data from transceiver 45 via path 514.
Control signals flow from DMA controller 503 to RAM 43 through an information channel 507. Control signals also flow from DMA controller 503 to data buffer 504 through another information channel 510. Data signals flow between data buffer 504 and RAM 43 through another information channel 508. DMA controller 503'signals client-state machine 502 through information channel 509 when there is a packet to transmit. Data buffer 504 sends data to twisted pair transmit logic 505 through information channel 511. Data buffer 504 receives data signals from twisted pair receive logic 506 through information channel 512. Transceiver 45 receives data from twisted pair transmit logic 505 through information channel 513. Transceiver 45 also sends data to twisted pair receive logic 506 through information channel 514. Twisted pair receive logic 506 signals client-state machine 502 through an information channel 515 at the start of a packet and at the end of a packet (RXDONE). Client-state machine 502 signals twisted pair receive logic 506 through an information channel 516 when a packet is to be received. Twisted pair transmit logic 505 signals client-state machine 502 through an information channel 517 when a transmit is complete. Client-state machine 502 signals twisted-pair-transmit logic 505 through an information channel 518 when a packet is to be transmitted.
FIG. 4 shows a block diagram of hub 30 which manages the network access. A backbone physical interface 51 provides a physical interface of hub 30 to network 10. A backbone media access controller (MAC) 52 controls data flow between hub 30 and network 10. A bridge buffer RAM 53 provides temporary storage for data (packets) flowing between hub 30 and network 10. A repeater 57 directs data flow on LAN 12. A content addressable memory (CAM) 54 is addressable with a network address and outputs an associated port. A broadcast SRAM 56 is used for temporary storage of multi-port messages which are to be broadcast across LAN 12.
A network management subsystem 58 provides network management. Network management subsystem 58 includes a processor 60, an EPROM 62, a RAM 61 and a memory access controller (MAC) 59. EPROM 62 stores program information used by processor 60. RAM 61 stores programs used by processor 60. MAC 59 provides a means for processor 60 to communicate with other nodes on the network.
A transceiver 63 is used to send and receive data to and from a network device (node) connected to a connector 67. A transceiver 64 is used to send and receive data to and from a network device connected to a connector 68. A transceiver 65 is used to send and receive data to and from a network device connected to a connector 69. A transceiver 66 is used to send and receive data to and from a network device connected to a connector 70. While only transceivers 63 through 66 and connectors 67 through 70 are shown, many more transceivers and connectors can be added. For example, in the preferred embodiment of the present invention, the hub has 24 ports. A transformer/filter 73 connects transceiver 63 to connector 67. A transformer/filter 74 connects transceiver 64 to connector 68. A transformer/filter 75 connects transceiver 65 to connector 69. A transformer/filter 76 connects transceiver 66 to connector 70.
FIG. 5 shows a block diagram of transceiver 63. Transceiver 63 is connected to connector 67 through four UTP wire pairs. The first pair includes a connector line 81 and 82 (FIG. 5B). The second wire pair includes a connector line 83 and 84. The third wire pair includes a connector line 85 and 86. The fourth wire pair includes a connector line 87 and 88. When transceiver 63 receives the four streams of data over the four pairs (81-88), the data is received by equalizer circuits 91-94 whose function is to compensate for the insertion loss variations of the path with frequency (i.e., rolloff). Each of equalization circuits 91 through 94 ideally provides a clean and amplified signal. In addition, equalization circuit 91 also provides a carrier detector signal on a carrier detector line 180.
A phase locked loop (PLL) clock and data recovery circuit 101 receives a clean and amplified signal on line 181 and 182. PLL clock and data recovery provides a data signal on a line 171, a clock signal on a line 175 and a clock valid signal on a line 279. A PLL clock and data recovery circuit 102 receives a clean and amplified signal on line 183 and 184. PLL clock and data recovery provides a data signal on a line 172, a clock signal on a line 176 and a clock valid signal on a line 280. A PLL clock and data recovery circuit 103 receives a clean and amplified signal on line 185 and 186. PLL clock and data recovery provides a data signal on a line 173, a clock signal on a line 177 and a clock valid signal on a line 281. A PLL clock and data recovery circuit 104 receives a clean and amplified signal on line 187 and 188. PLL clock and data recovery provides a data signal on a line 174, a clock signal on a line 178 and a clock valid signal on a line 282.
Referring to FIG. 5A, elasticity buffers 111, 112, 113 and 114 synchronize the data signals from PLL clock and data recovery circuits 101-104 to a single clock. Elasticity buffer 111 receives the data signal and clock signal from PLL clock and data recovery circuit 101 and produces a synchronized data signal on line 191. Elasticity buffer 112 receives the data signal and clock signal from PLL clock and data recovery circuit 102 and produces a synchronized data signal on line 192. Elasticity buffer 113 receives the data signal and clock signal from PLL clock and data recovery circuit 103 and produces a synchronized data signal on line 193. Elasticity buffer 114 receives the data signal and clock signal from PLL clock and data recovery circuit 104 and produces a synchronized data signal on line 194.
A logic OR gate 170 receives the clock signal on line 175, the clock valid signal on line 279, the clock valid signal on line 280, the clock valid signal on line 281 and the clock valid signal on line 282. OR gate 170 produces a clock signal (Clk 0) on line 190. The Clk 0 signal passes through OR gate 170 when the four clock valid signals are asserted low. Driver buffer 106 forwards data to repeater 57 on a line 126, a line 127, a line 128 and a line 129. Driver 106 also provides a clock signal on a line 129. Receive line state logic 105 is used to receive and forward transfer set-up requests over the first and the second twisted wire pairs. Receive line state logic 105 receives the carrier detector signal on carrier detector line 180, the data signal on line 171, the data signal on line 172 and the clock signal on line 175. Receive line state logic 105 produces a priority (PRI) request signal on line 121, a receive line state signal (RLS0) on line 122, a receive line state signal (RLS1) on line 123, and a receive line state signal (RLS2) on line 124 for forwarding to repeater 57. Repeater enables receive line state logic 105 by placing a receive line state enable signal on a line 125. A receiver enable signal (RXEN) is generated by repeater 57 to select receive line state logic 105 or driver buffer 106 to forward information to repeater 57.
Referring to FIG. 4, when transceiver 63 transmits data to repeater 57, it places a first data signal (TDATA0) on transmit data line 137 (in FIG. 5A), a second data signal (TDATA1) on transmit data line 138, a third data signal (TDATA2) on transmit data line 139 and a fourth data signal (TDATA3) on transmit data line 140. When transceiver 63 transmits control signals to repeater 57, it places a first transmit line signal (TLS0) on line 132, a second transmit line signal (TLS1) on a line 133, a third transmit line signal (TLS2) on a line 134, and a transmit line clock (TLSCK) on a line 135. TLSCK is used to store the TLS values. Transmit line state logic 115 generates tones and drives the TLS values to be forwarded to a multiplexer/transmitter 116.
Multiplexer/transmitter 116 (FIG. 5A), in response to a transmit enable signal (TXEN) on a line 136, selects either data signals on lines 137, 138, 139 and 140 to be forwarded to the four twisted wire pairs 81 through 88, or the tones and driver enables from transmit line state logic to be forwarded to the third and fourth twisted wire pairs 85 through 88. A transmitter clock (TXCLK) is provided to transmit line state logic 115 and multiplexer transmitter 116 on a line 141.
FIG. 6 is a block diagram showing data flow within repeater 57. Repeater 57 essentially functions to channel transferred data. Twisted pair receive logic 212 receives data and control signals from the transceivers, e.g., transceivers 63, 64, 65 and 66. For example, twisted pair receive logic 212 is connected to lines 121 through 131 of transceiver 63. Broadcast RAM readback logic 211 receives data from broadcast SRAM 56. Backbone receive logic receives data from bridge buffer RAM 53.
Twisted pair transmit logic 220 sends data and control signals to the transceivers, e.g., transceivers 63, 64, 65 and 66. For example, twisted pair transmit logic 220 is connected to lines 132 through 141 of transceiver 63. Broadcast write logic 219 sends data to broadcast SRAM 56. Backbone transmit logic sends data to bridge buffer RAM 53.
The data received by twisted pair receive logic 212, broadcast RAM read-back logic 211 and backbone receive logic 210 is channeled through a first-in-first-out (FIFO) buffer 215 to either backbone transmit logic 218, broadcast write logic 219 or twisted pair transmit logic 220. FIFO buffer 215 also provides arbitration information to a receiver port arbiter 214.
Receiver port arbiter 214 selects from which port to receive a data transmission. In general, a simple arbitration scheme is used. For example, a round robin arbitration scheme may be used in which the last port from which a data transmission is received is given lowest priority. A transmit arbiter 217 determines to which port of backbone transmit logic 218, broadcast logic write logic 219 or twisted pair transit logic 220 data is to be transmitted. Transmit arbiter 217 determines where to send a message by forwarding a network address of the message to CAM 54. CAM 54 returns a port number to transmit arbiter 217. Repeater 57 also includes a repeater state machine 216 and a training state machine 213.
FIG. 7 shows a state diagram for repeater state machine 216. After start-up of the repeater and training of all ports (as explained below) has taken place, repeater state machine 216 is in idle state 231. Upon receiving a request for transfer from receiver port arbiter 214, repeater state machine enters an acknowledge port state 232. When repeater state machine 216 is in the acknowledge port state, repeater 57 sends an acknowledge signal to the port which was selected by receiver port arbiter 214. If repeater 57 times out before it begins to receive a data packet from the selected port, repeater state machine 216 enters a set retrain port state 239. In set retrain port state 239, repeater state machine 216 signals training state machine 213, to retrain the port. Repeater state machine 216 then returns to idle state 231.
From acknowledge port state 232, upon repeater 57 beginning to receive a network data packet, repeater state machine 216 enters a determine destination state 233. While repeater state machine 216 is in determine destination state 233, transmit arbiter 217 determines where to send a message by forwarding the network address in the network data packet to CAM 54. CAM 54 returns a port number to transmit arbiter 217.
If transmit arbiter 217 determines the destination is to a port within local network 12, repeater state machine 216 enters a transmit to port state 235. In transmit to port state 235, data as it is received from the port selected by receive port arbiter 214 is forwarded immediately to the port selected by transmit arbiter 217. Upon repeater 57 receiving the complete network data packet and completion of the forwarding of the data, repeater state machine 216 returns to idle state 231. If the complete data packet is not received within a specified time, repeater state machine 216 enters set retrain port state 239.
In determine destination state 233, if transmit arbiter 217 determines the destination is to multiple ports within local network 12, repeater state machine 216 enters a buffer to local RAM state 237. In buffer to local RAM state 237, data as it is received from the port selected by receive port arbiter 214 is forwarded to broadcast SRAM 56. Ira complete data packet is not received within a specified time, repeater state machine 216 enters set retrain port state 239. Upon repeater 57 receiving the complete network data packet and completion of the forwarding of the data to broadcast SRAM 56, repeater state machine 216 enters a transmit to all ports state 238. In transmit to all ports state 238, repeater 57 reads the broadcast message in broadcast SRAM 56 and forwards the message to each of the ports specified. Upon completion of the data transmissions, repeater state machine 216 returns to idle state 231.
In determine destination state 233, if transmit arbiter 217 determines the destination is to the backbone of local network 12, repeater state machine 216 enters a buffer to bridge state 234. In buffer to bridge state 234, data as it is received from the port selected by receive port arbiter 214 is forwarded to bridge buffer RAM 53. If a complete data packet is not received within a specified time, repeater state machine 216 enters set retrain port state 239. Upon repeater 57 receiving the complete network data packet and completion of the forwarding of the data to buffer RAM 53, repeater state machine 216 returns to idle state 231. If buffer RAM 53 runs out of available memory locations before completion of the transfer of the network data packet, repeater state machine 216 enters a set busy signal state 236. In set busy signal state 236, repeater 57 sends a busy signal to the transmitting data port and throws away the network data packet. Upon completion of the transfer of the network data packet to repeater 57, repeater state machine 216 returns to idle state 231.
FIG. 8 is a state diagram for the training state machine 213 shown in FIG. 6. After a reset or whenever it is necessary to train a port, training state machine 213 proceeds through the training states. Before training a port, training state machine 213 is in an idle state 241. When the training state machine 213 receives a training idle up signal from a port which requests training, the training state machine 213 enters a drive-T-idle (training idle)-down state 242. In drive-T-idle-down state 242, repeater 57 sends a training idle down signal to the port requesting training.
Upon receiving a request-to-transmit signal from the port to be trained, training state machine 213 enters a request-to-repeater state machine state 243. In request-to-repeater-state-machine state 243, training state machine 213 waits for repeater state machine 216 to acknowledge the port to be trained. Upon repeater state machine 216 providing the acknowledgment, training state machine 213 enters an acknowledge client state 244. In acknowledge-client state 244, training state machine 213 waits for the port to start sending a training packet.
Upon the port starting to send a packet, training state machine 213 enters a receive training packet state 245. In receive-training-packet state 245, training state machine 213 waits for completion of the sending of the training packet. When the training packet has been received, training state machine 213 enters a training completion state 246. In the training completion state 246, a check is done to see whether receive training is complete. For example, in the preferred embodiment, training is complete if 25 consecutive training packets have been received without errors. If there are errors in reception, the equalization and clock frequencies are adjusted in the transceiver for the port. If receive training is not complete, training state machine 213 returns to drive T-idle-down-state 242.
When receive training is complete, training state machine 213 enters a request-to-repeater-arbiter state 247. In request-to-repeater-arbiter state 247, training state machine 213 requests transmit arbiter 217 to initiate the transmission of a training packet to the port being trained. Upon receiving an acknowledgment from repeater state machine 216, training state machine 213 enters a transmit-training-packet state 248. Upon completion of the transmission of the transmit-training-packet state, training state machine 213 enters a training complete state 249. If transmit training is not complete, training state machine 213 returns to request-to-repeater-arbiter state 247.
When transmit training is complete, training state machine 213 enters line idle state 250. Training state machine 213 remains in line idle state 250 during normal operation of the port. When the port requests retraining, training state machine 213 returns to drive-training-idle-down state 242.
FIG. 9 shows a state diagram for client-state machine 502 (FIG. 3A). Client-state machine 502 is initially in an idle state 251. When hub 30 signals that a packet will be incoming to the client, client-state machine 502 enters a wait-for-packet state 252. In wait-for-packet state 252, if the client sees the receive line state transition to a state other than incoming, such as idle, client-state machine 502 returns to idle state 251. Upon the client beginning to receive a packet, client-state machine 502 enters a receive-packet state 253.
In the receive-packet state 253, client-state machine 502 waits for the end of the packet to be received. When the end of the packet is received and client-state machine 502 is not waiting on a busy signal, client-state machine 502 returns to idle state 251. When the end of the packet is received and client-state machine 502 is waiting on a busy signal, client-state machine 502 enters a wait to re-transmit state 258.
From idle state 251, when the client desires to transmit a data packet, the client-state machine 502 enters a send request state 254. In the send request state 254, the client sends a request-to-transmit signal to hub 30. The client then waits for an acknowledgment signal from hub 30 (indicating that the link is clear to send). While waiting for an acknowledgment, if hub 30 signals the client that a packet will be incoming to the client, the client-state machine 502 enters the wait-for-packet state 252 to inhibit messsage transmission from the client. In the send-request state 254, when the client receives an acknowledgment from hub 30, client-state machine 502 enters a transmit packet state 256. In the transmit packet state 256, the client sends a data packet to hub 30. Upon the end-of-packet being sent, client-state machine 502 enters a wait-for-idle/busy state 257. In wait-for-idle/busy state 257, if the client receives an idle signal from hub 30, transmission of the packet was successful and client-state machine 502 returns to idle state 251. If the client receives a busy signal from hub 30, client-state machine 502 enters wait to re-transmit state 258.
In the wait-to-transmit state 258, client-state machine 502 waits for hub 30 to stop sending a busy signal. If hub 30 signals that a packet will be incoming to the client, client-state machine 502 enters wait-for-packet state 252. When in wait-to-transmit state 258, if client-state machine 502 detects the busy signal from hub 30 being de-asserted, client-state machine 502 returns to send-request state 254. When in wait-to-transmit state 258, if client-state machine 502 times out waiting for hub 30 to de-assert the busy signal, the client-state machine 502 enters a discard-packet state 259. When in the discard-packet state 259, the client discards the network packet and returns to the idle state 251.
There are situations where a client might be the end-node destination address for a very long string of incoming packets and given the above description it might appear that a send request would not be allowed. In response to an incoming packet signal, the client must switch to the wait-for-packet state 252 then to the receive-packet state 253 upon the reception of a packet. However, according to one embodiment of this invention, to preclude the client from not being able to send an out bound data packet, a request window is built into the normal request cycle. The request window is a short period of idle signal (roughly 500 ns) following a data packet to the client. This idle period is sufficient to enable the client to send tip a request-to-send signal (state 254) to hub 30. Hub 30 stores the request-to-send signal in RAM 61, FIG. 4, and references the client destination address for future use after the data packet is received by the client. Alternatively, a simple register associated with each transceiver (63-66) could be used to record that the associated end node has a send request pending.
Another alternative employed in the preferred embodiment is to have the client enter a send request state 254 from state 251 even if an incoming control signal is being received. Since the signalling is over a duplex path, such bidirectional signals do not interfere. As soon as the send request is sent, the client-state machine 502 enters a wait-for-packet state 252. Then in the wait-for-packet state 252, the client switches to either idle state 251 or to the receive-packet state 253.
FIG. 10 shows a state diagram for client-training-state machine 501. Upon receipt of a reset, client-training-state machine 501 enters a transmit-T-idle-up state 261. In transmit-T-idle-up state 261, the client forwards to hub 30 a T-idle-up signal. When hub 30 receives the T-idle up signal from the client, the hub responds with T-idle back to the client. Upon hub 30 signaling the client that the T-idle-up signal has been received, client-training-state machine 501 enters request state 262. When client-training-state machine 501 is in request state 262, the client signals to hub 30 a request to transmit a training packet. Upon an acknowledgment from hub 30, client-training-state machine 501 enters a transmit-training-packet state 263. When client-training-state machine 501 is in transmit-training-packet state 263, the client transmits the training packet to hub 30. When the transmission is complete, client-training-state machine 501 enters a wait-for-response state 264.
When client-training-state machine 501 is in the wait-for-response state 264 and the client receives a T-idle signal from hub 30, client-training-state machine 501 returns to request state 262. When client-training-state machine 501 is in the wait-for-response state 264 and the client receives from hub 30 an incoming packet signal, client-training-state machine 501 enters a receive-training-packet state 265.
In receive-training-packet state 265, when the client has received the entire training packet, client-training state machine 501 enters a training-complete state 268. If training is not complete, client-training-state machine 501 enters a wait-for-incoming state 267. When client-training-state machine 501 is in wait-for-incoming state 267 and the client receives from hub 30 an incoming packet signal, client-training-state machine 501 enters receive-training-packet state 265.
When client-training-state machine 501 is in training complete state 268 and training is complete, client-training-state machine 501 enters training idle state 269. When client-training-state machine 501 is in training idle state 269, the client is in a normal operating state. Upon a transmission error occurring, the client receives a T-idle signal from hub 30. Upon receipt of the T-idle signal from hub 30, client-training-state machine 501 returns to transmit T-idle up state 261.
FIG. 11 shows an example of a filter design which may be used to implement filters 73 through 76 within hub 30, and may also be used to implement the filter portion of transformer and filter 36 within network interface 41. For example, this filter has a return loss of less than or equal to -20 dB for signals from 100 kHz to 15 MHz. The 3 dB cutoff frequency is between 19-21 MHz. Stopband attenuation is greater than or equal to 13.5 dB at 30 MHz. The filter includes, for example, resistors 281 and 289, capacitors 282, 283, 284, and 290, inductors 285, 286, 287 and 288, connected as shown. For example, resistors 281 and 282 are 50 ohms, capacitors 282 and 290 are 33 pF, capacitor 283 is 110 pF, capacitor 284 is 160 pF, inductor 285 and 287 are 330 nH, and inductors 286 and 288 are 680 nH.
In the preferred embodiment of the present invention, the physical layer implementation of the connection between hub 30 and network interface 41 is intended to provide a high speed communications link over low cost wiring. The below described specific application provides a 100 megabit/second (Mb/s) communication channel over voice grade telephone wire. This is done by multiplexing 4 adjacent channels at 25 Mb/s each.
The media type for the twisted pairs is, for example, Category III UTP, Category IV UTP or Category V UTP. The media distance is for example 100 meters when using Category III UTP, 120 meters when using Category IV UTP, or 150 meters when using Category V UTP. The media configuration is a 4 pair, 25 pair bundles, (10BASE-T compatible wiring systems).
In implementing the physical layer, a method of transmitting 25 Mb/s of information within a similar bandwidth to 10BASE-T encoding is desired to provide comparable attenuation and crosstalk characteristics. Comparable SNR and DC balance is also desired. For this purpose non-return to zero (NRZ) encoding using a 5B/6B block code is utilized to provide maximum balance. This is done by taking all balanced 6B symbol's and associating them with particular 5B symbols. Then, the remaining 5B symbols are associated with two alternative 6B symbols that are unbalanced by a single bit. These two symbols are chosen for a particular 5B mapping, such that one is weight 2 and the other is weight 4 as shown in the example in Table 1. During transmission, a status bit determines whether the last unbalanced 6B symbol sent was positive (weight 4) or negative (weight 2). If the status indicates the last unbalanced 6B symbol was positive, the encoder then uses the negative symbol for the next unbalanced 6B symbol and toggles the status bit. This way the DC balance is maintained in the data stream. Care is taken to ensure that the unbalanced symbols have no more than three consecutive bits on the symbol boundary. This way the run-length is limited to no greater than six bit times. The following block code listed in Table 1 below meets the above criteria.
TABLE 1______________________________________ weight weight ALT weight# 5B/6B # of 1's # 5B/6B # of 1's 5B/6B # of 1's______________________________________ 0 000111 3 16 110100 3 1 001011 3 17 111000 3 2 001101 3 18 010101 3 3 001110 3 19 110010 3 4 010011 3 20 011011 4 100100 2 5 010110 3 21 011101 4 100010 2 6 011001 3 22 011110 4 100001 2 7 011010 3 23 100111 4 011000 2 8 011100 3 24 101011 4 010100 2 9 100011 3 25 101101 4 010010 210 100101 3 26 101110 4 010001 211 100110 3 27 111010 4 000101 212 101001 3 28 110101 4 001010 213 101100 3 29 110110 4 001001 214 110001 3 30 111001 4 000110 215 101010 3 31 110011 4 001100 2______________________________________
Table 2 below lists the frame format for the transfer of data at the physical level.
TABLE 2______________________________________Preamble 8 symbols (sextets) of alternating 0s and 1s.Start Delimiter 1 symbol (sextet) of a specific one- zero pattern.Destination Address 48 bits which are split up among the four pairs.Source Address 48 bits which are split up among the four pairs.Type/Length Field 16 bits which are split up among the four pairs.Data block 46-1500 bytes split up among the four pairs.Cyclic Redundancy check 32 bits used to ensure frame integrity and which are split up among the four pairs.End Delimiter 2 symbols (sextets) of continuous ones.Abort symbol 2 symbols (sextets) of continuous zeroes.______________________________________
The frames are distributed among the four channels by breaking up the address, data, Type/Length and Cyclic Redundancy Check (CRC) segments and multiplexing this information. The first 5 bits are coded into a 6 bit symbol and transmitted onto channel 0. The second 5 bits are coded into a 6 bit symbol and transmitted onto channel 1, and so on. CRC is generated based upon the data frame's bit sequence, and compared on the receive end after demultiplexing the frame.
Because data is typically bounded on octet boundaries, and the symbols are gathered on quintet boundaries, it is likely that a few extra bits will be stuffed into the final symbol to ensure encoding on proper boundaries. When the data is returned to octet boundaries, those bits will be removed, thus making the recovery of the data complete.
Table 3 below gives control symbols used in the frame format (described below) used at the physical layer in the preferred embodiment.
TABLE 3______________________________________End Delimiter (ED) 111111 111111Preamble (PREAMBLE) 010101 010101Start Delimiter (SD) 100101 100101Abort Symbol (ABORT) 000000 000000______________________________________
The code according to the preferred embodiment provides for a 15 MHz tone on PREAMBLE which will allow the minimum time for clock synchronization. Further, the code uses the same symbols in the data stream, but makes the decision that PREAMBLE/SD is only being looked for immediately after energy is detected on the link.
The transition from PREAMBLE into SD1 is designated by a "11" or "00" occurrence, and the SD symbol is balanced. The probability of misdetection can be reduced by requiring that the transceiver will not pass any received bits through until the clock has been secured, and by requiring six valid preamble bits to occur prior to accepting a valid SD. Inversion of the data stream can be determined by the polarity of the PREAMBLE-SD symbol boundary.
The End Delimiter is composed of all ones, and would be two such symbols back to back. This provides a sequence of twelve consecutive ones which cannot be generated by any valid data pattern. If a bit error occurs in the ED, it would appear as an invalid symbol.
The ABORT symbol is provided to allow HUB-to-HUB data transfers to be dropped with minimal effort. If a valid ED has not occurred, and two consecutive ABORT symbols appear, the receiving node considers the packet dropped.
The physical layer according to the preferred embodiment also includes scrambling. Scrambling is necessary to provide for clock recovery. In order to provide a system that operates within minimal excessive bandwidth (approximately 35%), a very low bandwidth PLL is required. This means that the distribution of spectral components must be random in order to prevent clock drift.
Scrambling is also necessary to provide for crosstalk reduction. By spreading the energy in the transmitted signal, it has been found that crosstalk is reduced by a few dB. This improves the signal-to-noise ratio (SNR) of the system. Scrambling is also necessary to provide for emissions reduction.
For the preferred embodiment of the present invention, a stream cipher of 11 bits provides the spectral dispersion necessary to ensure the above characteristics are met. Unlike a synchronous scrambler, the stream cipher does not propagate errors, nor does it exhibit the potential to "lock-up". The primary issue with stream ciphers has to do with synchronization. Since the data out of the cipher is a function of the incoming data and a pseudo random bit sequence (PRBS) of a time-dependent value, it is necessary on the receive end to know exactly what point in the sequence the data is associated with. This can be done by using a cipher on the data and presetting the cipher before performing an XOR function on its contents with the data. The bit recurrence relation is S[n]=S[n-9]XOR S[n-11]. The four channels each have a different cipher which is initialized to a different quadrant of the PRBS to avoid the likelihood of common patterns on each wire.
FIG. 12 shows logic blocks within network interface which prepare data to be forwarded to hub 30. A scrambler/descrambler 293 scrambles message, residing in a memory 291, which are to be forwarded to hub 30. Scrambler/descrambler 293 descrambles message, residing in memory 291, which have been received from hub 30. Serialization and block coding logic 292 block codes and serializes scrambled data which is then forwarded to hub 30 via a data path 295. Deserialization and block decoding logic 293 deserializes and block decodes scrambled data which is received from hub 30 via a data path 296.
FIG. 13 shows a diagram which explains data flow within the logic blocks shown in FIG. 12. A row of twenty bits 303 are shown in groups of five bits. Byte boundaries 301 show where byte boundaries for the twenty bits would exist in memory 291. Scrambling bits 303 yields a row of twenty bits 304. Bits 304 are serialized and block coded to produce four serial data streams 305 of six bits each. Each data stream is packetized and put onto a separate twisted pair. After being sent across LAN 12, a network device receives and depacketizes four serial data streams 307 which are identical to data streams 305. Streams 307 are deserialized and decoded to produce a row of twenty data bits 308. Data bits 308 are then descrambled to produce a row of twenty data bits 309. Data bits 309 are identical to data bits 303.
In order to maximize data flow in network 12 and avoid crosstalk, using four UTP wires, for data channels, half-duplex data channel is used. However, full duplex is used for control/status channels. This allows for noise immunity comparable to IEEE 10BASE-T standards. Using four twisted-pairs in a 10BASE-T cable and half-duplex transmission, 25 Mb/s throughput is required through each twisted wire pair.
In order to maintain adequate noise immunity, the channel bandwidth must not be significantly increased. Through empirical measurements, it has been determined that crosstalk is acceptable when system bandwidth is kept below 21 MHz. In addition, a simple binary (two level) code provides lower cost implementation.
Operating with a two level NRZ block code of reasonable efficiency, the bandwidth of the system can be constrained to less than 21 MHz. This keeps noise down, and the two level code provides robust noise-immunity. The block code must be balanced and efficiency must be above 80%. Therefore, as discussed above, a 5B/6B block code is used.
This enabling scheme utilized by the present invention allows various other protocols to operate by either doing a 25 Mb/s full duplex channel on two-pairs (e.g., as in 25 Mb/s 10BASE-T), a 50 Mb/s full duplex communication channel on four-pairs (e.g., as in 50 Mb/s 10BASE-T, or 45 Mb/s ATM), or dual-100 Mb/s channels on separate four-pair cables (e.g., as in FDDI, ATM).
Control/status information is full duplex in order to keep latency down. Therefore, it is possible to use two pairs for upstream communication, and two pairs for downstream communications. The transition rate of these channels is kept very low in order to minimize crosstalk effects on adjacent wires. By using tones of 0.9375 MHz-3.75 MHz crosstalk in bundles is minimized. Three tones per wire (plus a lack of tones/silence) can allow up to ten different control status signals.
In the preferred embodiment, eight line states are provided by the transceiver state machine. For the purposes of the description below, hub 30 is the master and the network devices are the slaves. Table 4 below summarizes the extant line signals.
TABLE 4______________________________________ TX TX RX RXCODE SLAVE MASTER PR 1 PR 0 PR 1 PR 0______________________________________000 SILENCE SILENCE 0 0 0 0001 IDLE IDLE 16 16 15-17 15-17010 REQ 0 N/A 16 8 15-17 7-9011 REQ 1 SYNCH 8 16 7-9 15-17100 T IDLE T IDLE 8 8 7-9 7-9101 RSVD Incoming 16 4 15-17 3-5110 RSVD RSVD 4 16 3-5 15-17111 RSVD RSVD 8 4 7-9 3-5______________________________________
The listed transmits numbers (under TX PR 1 and TX PR 0) are the number of clock cycles each pulse contains. The listed receive numbers (under RX PR 1 and RX PR 0) account for sampling error.
Line state (Code 000) provides for the transmitter to be turned off completely. As seen by Table 4, the first transmitter wire pair (TX PR 0), the second transmitter wire pair (TX PR 1) the first receiver wire pair (RX PR 0) and the second receiver wire pair (TX PR 2) are all at 0 (i.e., silent). In the event that the MASTER detects silence on its receiver for an extended period of time, it will transmit silence to prevent transmitting onto an unterminated line. The SLAVE and the MASTER indicate SILENCE in the event they are about to begin reception of data. The SILENCE state allows for the twisted pair media to settle before data is inserted onto the wires.
Line state (001) indicates that the SLAVE and MASTER are connected, and the link is inactive. The state is entered upon the end of a data transmission in one of two ways. In the event of a proper transmission, the ETD/ABORT sequence would create the first IDLE symbol which would tell the receiver on the opposite end of the link to disable its data reception circuits. In the event of an aborted frame, the ETD would not appear, and the ABORT symbol would provide the first component of the IDLE tone.
Line state (010) is used by the SLAVE node to indicate a low priority request. Line state (011) is used by the SLAVE node to indicate a high priority request. This line state is used by the MASTER node to provide a synchronization pulse to end nodes.
Line state (100) is used to initiate a link connection sequence by the SLAVE node. Upon detection of this tone, the MASTER will indicate T-IDLE (training idle) which will indicate to the SLAVE that a connection exists. Then, the connection arbitration cycle (training) is then executed. Line states (101,110,111) are not implemented in the preferred embodiment.
In a preferred embodiment of the present invention, the network device (client) transmits on pairs 0,1 and the hub transmits on pairs 2 and 3. Three frequencies, 0.975 MHz, 1.85 MHz and 3.75 MHz are used. Table 4 gives assigned control signals for the preferred embodiment.
The transceivers within hub 30 and network interface 41 generate and measure frequency of the tones. The acknowledge from the hub to a network device is not a tone frequency pair. Rather it is the event of the transition from the hub driving a tone to the hub driving no signal.
FIG. 14 is a simplified timing diagram which illustrates a transaction on four pairs (staggering not shown). For the example transaction, two frequencies, e.g. 1 MHz and 2 MHz, are used. The network device (client) transmits on pairs 0,1 and the hub transmits on pairs 2 and 3. Table 5 below gives the assigned control signals for a preferred embodiment.
TABLE 5______________________________________ Signaled ControlFrequency of Tone Oscillation SignalFirst Pair (0 or 2) Second Pair (1 or 3) Client Hub______________________________________1 MHz 1 MHz Req 0 Busy1 MHz 2 MHz T-idle T-idle2 MHz 1 MHz Idle Incoming2 MHz 2 MHz Req 0 Idle______________________________________
The transceivers within hub 30 and network interface 41 generate and measure frequency of the tones. The acknowledge from the hub to a network device in not a tone frequency pair. Rather it is the event of the transition from the hub driving an IDLE to the hub driving no signal.
In FIG. 14, signal waveform 310 represents a signal on a first twisted wire pair between network interface 41 and hub 30. A signal waveform 311 represents a signal on a second twisted wire pair between network interface 41 and hub 30. A signal waveform 312 represents a signal on a third twisted wire pair between network interface 41 and hub 30. A signal waveform 313 represents a signal on a fourth twisted wire pair between network interface 41 and hub 30.
In a time period 315, network interface 41 is driving an idle signal on the first and second twisted wire pairs. Likewise, hub 30 is driving an idle signal on the third and fourth twisted wire pairs.
In a time period 316, network interface 41 is driving a request signal on the first and second twisted wire pairs. Hub 30 continues driving an idle signal on the third and fourth twisted wire pairs.
In a time period 317, hub 30 acknowledges the requested by allowing signals on the third and fourth twisted wire pairs to float to a middle voltage.
In a time period 318, network interface 41 transmits a data packet on all four twisted wire pairs.
In a time period 319, the end of packet has been reached. Network interface 41 stops driving the third and fourth twisted wire pairs. Network 41 starts driving an idle signal on the first and second twisted wire pairs.
In a time period 320, network interface 41 continues driving an idle signal on the first and second twisted wire pairs. Hub 30 begins driving an idle signal on the third and fourth twisted wire pairs. While this example has been for transmission of a single packet, multiple packets may also be transmitted after a single arbitration.
Key constraints of the above described system include the use in a network of four twisted wire pairs (UTP) to attach each network node to the hub. During data transmission or reception, the direction of data flow on all four twisted wire pairs is in a single direction. It is thus not possible to reliably determine whether two nodes are transmitting simultaneously because there is no way to signal a transmitting node since it is not receiving at that time. In the hardware configuration, twisted wire pairs from several clients can be combined into one cable bundle. Due to near end crosstalk, during data reception, the hub is not allowed to transmit the data packet to more than one port. However, the hub may send data packets to multiple ports while the hub is not receiving data packets. Additionally, when the hub is receiving data from one of the network nodes, the hub exchanges control signals with other network nodes. The control signals are tones which are at frequencies well below the data rate.
In order to facilitate the operation of the system over a broad range of possible cables, a period of characterizing of the cable is performed before initial transmission of user data. This is the training periods described above. It is performed each time a cable link is established, e.g., during power up or when error counts reach a predetermined level.
In the preferred embodiment, no existing network protocol is used to arbitrate network usage for this topology. Rather, as described above, a port of the hub is in one of three states at any particular point in time. The first state is where the port is transmitting a packet (four twisted wire pairs driven by client). The second state is where the port is receiving a packet (four twisted wire pairs driven by hub. The third state is during arbitration for a link (two twisted wire pairs driven by client, 2 twisted wire pairs driven the hub). At any one point in time, different ports of the hub can be in different modes, e.g., one port transmitting, one port receiving and the rest arbitrating for the next cycle.
During arbitration, pairs of low frequency tones are sent by the hub and client. These allow the hub and client to determine who gets to transmit next. In addition, other control information may be sent. During the training sequence the client notifies the hub of its network address. Also, network protocol errors retrigger the training sequence.
To support applications which require low latency and guaranteed network bandwidth availability, two priority levels of client data are supported. These two priority levels are preserved through the bridge to the backbone network.
To avoid packet loss through the bridge, a busy signal which indicates the buffer memory is full is sent to the client that has transmitted a packet which could not be stored. This signal is held until space is available in the bridge buffer. The advantage is that the packet can be retransmitted by the client hardware without depending on a software protocol timeout to retransmit.
To address the limitation of transmitting to only one client, the following method is used during reception of a packet. During reception of a packet, the repeater identifies the destination client before transmitting the packet. The data is transmitted to that port only. This has the added benefit of providing protection against an eavesdropping node. The hub does not fully receive the packet before retransmitting it. In the event the packet is intended for multiple destinations, the packet is buffered in the repeater and then retransmitted once it has been fully received.
During network operation, the hub checks all ports for requests. The following priority is used. Highest priority is granted high priority messages from the backbone. The next highest priority is granted high priority local messages. Then priority is granted to data priority messages from the backbone. Lowest priority is granted to data priority messages from the local network. When there are multiple clients requesting at the same priority level, they are satisfied in a round robin order.
The advantages of the above described embodiment of the present invention include good support for bridging, multiple priority levels and a predictable arbitration method under heavy loads.
Various preferred embodiments of the present invention can be adapted for use with various protocols. For example, preferred embodiments may be adapted to run similar to the IEEE 802.3 protocol. In one such embodiment, at the start of a packet, a client transmits on pairs 1 and 2. The hub repeats the data onto pairs 3 and 4 to the other clients. The transmitting client monitors pairs 3 and 4 for activity and the hub monitors pairs 1 and 2 for activity. Once the 802.3 arbitration has completed without a collision, i.e., the slot time has passed, the client is able to transmit on all 4 pairs. The 802.3 arbitration state machine can be used in a form to the version described above.
In an alternate embodiment, the client, at the start of a packet transmits on a first set of twisted wire pairs 1,2,3 and the hub repeats on a second set of twisted wire pairs 2,3,4. The client monitors pair 4 for activity and the hub monitors pair 1 for activity. After the arbitration is complete, the client can transmit data on all four twisted wire pairs.
Alternately, after the arbitration is complete the client can continue to transmit on only three pairs; however, in order to maintain a 100 Mb/s transmit throughput over the network, the transmission rate through each twisted wire pair would need to be correspondingly increased. For example, in order to transmit at 100 Mb/s on three lines with a 5B/6B two level code would require 40 megabaud per twisted pair, i.e., a maximum bandwidth per twisted pair of approximately 25-30 MHz.
In networks where bundles of twisted wire pairs are used, during arbitration a low frequency preamble is sent because data frequencies would generate too much crosstalk. If bundles are not used, the packet is transmitted during the arbitration at half or three quarters the final data rate, depending on whether 2 or 3 pairs are available.
In order to implement training in such an embodiment, a method similar to that described in the above described training state machines is used. In such an embodiment, for example, idle signals are sent on the cable to indicate whether a port has been trained or not. Until the training is complete, the port is not allowed to send regular packets.
The above-described embodiment of the invention has utilized a protocol in which for control signals tones are transmitted in full duplex at low frequency relative to data signals which are transmitted in half duplex. However, alternate embodiments of the present invention allow for additional adaptations to existing protocols. For example, for protocols which require collision detection, such as IEEE 802.3 protocol, various alternate embodiments may be implemented in accordance with the present invention.
For example out-of-band signaling may be used. Collision information is propagated back to the end node with a frequency that can be filtered out from the data stream. A low or high frequency could be used. Even a DC signal could be sent back on one pair to indicate collision. This would allow the data packet to be sent on all 4 pairs immediately, thus increasing network efficiency.
FIG. 15 gives one block diagram of an implementation which allows collision detection by sending collision information over a different frequency than data. A data signal generator 331 operating at a first frequency range is connected in parallel to with collision signal generator 332 and resistor 333. Collision signal generator 332 generates a collision signal at a frequency different than the first frequency range used for data. Data signals and collision signals are transmitted through transformer 334, over a twisted wire pair 335 and through a transformer 337. In parallel with a resistor 337 a filter 338 for data frequencies forwards the data signals using an amplifier 340. Likewise, a filter 339 for the collision frequency 339 forwards the collision signal using an amplifier 341.
FIGS. 16 and 17 show potential frequency spectrums for signals sent across twisted pair 335. Data signals are in a range between a first frequency f1 and a second frequency f2. Collision signals are sent a frequency f3. FIG. 16, illustrates the case where the spectrum for data frequencies 346 are at lower frequencies than the spectrum for collision frequency 347. FIG. 17, illustrates the case where the spectrum for data frequencies 346 are at higher frequencies than the spectrum for collision frequency 347.
Alternately, common-mode signalling may be used. In this case, the twisted wire pairs carry the data stream with differential mode signaling. Again, all 4 twisted wire pairs send data immediately, and collision signaling is sent back as a common mode signal on one pair with a return path on another pair. Alternately, radio frequency interference (RFI) is minimized by sending a common mode AC signal on two twisted wire pairs simultaneously. The AC signal is 180 degrees out of phase on each pair to cancel the electromagnetic fields created by a single transmitter.
FIG. 18 shows a block diagram of an implementation which provides common-mode collision signaling. A data signal generator 360 transmits data signals through transformer 361, over a twisted wire pair 363 and through a transformer 365. A filter 366 forwards the data signals using an amplifier 367. Likewise, a data signal generator 370 transmits data signals through transformer 371, over a twisted wire pair 373 and through a transformer 375. A filter 376 forwards the data signals using an amplifier 377. A collision generator 382 is connected to a transmission resistance 364 and a transmission resistance 374. In response to an enable signal on a line 383, collision generator 382 generates a differential signal through twisted wire pair 363 and twisted wire pair 373. A collision detector consisting of an amplifier 381 and a resistor 380 is coupled between a reception resistor 362 and a reception resistor 372. The collision detector detects and forwards a collision signal generated by collision generator 382.
In an alternate embodiment, in-band signalling can be used. In this embodiment, collision information is driven to a transmitting node with an in-band frequency signal. The receiving node has a hybrid transformer that allows echo cancellation of the outgoing data stream. The network node is thus able to verify a received collision signal in addition to the data being sent. Also, active circuits which provide echo cancellation may be used which allows half duplex signaling on a four twisted wire pairs.
FIG. 19 shows a block diagram of an implementation which provides for in-band collision signaling. A transmit amplifier 390 transmits data signals through a transformer 391 over a twisted wire pair 393 and through a transformer 395 to an amplifier 397. Likewise, a transmit amplifier 398 transmits data signals through transformer 395 over twisted wire pair 393 and through transformer 391 to an amplifier 399. A hybrid transformer 392 and a hybrid transformer 394 serve to cancel energy from being received by a nodes own transmitter. However, hybrid transformer 392 and hybrid transformer 394 will not block the incoming reception from another node. If in either case, a node is transmitting and receiving data at the same time, this indicates a collision has occurred.
FIG. 20 shows how the implementation shown in FIG. 15, or the implementation shown in FIG. 18 could be used in a network where a network device 419 sends data to a network device 420 over four twisted wire pairs 411, 412, 413 and 414. Within network device 419, a transmitting amplifier 401 sends data over twisted wire pair 411, a transmitting amplifier 403 sends data over twisted wire pair 412, a transmitting amplifier 405 sends data over twisted wire pair 413 and a transmitting amplifier 407 sends data over twisted wire pair 414. Within network device 420, a receiving amplifier 402 receives data over twisted wire pair 411, a receiving amplifier 404 receives data over twisted wire pair 412, a receiving amplifier 406 receives data over twisted wire pair 414 and a receiving amplifier 408 receives data over twisted wire pair 415.
Collision detection is accomplished, for example, using a separate frequency as in the implementation shown in FIG. 15 or FIG. 18. Collision detection circuitry 415 within network device 419 detects collisions by listening for a collision signal sent back on twisted wire pair 413 and/or twisted wire pair 414 from network device 420 (drivers not shown). Collision detection circuitry 416 within network device 420 detects collisions by listening for a collision signal sent back on twisted wire pair 411 and/or twisted wire pair 412 from network device 419 (drivers not shown).
In this embodiment, when network device 419 desires control of the network, it begins transmission on all of twisted wire pairs: 411, 412, 413 and 414. In addition, network device 419 sends a collision signal on one or both of twisted wire pairs 411 and 412. Collision detection circuitry 415 then listens for a collision signal on twisted wire pair 413 and 414. When a transmit enable signal 417 and a collision detection signal from collision detection circuitry 415 are both activated, a logical AND gate 418 signals a collision.
In another alternate embodiment, time multiplexing is used. In this embodiment the network nodes transmit on all four twisted wire pairs. After making an initial transmission, transmission ceases or a low frequency tone is sent during a collision window period. The collision window is used by the repeater to signal that a collision on the network has occurred. The original transmitting node would continue with packet transmission if no collision signal is returned during the collision window. Otherwise, the network node will back off, for example, in accordance with the IEEE 802.3 backoff algorithm. The use of a low frequency tone (or single tone) allows the collision signal to be sent back as a different tone. This allows a simple frequency detection circuit to be used to detect the collision tone.
FIG. 21 shows a hub 430 connected to a node 431 through four twisted wire pairs 433. Hub 430 is connected to a node 432 through four twisted wire pairs 434. In a time multiplexed hub based collision detection scheme, each node desiring to send information sends first tones during a collision interval. Hub 30 listens for the tones. If tones from more than one node is heard, hub 30 sends to all nodes a second tone indicating a collision has been detected.
FIG. 22 shows an example of signal timing packages used in a time-multiplexing scheme. Signal line 425 represents potential signals sent by node 431. Signal line 426 represents potential signals sent by hub 30. In a time period 427, node 431 finishes a sending a last data packet over four twisted wire pairs 433. In a collision detection period 428, node 431 and any other nodes which desire to send data send the first tone to hub 430. If hub 30 detects a collision, hub 30 sends the second tone. Otherwise in a time period 429, node 431 can begin transmission of a new network packet.
In another alternate embodiment of the present invention, a collision signal is sent after the data packet. A modification to the IEEE 802.3 protocol in accordance with this embodiment allows half-duplex operation on all 4 twisted wire pairs immediately for each data transmission. When transmitting a packet, a network node transmits a complete packet using all four twisted pairs. At the end of the packet, a collision window is opened by all nodes, allowing the repeater (Hub) to send a collision signal back to the original transmitting nodes. A network with low collision counts can have a significant increase in throughput efficiency by allowing all four pairs to transmit at the beginning of the data packet, as allowed by this embodiment.
FIG. 23 shows signal timing packages for this alternate scheme. Signal line 435 represents potential signals sent by node 431. Signal line 436 represents potential signals sent by hub 30. When there is a collision, a collision indicator (e.g., a tone) is sent to the nodes which collided. All colliding nodes would be informed after the packets were complete. Each node would then back off per the algorithm of the network program, (e.g., the 802.3 protocol).
In the preferred embodiment, a tone preamble occurs during a collision slot time. In this embodiment, a single tone is sent throughout the collision window as the data packet preamble. The single tone allows a collision signal to be sent back at an in band tone of another frequency, allowing ease of collision detection.
FIG. 24 illustrates the case where there is a collision window before each packet transmission. During the collision window, network nodes which desire to transmit data inform a hub 440 by sending first tones to hub 440. For example, a network node 441 sends to hub 440 the first tone over a first set of twisted wire pairs 444. A network node 442 sends to hub 440 the first tone over a first set of twisted wire pairs 446. As soon as hub 440 receives the first tone from any network node will begin sending an incoming signal to all nodes. For example, hub 440 will send an incoming signal to node 441 over a second set of twisted wire pairs 443. Hub 440 will send an incoming signal to node 442 over a second set of twisted wire pairs 445. All nodes will then be allowed to make a request to send data for a time duration set by the protocol. Each node measures the time duration from the time the node receives the incoming signal from hub 440. Hub 440 will wait until all possible requests to transmit have been heard. Then, if there has been more than one request to transmit data, hub 440 will send the collision tone in place of the incoming tone. Otherwise, hub 440 will cease transmissions allowing the one node requesting data transmission to proceed with the transmission.
The method of transmitting data described above can be modified in order to reduce the possibility of undetectable errors occurring from noise bursts affecting all four channels simultaneously, and thereby corrupting several successive 5B/6B symbols propagating in parallel through the channels. In this modification 6B symbols on two channels are offset in time by half the time for transmission of a symbol, relative to the symbols on the remaining two channels. As a result a noise burst affecting the channels for the duration of transmission of up to four bits can corrupt at most six consecutive 5B symbols (thirty consecutive bits). Such corruption can always be detected using a 32-bit CRC code as described herein.
Various different 5B/6B block codes may be used in place of the block code given in Table 1 above. One possible alternative 5B/6B code is shown in Table 6 below.
TABLE 6______________________________________5-bit data block 6-bit code value Alternate 6-bit code______________________________________ 0 00000 000110 111001 1 00001 001110 2 00010 110010 3 00011 000111 4 00100 100110 5 00101 010011 6 00110 100001 011110 7 00111 011000 100111 8 01000 110100 9 01001 01011010 01010 000101 11101011 01011 10001112 01100 11000113 01101 001001 11011014 01110 01101015 01111 01010116 10000 010100 10101117 10001 100100 01101118 10010 10010119 10011 10101020 10100 00101121 10101 10100122 10110 101000 01011123 10111 001010 11010124 11000 01100125 11001 10110026 11010 010010 10110127 11011 01110028 11100 100010 10111029 11101 001100 11001130 11110 00110131 11111 111000______________________________________
Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims. | A method for transmitting data packets, grouped as data octets, over a LAN having a central hub linked to each of a plurality of network nodes via a physical medium consisting of four pairs of unshielded twisted pair (UTP) cable. The transmission method sequentially divides the data into data quintets. The quintets are then arranged into blocks of data quintets and sequentially distributed into four individual serial code streams. The four serial code streams are sequentially scrambled to produce four streams of randomized quintets. The randomized data streams are sequentially block encoded into 6-bit symbol data which are then transmitted using NRZ modulation across the network by transmitting each data stream over one of said pairs of cable. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to the gravel packing of wells and in more particular relates to an apparatus for delivering a particulate-laden fluid and providing a distribution of the fluid at different levels within the wellbore annulus being packed.
[0003] 2. Background
[0004] In producing hydrocarbons or the like from loosely or unconsolidated and/or fractured subterranean formations, it is not uncommon to produce large volumes of particulate matter (e.g. sand) in conjunction with the formation fluids. As is known in the art, these particles routinely cause a variety of problems that result in added expense and increased downtime. Accordingly, it is extremely important to control the production of these particulates in most operations.
[0005] Probably the most common technique for controlling the production of particulates (e.g. sand) from a well is one that is known as “gravel packing”. In a typical gravel pack completion, a well screen is lowered into the wellbore and positioned across the interval of the well that is to be completed. Particulate material, collectively referred to as gravel, is then pumped as a slurry down the tubing on which the screen is suspended. The slurry exits the tubing above the screen through a “crossover” tool or the like and flows downward in the annulus formed between the screen and the well casing or open hole, as the case may be.
[0006] The liquid in the slurry flows into the formation and/or the openings in the screen that are sized to prevent the gravel from flowing through them. This results in the gravel being bridged on or “screened out” on the screen and in the annulus around the screen where it collects to form the gravel pack. The gravel is sized so that it forms a permeable mass which blocks the flow of any particulates produced with the formation fluids.
[0007] One of the main problems with gravel packing, especially where long horizontal or inclined intervals are to be completed, is obtaining equal distribution of the gravel along the entire completion interval, i.e. completely packing the annulus between the screen and the casing in cased hole completions or between the screen and the wellbore in open hole completions. Poor distribution of the gravel (i.e. incomplete packing of the interval resulting in voids/unpacked areas in the gravel pack) is often caused by the dehydration of the gravel slurry into more permeable portions of the formation interval that, in turn, causes the formation of gravel “bridges” in the annulus before all of the gravel has been placed. These bridges block further flow of the slurry through the annulus causing insufficient placement of the gravel. Subsequently, the portion of the screen that is not covered or packed with gravel is thereby left exposed to erosion by the solids in the produced fluids or gas and/or that portion of the screen is then easily blocked or “plugged” by formation particulates (i.e. sand).
[0008] U.S. Pat. No. 4,945,991, Jones, L. G., “Method for Gravel Packing Wells” discloses a screen with rectangular perforated shunt tubes attached to the outside of a screen longitudinally over the entire length of the screen. In this method, the perforated shunts (i.e. flow conduits) extend along the length of the screen and are in fluid communication with the gravel slurry as it enters the annulus in the wellbore adjacent the screen.
[0009] If a sand bridge forms in the annulus formed by the screen and the wellbore prior to placing all of the gravel, the gravel slurry will flow through the conduits past the sand bridge(s) and out into the annulus through the perforations spaced along the conduits to complete the filling of the annulus above and/or below the bridge(s). U.S. Pat. No. 5,113,935 is a further modification of this type of well screen. In some instances, valve-like devices are provided for the perforations in these conduits so that there is no flow of slurry through the conduits until a bridge is actually formed in the annulus; see also U.S. Pat. No. 5,082,052.
[0010] In many prior art, alternate path well screens, the individual perforated conduits or shunts are shown as being preferably carried externally on the outside surface of the screen; see U.S. Pat. Nos. 4,945,991; 5,082,052; 5,113,935; 5,417,284; and 5,419,394. This positioning of the shunt tubes has worked in a large number of applications, however, these externally-mounted perforated shunts are not only exposed to possible damage during installation but, more importantly, effectively increase the overall diameter of the screen. The latter is extremely important when the screen is to be run in a small diameter wellbore where even fractions of an inch in the effective diameter of the screen may make the screen unusable or at least difficult to install in the well. Also, it is extremely difficult and time consuming to connect respective shunt tubes attached to the outside of the screen to shunt tubes attached to the outside of the following screen in the course of assembling the screen and lowering it into the wellbore.
[0011] In order to keep the effective diameter of a screen as small as possible, external perforated shunt tubes are typically formed from “flat” rectangular tubing even though it is well recognized that it is easier and substantially less expensive to manufacture a round tube and that a round tube has a substantially greater and more uniform burst strength than does a comparable rectangular tube.
[0012] An additional disadvantage to mounting the shunt tubes externally, whether they are round or rectangular, is that the shunt tubes are thereby exposed to damage during assembly and installation of the screen. If the shunt tube is crimped during installation or bursts under pressure during operation, it becomes ineffective in delivering the gravel to all levels of the completion interval and may result in the incomplete packing of the interval. One proposal for protecting these shunt tubes is to place them inside the outer surface of the screen; see U.S. Pat. Nos. 5,476,143 and 5,515,915. However, because these prior art, alternate path well screens incorporate the perforated shunts and require that holes be drilled in the wire wound portions of the screen and/or the shunt tubes, some additional form of seal between the drilled hole in the wire and shunt tube is needed to prevent slurry flow and possible erosion in the internal surface of the screen annulus formed with the base pipe. This substantially increases the cost of the screen without substantially decreasing the over all diameter of the screen. In addition, the connections between the joints of screen in these prior art well screens, require either a union type connection, which is understood by those skilled in the art, that is incapable of withstanding torque being applied, a timed connection to align all of the shunt tubes from screen joint to screen joint, a jumper shunt tube between screen joints or a cylindrical cover plate over the connection between screen joints that is either welded to the base pipe or held in place by metal bands. All of these alternatives are expensive, time consuming and/or very difficult to handle on the rig floor while making up and installing the well screens.
[0013] Other downhole well tools have been proposed for fracturing a formation (U.S. Pat. No. 5,161,618) or treating a formation (U.S. Pat. No. 5,161,613) whereby individual conduits or shunt tubes are positioned internally within a housing or the like to deliver a particulate treating or fracturing fluid to selective levels within the wellbore. However, the outlets through the housing of these tools remain open after the particular operation is completed which would be detrimental in gravel packing completions since the produced fluids could then carry particulates back into the housing through these openings after the gravel pack has been completed and the well has been placed on production.
[0014] U.S. Pat. No. 5,333,688 discloses a gravel pack screen having shunt tubes positioned within the base pipe of the screen where they do not increase the overall diameter of the screen. Gravel slurry carried by these shunt tubes is delivered to different levels in the well annulus around the screen through the spaced outlets through the housing. However, by placing the shunt tubes within the base pipe (i.e. ultimately part of the production flowpath), an intricate and sophisticated valve is required to each of the outlets after the gravel packing operation is completed, thereby adding substantially to the costs of the screen and of installation. As well, with the shunt tubes in the production flowpath any remedial or production data gathering work will be inhibited by the tubes and will cause such work to be expensive or incapable of being performed.
SUMMARY OF THE INVENTION
[0015] The present invention provides an apparatus for gravel packing an interval of a wellbore wherein there is good distribution of gravel over the entire completion interval even if a sand bridge or void or the like is formed in the well annulus before the placement of the gravel is completed. The present apparatus is similar to that disclosed in U.S. Pat. No. 4,945,991 but includes unperforated shunt means (e.g. conduits and arrangement of conduits) positioned within the annulus formed between the base pipe and the outer surface of the screen that can deliver the gravel slurry to different levels of the interval during the gravel pack operation. This is believed to provide a more reliable means of deploying the apparatus in some applications (e.g. completion of long openhole intervals) over the prior art apparatus with the external shunts.
[0016] The present invention provides for distributing the gravel slurry to different points of the wellbore annulus from a multiplicity of unperforated flow conduits or shunt tubes positioned within the annulus formed between the base pipe and the outer surface of the screen, thereby providing the necessary alternate flowpaths for the slurry without substantially increasing the overall, outside diameter of the screen. The shunt tubes are connected to exit nozzle chambers placed at different points along the screen to allow for dispersion of the slurry around the complete circumference of the screen and along the entire length of the screen.
[0017] Also, by placing the unperforated shunt tubes within the annulus formed between the base pipe and the outer surface of the screen, a) the shunt is protected from damage and abuse during handling and installation of the gravel pack screen; b) a more desirable “round” tube can be used to form the shunt tubes thereby providing shunts with greater burst strength and less chance of failure during operation than most external shunts; c) the ability is present to increase the number of shunts and thereby provide more flow area for delivery of the gravel slurry along the completion interval; and d) an externally smooth outside diameter on the outer surface of the screen is permitted to simplify the installation of the well screen
[0018] More specifically, the well screen of the present invention is comprised of a base pipe that has multiple openings through the wall thereof and an outer surface which is spaced from the base pipe to form an annulus between the base pipe and the outer surface. Typically, multiple alternate flow paths (e.g. shunt tubes) are spaced radially around the base pipe within the annulus and extended axially along the length of the base pipe and connected to exit nozzle chambers at designated intervals along the outer surface of the screen. Solid support members are interspersed between the shunt tubes to aid in supporting and spacing the outer surface away from the base pipe.
[0019] The outer surface of the screen is comprised of a continuous length of wire wrapped around the radially spaced shunt tubes and the support members and is welded at each point of contact with the tubes and support members. Each coil of the wrap wire is spaced slightly from the adjacent coils to form fluid passages between the respective coils of wire. End rings are used to align the tubes and support members and none of the tubes or support members are welded to the base pipe. This eliminates problems associated with stress crack corrosion due to welding dissimilar metals. Multiple exit nozzle chambers are provided at designated intervals along the outer surface of the screen and the shunt tubes are connected to the exit nozzle chambers by a connector above and below. The present well screen may consist of only one section or it may consist of multiple sections that are connected together via a manifolded connector.
[0020] The manifolded connector allows for ease of make up of the joints of screen as it is run in the wellbore. The connector has multiple holes bored through the length of the box and pin ends. As the pin end is made up into an adjacent box end, there is a manifold area or space (e.g. common area) above the make up point that combines the flow from all of the shunt tubes. No other tie-in of the shunt tubes or additional cylindrical cover plates are required; therefore the make up is similar to conventional pipe or tubing make up as performed in daily operations. The top of the manifold area is sealed with a seal ring above and below. A slotted plate can be positioned on the box end of the connector to allow for return of the slurry fluid to aid dehydration across the manifolded connector. No special tools or timed connection or welding in the area of the connector are needed or required. The joints are made up end to end without any interruption in the flow between the joints. An additional concentric sleeve is provided below the box end of the connector to provide an area for hanging the screen on slips and/or latching the rig elevators to pickup the screen joint. Slotting of the concentric sleeve can be to provide additional area for return of the slurry fluid to aid dehydration across the concentric sleeve area. These areas for return of the slurry fluid help achieve an even leak off rate across the entire well screen assembly. The top joint of the sand screen incorporates perforations in the external member of the concentric sleeve to provide the means for pumping slurry into the alternate flowpaths.
[0021] In a typical gravel pack operation, the present screen is lowered into a wellbore and a gravel slurry is pumped down through the workstring to a cross-over tool and through a perforated packer bore extension that diverts the slurry flow to the well annulus surrounding the screen and the fluid returns to the surface via the workstring and wellbore annulus. The upper end of the shunt tubes within the screen are open to the annulus via the perforated external member of the concentric sleeve to receive the gravel slurry and the tubes manifolded together at the connections.
[0022] As the gravel slurry flows downward in the well annulus around the screen, it is likely to dehydrate on the formation and the screen as gravel is deposited around the screen to form the gravel pack. If enough fluid is lost from the slurry before the annulus is completely filled, a sand bridge is likely to form that will block further flow through the well annulus. The shunt tubes in the present well screen allow the slurry to by-pass this bridge in the well annulus and thereby complete the gravel pack.
BRIEF DESCRIPTION OF DRAWINGS
[0023] The apparent advantages and improvements of the present invention, as well as, actual construction and operation will be better comprehended by referring to the drawings that are not necessarily to scale and in which like parts are identified with like numerals and in which:
[0024] FIG. 1 is an elevational view, partly in cut away, of the well screen of the present invention in an operable position within a wellbore;
[0025] FIG. 1A is an elevational view, partly in cut away, of the well screen, having a slotted plate on the threaded box end for leak off, of the present invention in an operable position within a wellbore;
[0026] FIG. 2 is a partly section view of a single joint of the well screen of the present invention as set up to run in a wellbore;
[0027] FIG. 2A is a partly section view of a single joint of the well screen, having a slotted plate on the threaded box end for leak off, of the present invention as set up to nin in a wellbore;
[0028] FIG. 3 is a partly section view of a joint of the well screen of the present invention with several cross-sections taken along different lines of the well screen as indicated by the letters;
[0029] FIG. 3A is a cross-sectional view of FIG. 3 taken along section lines AA of FIG. 3 ;
[0030] FIG. 3B is a cross-sectional view of FIG. 3 taken along section lines BB of FIG. 3 ;
[0031] FIG. 3C is a cross-sectional view of FIG. 3 taken along section lines CC of FIG. 3 ;
[0032] FIG. 3D is a cross-sectional view of FIG. 3 taken along section lines DD of FIG. 3 ;
[0033] FIG. 3E is a cross-sectional view of FIG. 3 taken along section lines EE of FIG. 3 ;
[0034] FIG. 3F is a cross-sectional view of FIG. 3 taken along section lines FF of FIG. 3 ;
[0035] FIG. 3 . 1 is a partly section view of a joint of the well screen, having a slotted plate on the threaded box end for leak off, of the present invention with several cross-sections taken along different lines of the well screen as indicated by the letters;
[0036] FIG. 3 . 1 A is a cross-sectional view of FIG. 3 . 1 taken along section lines AA of FIG. 3 . 1 ;
[0037] FIG. 3 . 1 B is a cross-sectional view of FIG. 3 . 1 taken along section lines BB of FIG. 3 . 1 ;
[0038] FIG. 3 . 1 C is a cross-sectional view of FIG. 3 . 1 taken along section lines CC of FIG. 3 . 1 ;
[0039] FIG. 3 . 1 D is a cross-sectional view of FIG. 3 . 1 taken along section lines DD of FIG. 3 . 1 ;
[0040] FIG. 3 . 1 E is a cross-sectional view of FIG. 3 . 1 taken along section lines EE of FIG. 3 . 1 ;
[0041] FIG. 3 . 1 F is a cross-sectional view of FIG. 3 . 1 taken along section lines FF of FIG. 3 . 1 ;
[0042] FIG. 4 is an enlarged sectional view, partly cut away, of the manifolded connector end portions of two adjacent joints of the well screen of FIG. 1 ;
[0043] FIG. 4A is an enlarged sectional view, partly cut away, of the manifolded connector end portions, having a slotted plate on the threaded box end for leak off, of two adjacent joints of the well screen of FIG. 1A ;
[0044] FIG. 5 is a side view of the entire screen assembly in place in the wellbore and indicating the fluid flow while in the gravel packing position;
[0045] FIG. 6 is a side view of the entire screen assembly in place in the wellbore and indicating the fluid flow while in the gravel packing position with a sand bridge formed in the annulus.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0046] FIGS. 1 and 1 A illustrate the well screen 17 of the present invention in an operable position within the lower portion of a producing and/or injection well 20 . Well 20 has a wellbore 25 that extends from the surface (not shown) through an unconsolidated and/or fractured production and/or injection formation 22 . Even though well 20 is shown as a vertical, cased well, it should be noted that the present invention is equally applicable for use in open-hole wells and/or completions as well as horizontal and/or deviated (inclined) wellbores.
[0047] As shown, wellbore 25 is cased with casing 24 and cement 23 with perforations 21 within the interval of formation 22 that is to be gravel packed and/or fractured. Screen 17 is connected to the lower end of a cross-over tool 31 that is connected to the surface via a tubing or workstring (not shown) and is positioned across formation 22 forming an annulus 18 with casing 24 .
[0048] FIGS. 1-3 . 1 illustrate screen 17 as comprised of a perforated base pipe 1 . However, because base pipe 1 is shown as having multiple perforations 14 , it should be recognized that other types of base pipes, e.g. slotted pipe, etc., can be used in place of the perforated base pipe without departing from the present invention. One or more unperforated shunt tubes 7 (two shown) are spaced around the circumference of base pipe 1 and extend longitudinally along the length of the base pipe 1 . Unperforated shunt tubes 7 (i.e. flow conduits) are shown as being circular in cross-section, but it should be understood that conduits having other cross-sections (e.g. rectangular) can be incorporated without departing from the present invention.
[0049] As shown in FIGS. 1 and 1 A, outer surface 32 of screen 17 is comprised of a continuous length of wrap wire 33 that, in turn, may be cut to provide a “keystone” shape (not shown). Solid support rods or longitudinal rod wire 34 (three shown in FIG. 1 ) or the like—which are commonly used in prior art screens of this general type—are interspersed with and/or between shunt tubes 7 to aid in supporting and spacing outer surface 32 (wire 33 in the preferred embodiment) of screen 17 away from base pipe 1 . Shunt tubes 7 may be used as the only spacers between the base pipe 1 and the wire 33 without departing from the present invention.
[0050] Wire 33 is wrapped around the radially-spaced shunt tubes 7 and the longitudinal support rods 34 (Shown in FIGS. 3E and 3 . 1 E) on base pipe 1 and is normally welded at each point of contact with the tubes and wire rods. Each circumferential wrap of wire 33 is spaced slightly from the adjacent wraps to form passageways (e.g. slot openings) 5 between the respective wraps of wire. The wire is wrapped circumferentially in various lengths along the base pipe 1 and is shrink fit onto the base pipe 1 while covering the shunt tubes 7 and longitudinal support rods 34 forming the outer surface 32 . Connector rings 16 are shrink fit onto the outer surface 32 of screen 17 and base pipe 1 to connect the outer surface 32 of screen 17 to the base pipe 1 . This is basically the same process commonly used in the manufacture of wire-wrap screens that are commercially available, such as LINESLOT Screens, Reslink, Inc. Houston, Tex.
[0051] As shown in FIGS. 1,1A , 2 , 2 A, 4 and 4 A, a part of the outer surface 32 of screen 17 incorporates multiple exit nozzle chambers 6 spaced along the length of each screen joint 17 , shrink fitted onto base pipe 1 and comprised of several nozzles 10 ( FIGS. 1-4A ) that are connected to the unperforated shunt tubes 7 via connectors 9 . The outer surface 32 of screen 17 is connected to the exit nozzle chambers 6 via connector rings 16 that are shrink fitted on to the screen 17 and exit nozzle chamber 6 .
[0052] The preceding description of screen 17 indicates that it is constructed of a perforated base pipe 1 with a wire 33 or the like that is wrapped in closely spaced wraps to form a permeable liner, it will also be recognized by those skilled in the art that outer surface 32 may be formed from a slotted pipe, screen material, or the like, as long as it is permeable to fluids and impermeable to particulates. Accordingly, the “screen” as used throughout the present specification and claims is meant to be generic and to include and cover all types of those structures commonly used by the industry in gravel pack and frac pack operations which permit the flow of fluids through them while abating the flow of particulates (e.g. commercially available screens, slotted or perforated liners or pipes, screened pipes, prepacked or dual prepacked screens and/or liners or combinations thereof) into which shunt tubes 7 can be incorporated inside the outer surface of the screen 17 as disclosed in the present invention.
[0053] Additionally, screen 17 may comprise of only one joint (e.g. 30 foot section) or it may comprise of a multiple number of joints connected together. As an example, FIG. 4 illustrates a coupling 2 for joining two screen joints 2 A and 2 B together. Coupling 2 is comprised of a standard threaded box 2 b and a threaded pin 2 a . After the two joints have been joined and properly torqued a manifold area 13 is formed above the threaded connection by the extension 2 d that is threaded onto box 2 b . Manifold area 13 is connected to the shunt tubes 7 from joint 2 A via the channels 12 bored through exit nozzle chamber 6 above the threaded pin 2 a , and is in turn connected to the shunt tubes 7 from joint 2 B via channels 15 bored in the threaded box 2 b . Incorporation of this manifold area 13 allows for make up of the joints 2 A and 2 B without having to align the shunt tubes on the adjoining joints. The bored channels 15 in the threaded box 2 a connect or align with the concentric annulus 8 formed by the base pipe 1 and external concentric pipe 4 that is positioned between the top exit nozzle chamber 6 and the threaded box 2 b ( FIG. 4 ).
[0054] As known by those skilled in the art, the inability to bleed off the fluid from the slurry across the coupling 2 may cause insufficient dehydration of the fluid from the gravel slurry to occur in this area and thereby an incomplete pack is performed. A nonpreferred embodiment of the present invention may incorporate area 3 for bleed off of the fluid from the slurry ( FIGS. 1A, 2A , 3 . 1 and 4 A). The bleed off area 3 in coupling 2 is formed by milling a groove 2 c radially around the exterior of the threaded box 2 b , then covering the groove 2 c by a thin slotted cover plate 3 a that is held in place by the extension 2 d , made up to the outside of threaded box 2 b ( FIG. 4A ). Bored hole 2 e connects to bored channel 15 to allow bleed off of the fluid to the shunt tubes 7 ( FIG. 4A ). The bleed off area 3 is used when there is significant blank area between screen areas to provide bleed off of fluid that may be entrained in such area.
[0055] In a typical gravel pack operation, screen 17 is lowered into wellbore 20 ( FIG. 1 ) on workstring 32 and is positioned across the formation 22 . Ball 43 is pumped onto ball seat 42 and pressure is applied through ports 51 as is understood by those skilled in the art to set packer 30 . A gravel slurry 56 is then pumped down the workstring into cross-over tool 31 and out of outlet ports 31 a in crossover tool 31 through ports 50 and into annulus 18 of wellbore 25 . All of the shunt tubes 7 are manifolded together by concentric annulus 8 that is formed by base pipe 1 and external concentric pipe 4 to receive the gravel slurry via the wellbore annulus 18 through the ports 4 a in the external concentric pipe 4 .
[0056] As the gravel slurry flows downward in annulus 18 around the screen 17 , it will likely dehydrate due to fluid loss to formation 22 and/or through screen 17 . The fluid entering screen 17 will return to the surface through holes 14 in base pipe 1 , up washpipe 55 , passing through check valve 44 and through pipe 31 b in cross-over tool 31 ( FIGS. 5 and 6 ). As the fluid from gravel slurry 56 dehydrates on the screen 17 and/or the formation 22 , gravel 57 carried in slurry 56 is deposited and collects in the annulus 18 to form the gravel pack. As is known in the art, if enough fluid is lost from slurry 56 before annulus 18 is filled, a gravel bridge 60 ( FIG. 6 ) will form and block flow through annulus 18 and prevent further filling below bridge 60 . If this occurs while using the present invention, gravel slurry 56 can continue to be pumped downward into ports 4 a to concentric annulus 8 and then downward through the shunt tubes 7 and out the respective exit nozzles 10 by-passing gravel bridge 60 and completing the gravel pack.
[0057] Because many varying and different embodiments may be made within the scope of the invention concept taught herein which may involve many modifications in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | Apparatus for gravel packing a wellbore interval with enclosed alternate flowpaths (i.e. conduits) that can provide a good distribution of gravel over the entire completion interval. The alternate flowpaths for the slurry are positioned in the annulus formed by the base pipe and the external surface of the screen, and connected to corresponding exit nozzle chambers positioned at different levels on the screen, and therefore do not significantly increase the overall effective outside diameter of the screen. | 4 |
This invention relates to wristwatches of the type employing a quartz crystal with suitable divider networks for actuating a read-out such as a digital read-out provided by light emitting diodes or liquid crystals.
BACKGROUND OF THE INVENTION
Essentially, quartz crystal watches of the type with which the present invention is concerned utilize a crystal oscillator having an output frequency which is extremely stable. This frequency is divided down into suitable clock pulses for actuating a digital display on the face of the watch.
Whether the watch employs light emitting diodes or liquid crystal type displays, in each case an illuminating means is required to render the diplay visible. In the case of the light emitting diode display, the diodes normally remain de-energized since energization thereof is the greatest source of power drain and if they remain illuminated, the power cells would have to be replaced too frequently. On the other hand, the liquid crystal displays are visible at all times but they do not exhibit a great deal of contrast and a light is typically incorporated to increase the contrast of the display. Again, the light does not remain on at all times since this would be too great a power drain from the watch battery.
WIth both of the foregoing types of displays, it is accordingly necessary to provide a switch which will close the necessary terminals to effect the desired illumination of the display.
In my copending patent applications, Ser. No. 516,688 filed Oct. 21, 1974, entitled ACTUATING MECHANISMS FOR WRIST INSTRUMENTS; Ser. No. 538,743 filed Jan. 6, 1975, entitled ACCELERATION/DECELERATION ACTUATING MECHANISM FOR WRIST INSTRUMENTS; and Ser. No. 556,335 filed Mar. 7, 1975, entitled WRIST ACTUATED PRESSURE SWITCH FOR WATCHES, there are disclosed quartz crystal type watches as discussed above wherein various types of inertia switch means or pressure switch means are described for rendering the display visible.
Since the display is only illuminated at the time a user wishes to tell the time, the face of the watch is normally dark and appears blank. There is really no convenient means for a user to be advised whether the watch is properly operating unless he actuates the display. Moreover, since the watch face essentially appears blank, the watch itself is generaly inconspicuous and thus would not attract attention as might be the case with an ornate conventional type watch. Finally, there is no readily available observable means of determining how low the battery might be and thus replacement of the battery is often done simply on a fixed time basis regardless of how many times the actuating mechanism for illuminating the readout might be used.
BRIEF DESCRIPTION OF THE PRESENT INVENTION
With all of the foregoing in mind, the present invention contemplates a wristwatch of the foregoing type incorporating features which not only serve to render the watch more attractive by providing it with an attention attracting feature, but wherein proper operation of the watch can be determined at a glance and when the battery is drained beyond a certain point, there is also provided a clear indication to the user of this fact.
Briefly, the foregoing is accomplished in a quartz crystal controlled watch by providing a light emitting means in addition to the normal illuminating means for the display on or near the face of the watch. Means are included in the divider circuit portion of the watch for providing low frequency, low level current pulses derived from the crystal oscillator and connected to the light emitting means for periodically energizing the light emitting means at the low frequency to provide an attention attracting blinking light on the watch.
In the preferred embodiment, the light emitting means takes the form of a plurality of low level light emitting diodes arranged in a desired pattern on the watch face. Each individual light emitting diode is caused to periodically blink providing an attention-arresting feature. The low level light emitting diodes are continuously energized so that it is evident that the watch is operating properly when the lights are blinking. On the other hand, when the battery is drained below a certain point, the blinking lights no longer operate thus advising the user of the watch that the battery is low.
The blinking light arrangement thus serves the dual function of providing an attention attracting display and also a monitor as to the battery drainage.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention will be had by referring to the accompanying drawings in which:
FIG. 1 is a perspective view of a quartz oscillator wristwatch incorporating the blinking lights in accord with the present invention;
FIG. 2 is a plan view of the face of the watch of FIG. 1 illustrating a first pattern for the blinking lights;
FIG. 3 is a plan view similar to FIG. 2 but illustrating a modified pattern for a somewhat differently designed watch casing; and,
FIG. 4 is a simplified block diagram of the basic circuit common to both the watches of FIGS. 2 and 3 for providing the blinking light feature in accord with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 there is shown a watch 10 having a wristband 11 and time indicating means in the form of a digital read-out display 12. A manually operable push-button 13 is shown for actuating the illuminating means to render the display visible when a user wishes to tell time.
In accord with the invention, there is provided a light emitting means 14 preferably in the form of a plurality of low-level light emitting diodes arranged in a given pattern about the digital read-out 12. As will become clearer as the description proceeds, each of these individual low level light emitting diodes is energized by low frequency, low current pulses so that the various light emitting diodes blink. The energization is continuous so that as long as there is sufficient battery power, they will continuously blink thereby providing an attention attraction feature to the watch.
Referring to FIG. 2, the particular pattern of the light emitting diodes illustrated covers the face of the watch with the time indicating means in the form of a digital readout 12 in the central portion of the pattern. Thus, there are provided a plurality of rows of the light emitting diodes 14 as indicated at a, b, c, d, and e. The numbers of light emitting diodes in each row are 3, 4, 3, 4 and 3 respectively. Two of the light emitting diodes are omitted from the center row to leave room fr the digital read-out. The pattern is outlined by an hexagonal perimeter 15 and is symmetrical with respect to horizontal and vertical axes as shown. Other components of the watch illustrated in FIG. 2 are designated by the same numerals used in FIG. 1.
FIG. 3 shows a modified watch casing structure 10' provided with a band 11' and time indicating means in the form of a digital read-out 12'. A push-button 13' is used for actuating the illuminating means so that whan a user wishes to tell the time, he will depress the button 13'. In the watch of FIG. 3, there are again provided light emitting means in the form of a plurality of light emitting diodes 14' but in this case, the same are arranged in two sub-patterns respectively adjacent to the top and bottom of the read-out display 12'. As in the case of the light emitting diodes described in conjunction with the watch of FIGS. 1 and 2, each light emitting diode is energized by low frequency, low current pulses to blink.
Referring now to FIG. 4, there is shown a schematic block diagram of the basic components common to both of the watches described in FIGS 2 and 3. As shown in the lower central portion of FIG. 4, the watch incorporates a power source such as a battery 16 providing power on output lead 17 to the left of FIG. 4 and return lead 18 which may be grounded to the casing of the watch. A crystal oscillator circuit 19 is connected to the battery source 16 by way of the leads 17 and 18 for continuous energization. A divider circuit means 20 in turn connects to the crystal oscillator circuit for providing timing pulses to control the time indicating means or display 12.
In FIG. 4, the light emitting means in the form of the plurality of low level light emitting diodes 14 in FIG. 2 and 14' in FIG. 3 are indicated by the same numeral 14 as a box. Means are provided in the divider circuit means 20 for providing low frequency, low level current pulses derived from the crystal oscillator circuit 19 and connected to the light emitting means 14 as indicated by the plurality of vertical lines. A circuit is completed from the low level light emitting diodes 14 through a switch arm 21 to the return lead 18.
The illumination means for the display 12 is indicated by the box 22 connected between the power lead 17 and another switch arm 13 to return lead 18. The switch arm 13 corresponds to the push-button switches 13 and 13' described in FIGS. 2 and 3 and it will be noted that this switch is normally open. A suitable means which for simplicity is illustrated as a relay coil 23 connects across the illuminating means 22 and is arranged to turn the switch arm 21 from the low level light emitting diodes to an OFF position whenever the illuminating means 22 is energized. When the illuminating means is de-energized, the coil 23 is also de-energized so that the switch arm 21 will reconnect the low level light emitting diodes 14 into the circuit. In the particular embodiment shown in FIG. 4, there is provided an inertia switch 24 connected across the switch arm 13 so that the illuminating means 22 can be actuated by a flick of the wrist. This inertia switch may be of the type shown in any one of my heretofore referred to copending patent applications.
The timing pulses for operating the display 12 are derived from the divider circuit network 20 and passed to the display as indicated by lead 25. The low level light emitting diodes 14, on the other hand, are energized from low frequency, low current pulses as described which are derived from divider portions of the divider network circuit in such a manner and in accord with the preferred embodiment of the invention to individually energize the light emitting diodes in a random manner so that they will blink in a randon manner. It should be understood, however, that the sequence of energizing the light emitting diodes need not be random but could be programmed if desired to follow a specific lighting sequence, for example, 1 second and/or 1 minute intervals.
OPERATION
In operation, and with reference to FIG. 4, it will be appreciated that the crystal oscillator circuit is continuously energized so that proper timing pulses are provided by lead 25 to the display 12. When a user wishes to tell the time, he will depress the normally open push-button switch 13 to close the arm as shown in FIG. 4 and thus actuate the illuminating means 22. The display or time indicating means 12 will then be rendered visible.
Simultaneously with the energization of the illuminating means 22 as described heretofore, the coil 23 will be energized to thereby disconnect the low level light emitting diodes from the circuit by the movement of the switch arm 21 to its OFF position. When the illuminating means 22 is de-energized as by releasing the push-button switch 13, the coil 23 will also be de-energized thereby reconnecting the low level light emitting diodes through the switch arm 21 to the circuit.
If the push-button switch 13 is considered a first switch means to actuate the illuminating means when closed by a user to tell the time, and the switch arm 21 considered a second switch means, it is evident that the second switch means is reponsive to closing of this first switch means to open and disconnect the light emitting means in the form of the light emitting diodes and responsive to opening of the first switch means to close and reconnect the light emitting diodes so that the blinking light or lights stops during the period of time that the first switch means is closed; that is, during the short period of time that a user is telling the time.
From the foregoing it will be evident that an attractive display is provided by the low level light emitting diodes and that further, the light emitting diodes serve as a monitoring means to determine that the watch is properly operating. In the preferred embodiment described, the low level current pulses provided for energizing the low level light emitting diodes are responsive to a given drainage from the battery 16 to no longer have sufficient power to energize the light emitting diodes. As a consequence, the light emitting diodes will stop blinking before the battery is completely drained, thereby giving the user of the watch a warning that the battery is low.
The watch monitor of the present invention accordingly not only provides an attention attracting displsy for the watch but serves to indicate to the user that the watch is properly operating and also provides a warning to the user when the battery is sufficiently low that it should be replaced. | A crystal controlled digital wristwatch is provided with light emitting diodes in a pattern on its face which are periodically energized by low frequency, low current pulses derived from digital divider networks in the watch to provide blinking lights. When a manual push-button is depressed to illuminate the digital display of the watch, the circuit to the blinking lights is disconnected. The blinking lights serve as a monitor to indicate that the watch is operating correctly. When the battery is drained beyond a given point, the blinking lights are no longer energized advising the user that the battery is low. | 6 |
DESCRIPTION
1. Technical Field
My invention lies in the field of veterinary instruments and particularly in the field of dehorning devices for severing the horns of animals.
2. Background Art
Saws have been the cheif dehorning tools of the past. Use of a dehorning saw is time-consuming and, accordingly, is difficult to use effectively on an animal which is being restrained. Furthermore, even a slight movement of the animal will destroy the accuracy of the cut. More sophisticated devices are somewhat subject to the same disadvantages.
During the dehorning procedure it is desirable to simultaneously sear or cauterize the wound left when the horn is severed to help prevent infection. This is practically impossible to do when a saw is used. It is difficult to accomplish with other dehorning tools available.
DISCLOSURE OF THE INVENTION
In accordance with the present invention a dehorning tool is provided having cutting blades hinged to an operator controlled actuating mechanism which operates to advance and retract the blades. Camming means are provided to effect opening of the blades as they move forward for insertion of their cutting edges around a horn and for closing the blades upon retraction for severing the horn. A handle is rotatably mounted on the body of the device to permit rotation of the body and cutting blades to aid in severing the horn.
The dehorning device has the advantage that it can be quickly and accurately placed over a horn on an animal and the blades rapidly forced together and rotated to sever the horn. Great force can be applied to the blades due to the leverage achieved by the construction of the device. A further advantage of the device is the fact that the blades can be heated before use either by direct contact with heat or electrically for searing or cauterizing the wound left after removal of the horn.
DESCRIPTION OF THE FIGURES
The details of the invention will now be described in connection with the accompanying drawing, in which
FIG. 1 is a perspective side view of the dehorning tool;
FIG. 2 is a partial back cutaway view;
FIG. 3 is a side view shown with the outer casing cut away to show internal structure;
FIG. 4 is a partial front cutaway view;
FIG. 5 is a fragmentary cutaway view taken in the area of the handle on line 5--5 of FIG. 3;
FIG. 6 is a partial fragmentary cutaway view taken on line 6--6 of FIG. 3, and
FIG. 7 is a partial fragmentary cutaway view taken on line 7--7 of FIG. 3.
BEST MODE FOR CARRYING OUT THE INVENTION
In the following description and claims the end of the tool to which the lever arm and grip are attached is referred to as the top and the opposite end on which the cutting blades are mounted as the bottom. The term "proximal" refers to that part or area of an element nearest the top and the term "distal" refers to that part or area of the element further removed from the top than the proximal area. The front of the tool is defined by the side from which the gripping element and lever arm extend and the back and sides are correspondingly defined.
Referring now to the drawings, the dehorning tool of the invention comprises upper and lower housing sections 10 and 12, respectively, of tubular construction and forming the body 14 of the device. The body could be solid or of other construction. It is preferably made of metal but can be made of plastic or other suitable material.
An actuating arm 16 extends horizontally of the tubular body 14. It is attached at its proximal end by yoke 18 to lever arm 20 which is pivotally mounted by ears 22 to upper housing section 10 and hingedly attached at its distal end to cutting blades 24. The hinge construction comprises proximate ends 26 of cutting blades 24 mounted to tongue 28 of actuating arm 16 by means of bolt 30. It is seen from the description that movement of lever arm 20 in an upward direction withdraws the cutting blades 24 and movement of the lever arm in the downward direction extends them.
The bottom of lower housing section 12 ends in flared skirt 32 which permits the cutting blades 24 to move outwardly and cams them together as the cutting blades are moved inwardly.
For separating the cutting blades 24 to permit their cutting edges 33 to be placed over the animal horns, upstanding camming members or pins 34 are rigidly mounted between the sides of skirt 32 and internally of the cutting blades 24. From the described construction it will be seen that as actuating arm 16 is moved downwardly or outwardly the extending cutting blades 24 will be cammed apart by the camming pins 34 to open the cutting edges 33 to permit their placement about the animal horn. It will be further seen that as the actuating arm 16 is moved upwardly the withdrawing cutting blades 24 will be cammed by the inner sides or surfaces of flared skirt 32 to close the cutting edges 33 to sever the horn.
The cutting edges 33 are preferably of concave construction but can be of other configuration. Obviously, more than two cutting blades can be used and hingedly mounted on the distal end of actuating arm 16 by well known construction. Other means than skirt 32 and pins 34 can be used for camming the cutting blades to closed and open positions.
The dehorning tool is held by the operator by handle 36 rigidly attached to hollow sleeve 38 by means of welds 40. The sleeve 38 is rotatable on body member 14 between supporting annular flanges 41 to permit rotation of body 14 and, accordingly, cutting edges 33 to aid in severing the horn after the edges have been closed on it.
A gripping member 42 is rigidly attached to the top of body member 14 to aid the operator in moving lever arm 20 upwardly to close the cutting edges 33 about the horn. It is seen that the described construction provides increased leverage through lever arm 20 and actuating arm 16 to provide maximum force to close cutting edges 33 with a minimum force applied to lever arm 20. The cutting blades 24 will normally fall open by gravity when the tool is in upright position but, if necessary, they can be opened by moving lever arm 20 downwardly.
The preferred metal construction of the dehorning tool permits the cutting edges 33 to be heated by direct contact with a heat source, electrically, or by other means to permit simultaneous severing of the horn and searing or cauterizing of the wound left by removal of the horn to prevent infection. The dehorning tool may be used for dehorning cattle, sheep or other animals. | A dehorning tool has a tabular body with a lever arm pivotally mounted on the upper half and connected to an end of a actuating arm inside the body. The other end of the actuating arm is connected to the ends of two cutting blades. There are camming means inside of the blades to cam them open when the blades are extended and there are camming means on the outside of the blades which cam the blades together when the actuating lever is moved to retract the blades. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a pattern drawing device for forming minute patterns on thin films such as those formed on substrates during the process of manufacturing integrated circuits, display devices, optical devices and other such devices.
[0003] 2. Description of the Related Art
[0004] Thin film patterning steps are essential in the manufacture semiconductor substrates, optical devices and other such devices. Patterning, for example, is performed by applying a photo resist layer on the thin film to be processed, exposing a pattern on such photo resist, developing the exposed photo resist to form a resist pattern, and etching thin film using the resist pattern as an etch mask. A pattern drawing device is used for exposing the pattern on the photo resist, typically through the use of a photo mask or utilizing an exposure method employing an optical beam scanning technique. The latter is used in the preparation of an optical disk original and drawing of free patterns. For instance, Japanese Patent Laid-Open Publication No. S59-171119 and Japanese Patent Laid Open Publication No. H10-11814 describe a pattern drawing device employing a rotational scanning system. These pattern drawing devices mount a substrate coated with photo resist on a turntable, and draw patterns on the substrate by performing rotational scanning with a laser beam modulated with pattern data.
[0005] Nevertheless, with the aforementioned pattern drawing devices employing the rotational scanning system, the original pattern data read by the X-Y coordinate system with a device such as a scanner and saved as a stored pattern is converted into an r-θ coordinate system, and this r-θ pixel data is temporarily stored in the memory. The pixel data is then read from the memory in synchronization with the substrate rotation and used to modulate the optical beam so as to draw a pattern by selectively exposing the photo resist. Thus, data for the r-θ coordinate system must be converted each time the stored pattern to be drawn is rotationally scanned at least once (1 track worth). When it is necessary to draw a high-resolution pattern, because data must be converted from an X-Y coordinate system to the r-θ coordinate system for all drawing points on the circumference of each track, the operational load increases, and the conversion time expands, thereby restricting high-speed drawing. Moreover, when the processing performance of the CPU is relatively low, drawing of high-resolution or multi-valued patterns is restricted and a larger CPU capacity and/or larger memory will be required for adequate performance.
SUMMARY OF THE INVENTION
[0006] Accordingly, an object of the present invention is to provide a pattern drawing device capable of high-speed drawing even without improved CPU processing performance.
[0007] Another object of the present invention is to provide a pattern drawing device capable of high-resolution drawing even without CPU processing performance.
[0008] In order to achieve the foregoing objects, the pattern drawing device according to the present invention is capable of forming a plurality of tracks disposed concentrically on a substrate to thereby form a two-dimensional pattern, comprising: pattern generation means for repeatedly arranging, in positive or reverse, a basic pixel sequence to be the basis for each track at least in two places on one track and, by performing this pattern generation in a plurality of consecutive tracks, forming the two-dimensional pattern; modulation means for modulating a drawing beam scanning the substrate according to the pixel sequence data; and beam position setting means for synchronizing with the pixel sequence data and setting the scanning position of the drawing beam on the substrate.
[0009] According to the foregoing structure, patterns may be drawn while reducing the need to convert pixel data from the X-Y coordinate system to the r-θ coordinate system.
[0010] Preferably, the substrate is demarcated with a plurality of sector areas divided in the circumferential direction and cluster areas that combine one or more consecutive sector areas to form a plurality of cluster areas; and the pattern generation means outputs the basic pixel sequence as the drawing beam scans a track within a cluster area.
[0011] According to the foregoing structure, the control program of the overall pattern formation is simplified.
[0012] Preferably, the pattern generation means arranges a simulated pixel sequence which does not form a pattern between the basic pixel sequence. This will alleviate the operational load of the drawing processing since the conversion of pattern data is no longer required.
[0013] Preferably, the pattern generation means arranges a simulated pixel sequence which does not form a pattern on the track of the sector area other than the cluster area. This will simplify the pattern forming program since the setting of drawing in sector units is enabled.
[0014] Preferably, the track is a locus obtained by rotationally scanning the substrate with a drawing beam modulated with the pixel sequence data. For instance, pattern drawing using optical beams and light-sensitive films can be easily conducted.
[0015] The manufacturing method of a pattern drawing body according to the present invention comprises forming a plurality of tracks disposed concentrically on a substrate and drawing a two-dimensional pattern; wherein the two-dimensional pattern is formed by repeatedly arranging, in positive or reverse, a basic pixel sequence to be the basis for each track at least in two places on one track and, by performing this operation on a plurality of consecutive tracks, to form the two-dimensional pattern.
[0016] Preferably, the foregoing manufacturing method comprises the steps of: demarcating the substrate with a plurality of sector areas divided in the circumferential direction and a cluster area combined with one or a plurality of consecutive sector areas; including a plurality of cluster areas in the substrate; and arranging the basic pixel sequence on the track of the cluster area.
[0017] Preferably, a simulated pixel sequence is arranged which does not form a pattern on the track of the sector area other than the cluster area.
[0018] Moreover, the manufacturing method of a device comprising the pattern drawing body according to the present invention is capable of producing a pattern drawing body according to any one of the methods of manufacturing a pattern drawing body described above.
[0019] The foregoing pattern drawing device and drawing method may be employed in semiconductor devices comprising integrated circuits, LCD display devices, electrophoretic display devices and other display devices, as well as optical devices such as photo masks, light reflectors, optical waveguides, diffraction gratings among others, and devices comprising such pattern drawing bodies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a functional block diagram illustrating the overall structure of the pattern drawing device according to the present invention;
[0021] [0021]FIG. 2 is a block diagram illustrating a structural example of the pattern generator 40 ;
[0022] [0022]FIG. 3 is a diagram illustrating a usage example of the internal area of the memory 404 ;
[0023] [0023]FIG. 4 is a diagram illustrating a drawing example of the first pattern;
[0024] [0024]FIG. 5 is a diagram illustrating a structural example of the sector and cluster upon drawing the first pattern;
[0025] [0025]FIG. 6 is a flowchart illustrating the data-reading operation of the memory controller 405 from the memory 404 ;
[0026] [0026]FIG. 7 is a flowchart illustrating the data output processing according to the present invention;
[0027] [0027]FIG. 8 is a flowchart illustrating the processing other than the final dot of the sector;
[0028] [0028]FIG. 9 is a flowchart illustrating the processing other than the final dot of the cluster;
[0029] [0029]FIG. 10 is a flowchart illustrating the processing other than the final dot of the cluster;
[0030] [0030]FIG. 11 is a flowchart illustrating the processing other than the final dot of the track;
[0031] [0031]FIG. 12 is a flowchart illustrating the generation of the data transfer request signal;
[0032] [0032]FIG. 13 is a flowchart illustrating the readout bank switching inside the memory;
[0033] [0033]FIG. 14 is a diagram illustrating a drawing example of the second pattern;
[0034] [0034]FIG. 15 is a diagram illustrating a structural example of the sector and cluster upon drawing the second pattern;
[0035] [0035]FIG. 16 is a flowchart illustrating the processing other than the final dot of the sector in the drawing of the second pattern;
[0036] [0036]FIG. 17 is a flowchart illustrating the processing of the final dot of the track in the drawing of the second pattern;
[0037] [0037]FIG. 18 is a flowchart illustrating the processing of the final dot of the cluster in the drawing of the second pattern; and
[0038] [0038]FIG. 19 is a flowchart illustrating the processing other than the final dot of the cluster in the drawing of the second pattern.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] In FIG. 1, the optical beam (laser beam) 12 emitted from the laser beam generation device 11 , which functions as the optical beam light source, arrives at the half mirror 14 via the electro-optic modulator (EOM) 13 . A part of the optical beam 12 passes through the half mirror 14 and enters the first optical detector 15 , and the remainder enters the acousto-optical modulator (AOM) 17 . The optical detector 15 detects the intensity of the optical beam 12 . The detected optical intensity is converted into a level signal, and supplied from the optical detector 15 to the level adjuster 16 . The level adjuster 16 sets the transmittance and adjusts the intensity of the optical beam by controlling the control signal to be applied to the electro-optic modulator 13 in accordance with the position r in the diameter direction of the turntable 31 of the optical beam spot 21 . Thus, when rotational control of the turntable 31 is conducted to provide a constant angular velocity (CAV), the exposure energy density of a steady optical beam scanning the photo resist will be uniform across the face of the substrate. The electro-optic modulator 13 , first optical detector 15 , level adjuster 16 comprise the level adjustment loop.
[0040] The optical beam 12 reflected off the half mirror 14 is adjusted to a prescribed intensity using the level adjustment loop, and is delivered to the turntable 31 via the acousto-optical modulator (AOM) 17 , reflection mirror 18 , reflection mirror 19 and objective lens 20 . The acousto-optical modulator 17 modulates the intensity of the optical beam 12 by changing the transmittance in accordance with the pattern signal supplied from the pattern generator 40 (described in more detail below). The acousto-optical modulator 17 corresponds to the modulation means for modulating the drawing beam with the pixel sequence data. The objective lens 20 condenses the optical beam 12 on the substrate 32 , and forms a light spot 21 . The light spot 21 is controlled to provide a constant diameter (or focal depth) with a focus servo (not shown). The skew method, for example, may be employed as the focus servo. Moreover, when a plurality of laminated films are formed on the substrate, it is also possible to adjust the focus onto a specific film among such a plurality of laminated films. The diameter of the light spot 21 corresponds to the width in the diameter direction of one rotational scan (width of one track), and is used for writing (drawing) the pattern.
[0041] The spindle motor 35 rotatably drives the turntable 31 on which the substrate 32 is mounted. This rotation is controlled with a drive circuit (not shown) that generates a drive signal in accordance with the clock signal supplied from the pattern generator 40 . Moreover, the turntable 31 is mounted on a slider 34 which moves in the diameter direction thereof, with slider 34 being driven with a forwarding motor 33 . A single rotation of the turntable indexes the slider one pitch, and a spiral, rotational scanning locus can be obtained with the light spot 21 thereby. The forwarding amount of the forwarding motor 33 is controlled by the pattern generator 40 . Here, the turntable 31 , forwarding motor 33 , slider 34 and spindle motor 35 comprise a beam position setting means for setting the scanning position of the drawing beam on the substrate by synchronizing with the pixel sequence data. An alternative method of setting the beam position would be moving the imaging optics ( 18 to 21 ) along a diameter direction of a fixed turntable.
[0042] As illustrated in FIG. 2, the pattern generator 40 comprises a drawing point coordinate generation unit 401 , a drawing point coordinate data generation unit 402 , a pattern storage unit 403 , a memory 404 , a memory controller 405 , a D/A converter 406 and an oscillator 407 . These various functions may be realized with a computer system.
[0043] The drawing point coordinate generation unit 401 outputs the address of each pixel of the track to be drawn in a polar coordinate (r 1 , θ 1 ) format corresponding to the turntable in accordance with the data transfer request signal supplied from the memory controller 405 . For instance, one track worth of a pixel address group is consecutively generated. The drawing data generation unit 402 coverts the address of each pixel (r 1 , θ 1 ) represented with polar coordinates into the pattern data address of the position (x i , y 1 ) of the corresponding X-Y coordinate system. The coordinate conversion of polar coordinates (r i , θ i ) and X-Y coordinates (x 1 , y 1 ) can be conducted with the relational expression of x 1 =r 1 cosθ 1 , y 1 =r 1 sinθ 1 . Here, r i is the distance OP (corresponds to track number r i ) from the original point position O (0, 0) of the X-Y coordinates to the pixel of an arbitrary position P (x i , y i ), and θ i is the angle formed between the X axis and the segment OP. Data corresponding to the pattern to be drawn on the substrate may, for example, be retained beforehand in the pattern storage unit 403 as two-dimensional bitmap data obtained from a device such as a scanner. Moreover, this stored pattern data may also be converted CAD data (pattern design data by a computer) or the like. The storage unit 403 also stores information relating to the formation of the pattern to be drawn. This information is provided to the memory controller 405 via the memory 404 . The drawing data generation unit 402 reads the pixel data of the pattern to be drawn from the pattern storage device 403 with the X-Y coordinate system address (x 1 , y 1 ) corresponding to the series of polar coordinate addresses (r 1 , θ 1 ) supplied from the drawing point coordinate generation unit 401 described above, and stores this in the memory 404 . For instance, one track worth of pixel data may be stored in the memory 404 .
[0044] As shown in FIG. 3, the memory 404 , for example, comprises two independent memory areas, bank A and bank B, so that while one bank is being read or written, it is possible to read from or write to the other bank. Bank A is assigned the areas of memory addresses [0] to [SizeBank−1], and bank B is assigned the areas of memory addresses [SizeBank] to [2×SizeBank−1]. Data of bank B is renewed while the data D of the address, which is the current read-out address of bank A, is being read by the memory controller 405 . Therefore, while the pixel data group of the first track is being read, it is possible to write the pixel data group for the subsequent track into the other bank, thereby enabling the FIFO (First In First Out) operation.
[0045] The memory controller 405 sequentially reads the pixel data of each track from the memory 404 and supplies this data to the D/A converter 406 to produce the modulation input for the acousto-optical modulator 17 . The optical beam is then modulated by setting the transmittance of the acousto-optical modulator 17 in accordance with the pixel data.
[0046] When the memory controller 405 finishes reading one track worth of pixel data from one of the banks of the memory 404 , it begins reading the pixel data of the subsequent track from the other bank and simultaneously outputs a data transfer request signal to the drawing point coordinate generation unit 401 to begin loading the pixel data address of the next subsequent track. When this sequence is repeated, the drawing point coordinate generation unit 401 sequentially generates the pixel data address for each track from the first track to the final track, to provide the pixel data address for the full area of the substrate onto which the pattern is to be drawn. The memory controller 405 and D/A converter 406 supplying the pixel data operate in synchronization with the clock signal supplied from the oscillator 407 , and the clock output from this oscillator 407 also being used to control the rotation of the spindle motor 35 and the position of the forwarding motor 33 . This allows rotation of the turntable 31 and the diameter direction movement of the slider 34 to be synchronized with the forwarding of the pixel data. Therefore, the respective control systems of the turntable 31 and slider 34 are synchronized with the forwarding of the pixel data to draw a pattern during the rotational scanning of the r-θ system coordinates.
[0047] In the embodiments of the present invention, in order to reduce the operational processing load of the foregoing coordinate conversion in the drawing point coordinate generation or drawing data generation operations, the pattern generator 40 additionally comprises the functions of repeatedly using the data stored in the memory and generating zero data for any non-drawing area(s).
[0048] [0048]FIG. 4 illustrates an example of a pattern to be drawn on the substrate 32 in the embodiments of the present invention. This pattern comprises a drawing pattern 1 drawn in the right half area on the upper side from the center of the circular substrate 32 , a drawing pattern 2 drawn in the left half area on the upper side of the substrate, and a non-drawing area in the lower half area of the substrate. Drawing patterns 1 and 2 are figures axisymmetrical to the line passing through the center of the substrate and dividing the upper half as illustrated by the arrows drawn in the squares of drawing patterns 1 and 2 . Moreover, in FIG. 4, the scanning locus forming drawing pattern 1 is shown as locus 1 , the scanning locus forming drawing pattern 2 is shown as locus 2 , and the locus scanning the non-drawing area is shown is locus 3 .
[0049] The operation of the pattern generator, which draws this type of pattern, is now explained. As described above, the memory 404 includes the two memory banks, bank A and bank B, and SizeBank is the storage capacity (size) of the respective banks. Each of the two banks should have sufficient memory to hold the basic pixel sequence necessary to draw the longest locus within any cluster. Data of address [adrcrrnt] is represented with D [adrCrrnt].
[0050] As shown in FIG. 5, the pattern generator 40 performs processing by dividing the drawing area into fan-shaped area sectors of uniform size. In this example, a full circle of the scanning locus (1 track) is divided into 24 sectors. The number of sectors is appropriately selected in accordance with the drawing pattern. One or more consecutive sectors are grouped to define a cluster. In the illustrated example, cluster+ (sectors 0 to 5 ), cluster− (sectors 6 to 11 ) and the dummy cluster (sectors 12 to 23 ) are respectively assigned as sectors corresponding to drawing pattern 1 , drawing pattern 2 , and the non-drawing area. With cluster+, the memory address is scanned in the forward direction in correspondence with drawing pattern 1 to draw a basic pixel sequence on the substrate. With cluster−, the memory address is scanned in the reverse direction in correspondence with drawing pattern 2 to draw a basic pixel sequence in an opposite arrangement on the substrate. The number of pixels in cluster+ and cluster− is the same. With the non-drawing area, the addresses do not change and a simulated (zero) data is generated.
[0051] The processing of the memory controller 405 in the foregoing case is now explained with reference to the flowchart provided in FIG. 6 that illustrates the main routine of the memory controller 405 . FIG. 7 is a flowchart showing the data output subroutine, and FIG. 8 is a flowchart showing the subroutine for performing the dot (pixel) processing other than the sectors. FIG. 9 is a flowchart for explaining the subroutine of the final dot processing of the track. FIG. 10 is a flowchart for explaining the subroutine of the final dot processing of the cluster. FIG. 11 is a flowchart for explaining the subroutine of the final dot processing other than the clusters.
[0052] The operator, variable, and constant used in the respective flowcharts are defined as follows. The foregoing variable and the like are renewed as needed with a computer which monitors the operational mode of the device.
[0053] <=: Substitution from right side to left side
[0054] ++: Increment
[0055] −−: Decrement
[0056] =?: Comparison
[0057] cntDot_Sect: Variable indicating which number dot is to be processed within the sector (and within one track).
[0058] cntSect_Rev: Variable indicating which number sector is to be processed within the sector.
[0059] cntSect_Clst: Variable indicating which number sector is to be processed within the cluster.
[0060] cntTrack: Variable indicating which number track is to be processed within the drawing area.
[0061] adrCrrnt: Address for the memory controller to access the memory.
[0062] NDot_Clst: Number of dots structuring one sector on one track.
[0063] NSect_Rev: Number of sectors structuring one track; 24 in this example.
[0064] NSect_Clst: Number of sectors structuring one cluster; 6 in this example.
[0065] adrFrnt: Address corresponding to the top dot of the subsequent cluster+.
[0066] Variable adrCrrnt circulates at size 2×SizeBank. In other words, when adrCrrnt=2×SizeBank−1 and adrCrrnt is increased, adrCrrnt=0. Contrarily, when adrCrrnt=0 and adrCrrnt is decremented, adrCrrnt=2×SizeBank−1.
[0067] As shown in FIG. 6, the memory controller performs initialization when drawing start is ordered. That is, variables cntDot_Sect, cntSelect_Rev, cntSect_Clst, cntTrack, and adrCrrnt are respectively set to 0. Moreover, cluster+ is selected as the drawing area, and a corresponding flag is set in the drawing area (S 12 ).
[0068] Next, whether the track number currently being drawn has reached the track number of drawing finish is determined by checking whether the value of the variable cntTrack has reached the final value NTrack indicating the completion of the drawing track (S 14 ). When corresponding to the completion of the drawing track (S 14 ; Yes), the drawing processing is finished (S 16 ).
[0069] In the initialized state, since this does not correspond to the completion of the final drawing track (S 14 ; No), pixel data stored in the memory 404 is output (S 18 ). Whether the processing dot number of the current sector is the final dot number of such sector is determined by checking whether the variable cntDot_Sect is equivalent to NDot_Clst- 1 . Moreover, since a variable starts from “0”, the final dot number will be NDot_Clst- 1 (S 20 ). When the final dot of the sector has not been reached (S 20 ; No), the read-out number of the sector is increased by “1” (S 22 ), and processing other than the final dot of the sector is performed (S 24 ).
[0070] As shown in FIG. 8, the processing for dots other than the final dot of the sector determines whether the current drawing area is in the dummy area, cluster+ area or cluster− area (S 242 ). When in the dummy area, this subroutine is ended and the routine returns to step S 14 . When in the cluster+ area, the address for accessing the memory 404 is increased by “1” (S 244 ), and the routine returns to step S 14 . When in the cluster−, the address for accessing the memory 404 is decremented by “1” (S 246 ), and the routine returns to step S 14 and repeats the processing procedures.
[0071] When the processing dot number of the sector is the final dot number of such sector (S 20 ; Yes), the variable cntDot_Sect, which indicates the sector dot number, is set (reset) to “0” (S 20 ) in correspondence with the movement of the drawing point to the subsequent sector.
[0072] Next, whether the sector number is the final sector number of the track is determined by comparing the variable cntSect_Rev and the variable NSect_Rev- 1 (S 28 ). Moreover, when it is not the final sector (S 28 ; No), the variable cntSect_Rev is increased, and the sector number is increased by “1” (S 30 ).
[0073] Whether the area of the current drawing point is the dummy area is determined (S 32 ). When in the dummy area (S 32 ; Yes), as described below, “0” data is output, and, without reading from the memory 404 , the routine returns to step S 14 and repeats the processing procedures from that point.
[0074] When not in the dummy area (S 32 ; No), whether the sector of the current drawing point is the final sector within the relevant cluster is determined by comparing the variable cntSect_Clst and the variable NSect_Clst- 1 (S 40 ). When it is not the final sector (S 40 ; No), this implies the final dot of the sector (S 20 ; Yes), the variable cntSect_Clst is increased by “1” (S 42 ), and processing other than the final dot of the cluster is performed (S 44 ).
[0075] As shown in FIG. 9, the processing other than the final dot of the cluster determines whether the current drawing area is in the cluster+ area or cluster− area (S 442 ). When in the cluster+ area, the address for accessing the memory 404 is increased by “1” (S 444 ), and the routine returns to step S 14 . When in the cluster− area, the address for accessing the memory 404 is decremented by “1” (S 446 ), and the routine returns to step S 14 and repeats the processing procedures.
[0076] Next, when the sector of the current drawing point is the final sector within the relevant cluster (S 40 ; Yes), “0” is set to the variable cntSect_Clst in order to reset the count (S 42 ). Processing of the final dot of the cluster is then performed (S 44 ).
[0077] As shown in FIG. 10, the processing of the final dot of the cluster determines whether the current drawing area is in the cluster+ area or the cluster− area (S 442 ). When in the cluster+ area, an address in which “ 1 ” is added to the address adrCrrnt for accessing the current memory 404 as the address AdrFrnt of the top dot of the subsequent cluster is set (S 484 ). An area flag is set to the cluster (S 486 ), and the routine returns to step S 14 . When the current drawing area is in the cluster, the variable adrFmt is set to the variable adrCrrnt (S 488 ). An area flag is set to the dummy (S 490 ), and the routine returns to step S 14 and repeats the processing procedures.
[0078] Next, when it is the final sector of the track (S 28 ; Yes), “0” is set to the variable cntSect_Rev, the sector number is reset (S 50 ), the variable cntTrack is increased by “1”, and the processing track is set to the subsequent track (S 52 ). The final dot processing of the track is then performed (S 54 ).
[0079] As shown in FIG. 11, the final dot processing of the track determines whether the current drawing area is in the dummy area, cluster+ area or cluster− area (S 542 ). When in the dummy area, cluster+ is set to the area flag (S 548 ), and the routine returns to step S 14 and repeats the processing procedures.
[0080] When the current area is in the cluster+ area, “1” is added to the variable adrCrrnt, the access address of the memory is increased (S 544 ), cluster+ is set to the area flag (S 548 ), and the routine returns to step S 14 and repeats the processing procedures.
[0081] When the current area is in the cluster− area, the variable AdrFmt is set to the variable adrCrrnt (S 546 ), cluster+ is set to the area flag (S 548 ), and the routine returns to step S 14 and repeats the processing procedures.
[0082] The foregoing procedures are repeated from step 14 and address designation of the memory 404 is conducted in order to read data repeatedly.
[0083] As described above, the memory controller 405 designates the address of the memory 404 , reads dot (pixel) data, and draws the pattern.
[0084] [0084]FIG. 12 is a flowchart for explaining the generation of a data transmission request signal of the memory controller 405 . As described above, when the memory controller 405 finishes reading the data from bank A of the memory 404 , it transmits the data transfer request signal to the drawing point coordinate generation unit 401 . In this routine, the drawing point coordinate generation unit 401 generates SizeBank worth of coordinates, and the drawing data generation unit 402 transmits data of the respective drawing points to bank A. Similar processing is performed when data of bank B has been read.
[0085] Data transfer request processing foremost sets “0” to the data transfer request flag bankReq, and resets it (S 62 ). Next, whether the current readout position is at a prescribed position; that is, the sector top position of the top sector of the track in which the sector within the track is number 0 and the dot number within the sector is also number 0 is determined by checking whether the variable cntSect_Rev is “0” and the variable cntDot_Sect is “0” (S 64 ).
[0086] When it is in the sector top position of this track (S 64 ; Yes), whether the memory controller 405 accessed the final address of bank A or bank B of the memory 404 is determined with the value of the variable crossBorder described below (S 66 ). When the variable crossBorder value is not “1” and the final address has not yet been accessed (S 66 ; No), the routine returns to step S 64 without generating the data transfer request, and repeats the processing. When the final address has been accessed (S 66 ; Yes), “1” is set to the data transfer request flag bankReq, the data transfer request signal is sent to the drawing point coordinate generation unit 401 (S 68 ), and the routine returns to step S 64 and repeats the processing.
[0087] Meanwhile, when the current readout position is not the sector top position of the track (S 64 ; No), whether the data transfer request has been generated is determined by checking whether the variable bankReq is “1” (S 70 ). When the data transfer request has not been generated (S 70 ; No), the routine returns to step S 64 and repeats the processing. When the data transfer request has been generated (S 70 ; Yes), “0” is set to the variable bankreq, the variable bankreq is reset (S 72 ), and the routine returns to step S 64 . The variable bankreq is reset and the data transfer request will extinguish (S 62 ). One loop in the respective processing step 64 to step S 72 is in synchronization with the clock of the oscillator 407 . The data transfer request signal bankReq is transferred in synchronization with the rotation of the turntable in order to prevent the overwriting of necessary data on the memory. Reuse of the drawing data may be repeated within one full circle.
[0088] [0088]FIG. 13 is a flowchart for explaining the variable crossBorder which detects the bank switching. The variable crossBorder becomes “1” when the memory controller accesses the final address of bank A or B, and becomes “0” after the output of the variable bankReq signal.
[0089] Foremost, in the detection processing of the bank switching, the memory controller resets the variable crossBorder (S 82 ). Whether the current readout address of the memory 404 is the maximum address of bank A or the maximum address of bank B is determined by checking whether the variable adrCrrnt value indicating the readout address is equivalent to SizeBank−1 or 2×SizeBank−1 (S 84 ). When the readout address of the memory 404 is the final address of bank A or bank B (S 84 ; Yes), readout for one of the banks is ended, or the variable crossBorder indicating that the readout position is at the memory bank boundary is set to “1” (S 86 ), and the routine returns to step S 64 and repeats the processing.
[0090] When the readout address of the memory 404 is not the final address of bank A or bank B (S 84 ; No), whether the data transfer request has been generated is determined by checking whether the variable bankReq is “1” (S 88 ). When the data transfer request has not been generated (S 88 ; No), the routine returns to step S 84 and repeats the processing. When the data transfer request has been generated (S 88 ; Yes), the variable crossBorder is set to “0”, the variable crossBorder is reset (S 90 ), and the routine returns to step S 84 . The variable crossBorder is reset and the bank switching signal is extinguished (S 62 ). One loop of the respective processing step S 84 to step S 90 is in synchronization with the clock of the oscillator 407 . Thus, when the readout address passes through bank Boundary, the variable crossBorder becomes “1”, the variable bankreq becomes “1”, and is reset to “0” when the data transfer request signal is generated.
[0091] The repetition of this series of operations will reduce in half the processing necessary for generating the drawing point data in comparison to conventional processing, and high-speed drawing is thereby enabled.
[0092] [0092]FIG. 14 is an explanatory diagram for explaining another embodiment. In this illustration, shown is an example of drawing four patterns with one pattern data of the J-shaped arrow. Four patterns are formed by drawing loci 1 , 2 , 3 and 4 having mutually equivalent lengths, which form the locus of one track, with the same drawing data.
[0093] [0093]FIG. 15 depicts a layout of the cluster in such a case. The drawing area is divided into 24 sectors, and sectors 0 to 5 correspond to cluster0+, sectors 6 to 11 correspond to cluster1+, sectors 12 to 17 correspond to cluster2+, and sectors 18 to 23 correspond to cluster3+. Here, the “+” of the cluster represents that the address designation will be read out in the increased (forward) direction.
[0094] In this embodiment, the subroutine contents of the processing illustrated in FIG. 6 are changed as illustrated in FIG. 16 to FIG. 20.
[0095] In other words, as shown in FIG. 16, with the processing other than the final dot of the sector (S 24 ), the memory controller 405 increases the address for accessing the memory 404 by “1” (S 244 ), and the routine returns to step S 14 . Moreover, as shown in FIG. 17, with the processing of the final dot of the track (S 54 ), the memory controller 405 increases the address for accessing the memory 404 by “1” (S 544 ). Further, the value of the current address adrCrrnt is set to the variable adrBack indicating the memory address corresponding to the top dot of the cluster (S 545 ), and the routine returns to step S 14 . As shown in FIG. 18, with the processing of the final dot of the cluster (S 48 ), the memory controller 405 sets the address for accessing the memory 404 to adrBack, increases this by “1” (S 244 ), and the routine returns to step S 14 . As shown in FIG. 19, with the processing other than the final dot of the cluster (S 44 ), the memory controller 405 increases the address for accessing the memory 404 by “1” (S 244 ), and the routine returns to step S 14 .
[0096] In the second embodiment, in comparison to the case where the drawing point coordinate generation unit 401 and drawing data generation unit 402 generate the entire drawing point data, the data processing required will reduced by approximately 75% since the same data is used four times.
[0097] Therefore, according to the embodiments of the present invention, because data of the basic pattern is repeatedly used, or the dummy data is used to draw the overall pattern, the operational load required for data conversion is greatly reduced in comparison with methods that convert the overall pattern data.
[0098] As described above, according to the pattern drawing device of the present invention, since a pattern is drawn by repeatedly using the data converted in the r-θ coordinate system, the operational processing load of data conversion is reduced, and faster drawing becomes possible without requiring additional CPU performance. The resolution may also be improved thereby.
[0099] This application claims priority from Japanese Patent Application No. 2001-217152, filed Jul. 17, 2001, the entire contents of which are herein incorporated by reference. | The present invention provides a pattern drawing device that enables drawing with reduced operational processing loading of the associated CPU. Thus, in a pattern drawing device for forming a plurality of tracks disposed concentrically on a substrate to produce a two-dimensional pattern, a basic pixel sequence is prepared and used repeatedly in forward (positive) and/or reverse (negative) order to produce symmetric portions of the two-dimensional pattern. | 1 |
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/763,091, filed Jan. 21, 2004, which claims the benefit of provisional Application No. 60/441,797, filed Jan. 21, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to locking astragals and more particularly to locking astragals with self positioning seals.
[0004] 2. Background Art
[0005] Double entrance doorways are used in a large variety of residential homes and commercial buildings. Typically, an active door provides for day to day ingress and egress to and from the residential home or building, and an inactive door remains closed, except in instances when a width greater than or equal to the width of the active door and less than or equal to the width of the double entrance doorway is required, such as, for example, for delivery of furniture and/or equipment that cannot fit through the double entrance doorway. If large objects, such as furniture and/or equipment must pass through the double entrance doorway, both the normally inactive door and the active door of the doorway are opened, to create a wide entrance way, through which the furniture and/or equipment may pass.
[0006] Mating edges of the inactive door and the active door do not typically contact one another directly, but are separated by an astragal, the astragal being attached to the edge of an inactive leaf, the astragal extending the length of the inactive door, cushioning the closing of the active door and associated inactive leaf of the doorway, and sealing gaps between the inactive door and the active door.
[0007] The astragals often have upper and lower bolt-slide assemblies, which lock the astragals and the inactive doors to upper and lower portions of a door frame surrounding the double entrance door way. The upper and lower bolt-slide assemblies have bolts, which slide within upper and lower ends of the astragal, and are pushed outwardly from the inactive door to extend beyond the ends of the astragal, and are received by upper and lower apertures in the upper and lower portions of the door frame, also known as the header and threshold sill, respectively, to lock the inactive door in place.
[0008] Stationary seals are typically used at the lower end of the astragals for sealing and preventing drafts from entering the residential homes and/or commercial buildings through the double entrance doorways at the threshold sill. Since many different types, sizes, and shapes of thresholds are used, the drafts remain an unwanted by product of using the stationary sills. In many instances, the fixed size of the seals, and the materials used, for the stationary seals, are either too thick or too thin to fill the gap between the lower end of the astragal and the threshold sill, and, thus, result in not providing an adequate seal, and/or the seal degrading over time.
[0009] There is thus a need for an astragal having self positioning astragal seal that prevents unwanted drafts, is easy to use and install in a quick, convenient, and efficient manner, is durable and long lasting, maintains its seal against drafts over time, even in situations where repeated opening and closing of the inactive door is necessary, and can be used with a variety of astragals and threshold sills, types, sizes, and shapes of threshold sills, doors, and door frames.
[0010] The self positioning astragal seal should be capable of automatically positioning at least one seal at the lower end of the astragal adjacent the threshold sill, and prevent drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or of automatically positioning at least one seal at the upper end of the astragal adjacent the header, and prevent drafts at the vicinity of the header.
[0011] The self positioning astragal seal should independently position itself abuttingly adjacent the sill and/or the header when the bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame.
[0012] The astragal should also have a lock for locking the bolts into the extended position, and unlocking the bolts at a user's discretion, thus, provide additional security.
[0013] Different astragals have heretofore been known. However, none of the astragals adequately satisfies these aforementioned needs.
[0014] Locking astragals have been disclosed. However, none of these astragals adequately satisfies the aforementioned needs.
[0015] U.S. Pat. No. 6,666,486 (Fleming) discloses a slide bolt unit for releasably locking a door or window or the like, such as a semi-active door in a double door entry set. The slide bolt unit includes an elongated slide bolt carried by a channel-shaped housing adapted for recessed mounting into a side edge of a door or the like. An actuator tab on the slide bolt is exposed through a position control slot formed in the housing for fingertip actuation to displace the slide bolt between an advanced position engaging a keeper on an adjacent header or sill or the like to lock the door in a closed position, and a retracted position to permit door opening. The actuator tab has a slotted profile defining lock shoulders biased by a spring for releasably engaging and locking with the housing at opposite ends of the position control slot, and a narrowed central slide track for alignment with the position control slot upon fingertip depression of the actuator tab to permit sliding displacement of the actuator tab along the position control slot from one end to the other.
[0016] U.S. Pat. No. 6,491,326 (Massey, et al.) discloses a swing adaptable astragal with lockable unitary flush bolt assemblies, which includes an improved astragal assembly for double door entryways having an extruded aluminum frame into which upper and lower flush bolt assemblies are slidably disposed. The flush bolt assemblies include a relatively long metal bolt about which is injection overmolded a series of retainer guides, which ride in the frame. Locking mechanisms are also integrally overmolded onto the bolts. The frame and all components of the astragal assembly are symmetrical and reversible so that the assembly is non-handed; that is, it can be adapted to both a right hand swing and a left-hand swing inactive door. A strike plate mounting system and bottom-sealing block are provided, and the upper end of the assembly includes means for sealing against the stop of a head jamb. Drafts at the upper and lower inside corners of the doors of a double door entryway are thus prevented.
[0017] U.S. Pat. No. 6,457,751 (Hartman) discloses a locking assembly for an astragal, which is attached to the inactive door of a double door unit that is installed in a residence or a building. The astragal is attached to the edge of the inactive door in the space between the inactive door and the active door. A separate locking assembly is attached adjacent the top end of the door and also adjacent the bottom end of the door. A plug having an elongated locking bolt extending from the plug is mounted in the front end of the carriage member. Additional structure is provided for reciprocal travel of the carriage member between a locked position and an unlocked position.
[0018] U.S. Pat. No. 6,453,616 (Wright) discloses an astragal for use with exterior double door installations, such as french doors. When attached to the edge of the generally inactive door, the astragal provides a door stop for the active door, a seal to prevent intrusion of water, and a lock for the inactive door. The invention particularly pertains to extruded metal astragals capable of increasing the resistance of the double door system to high wind conditions. The astragal comprises a longitudinally extending base member that has at least one longitudinally extending channel and a pair of spaced apart outwardly extending legs. At least one bolt is slidably inserted in the channel adjacent to one of the first and second ends of the channel. The astragal is attached to the door by at least one cleat whose spaced apart arms engage the legs of the base member, providing resistance to the astragal rocking in relation to the door edge when the doors are under wind forces.
[0019] U.S. Pat. No. 5,857,291 (Headrick) discloses an astragal with integral sealing lock block, for use with a double door installation, which includes an astragal strip secured along the vertical edge of the inactive door. A lock block is slidably disposed in at least one end of said astragal strip and can be moved between an extended position for securing the door and a retracted position for freeing the door. The lock block has a projecting bolt receivable in a receptacle in the door frame, when the lock block is slid to its extended position. A gasket is secured to the end of the lock block, and the bolt passes through an opening in the gasket. The gasket engages and seals against the door frame when the lock block is in its extended position. Gaskets are also provided on the sides of the lock block for engaging and sealing against the doors of the double door installation. When the doors are closed and secured in place, the lock block and gasket assembly prevents drafts from flowing under the door installation beneath the astragal thereof.
[0020] U.S. Pat. No. 5,590,919 (Germano) discloses a T-astragal and sleeve for use with double swinging doors, such as french doors. The T-astragal includes a cap portion perpendicular to a base portion, wherein both the cap and base can be formed from wood, such as plywood or plastic. The T-astragal is a moulding that extends the full height of the swinging doors. One side of the base portion is fixably coupled to the free end of one of the swinging doors by nails or screws. The free end of the other swinging doors is able to swing up to and against a shoulder portion formed from the cap and base portions. A metal pipe shaped sleeve having an approximate length of one foot is partially positioned along the longitudinal axis of the T-astragal molding. A bolt slides within the sleeve from a rest position to an extended position, where the extended position locks the attached door to a matching slot in the door frame.
[0021] U.S. Pat. Nos. 5,350,207 and 5,328,217 (Sanders) disclose a locking astragal for attachment to an inactive leaf of a double doorway, in which an elongated astragal casing has a channel and bolt-slide assemblies mounted slidably within the channel. Each bolt-slide assembly includes a latching member and bolt. By depressing the latching member, the latching member can slide through the channel to extend and lock the bolts into indentations in the upper and lower surfaces of the door frame. The bolts may also be retracted back into the astragal to open the inactive leaf. Each latching member has an integral spring, which simplifies fabrication and assembly.
[0022] U.S. Pat. No. 4,999,950 (Beske, et al.) discloses an inwardly swinging door assembly, which includes a door member hingedly mounted to a frame. A multi-point lock engages the frame at more than one point. Weather stripping is cooperatively connected to the edged surfaces. A pressure equalization member is cooperatively connected to the frame, for engaging the weather strip connected to the bottom edged surface.
[0023] U.S. Pat. No. 4,644,696 (Bursk) discloses a patio door assembly for removable astragal, in which a double door installation includes an astragal, which is removably mounted in the head jamb and sill portions of a door frame independently of the doors, and which includes a locking mechanism in one door which incorporates a bolt arranged to project through the astragal into the other door to effect firm locking of both doors to each other and to the astragal. The mounting for the astragal in the door frame includes a sill anchor, which is fixed on the sill, and is provided with a vertical projection that fits in complementary relation within the hollow lower end of the stem portion of the astragal. At its upper end, the astragal is releasably secured to the head jamb by a latch assembly and an anchor of generally inverted cup shape, which is set in a complementary recess in the head jamb and functions as a keeper for the flush bolt, which is mounted for vertical sliding movement in the hollow upper end of the astragal stem portion.
[0024] U.S. Pat. No. 4,535,578 (Gerken) discloses a seal-actuating mechanism for a wall panel, which when mounted in a wall panel of the type having channel-shaped opposed frame members can be installed, replaced or repaired without removing the exterior finished surface of the wall panel. The seal-actuating mechanism includes a rotatable shaft mounted between the opposed frame members, and an operator member including pivot lever means is mounted on each end thereof. At least one tension member is disposed in the cavity of each frame member, one end of which is coupled to the pivot lever means, and the other end of which is coupled to the shiftable seal assembly, so that when the shaft is rotated the seal assembly is shifted respectively from an extended unlatched position to its retracted latched position.
[0025] U.S. Pat. No. 4,489,968 (Easley) discloses a selectively operable doorstop for converting a double-acting door to a single-acting door. A selectively removable or retractable doorstop for converting double-acting, double or single doors to a single-acting, single door, for permitting control over traffic into and out of public premises at desired times. The doorstop includes an intercept portion which can be selectively removably or retractably inserted into the path of a double-acting door thereby restricting it to opening in one direction only. Different embodiments of the doorstop are provided respectively for temporary or permanent mounting on or in a doorjamb, or on or in the stile of a temporarily fixed-in-place door, thus giving a selection of options for any specific situation.
[0026] U.S. Pat. No. 4,488,378 (Symon) discloses an entrance for buildings, which comprises first and second doors mounted in a common door frame, each door including a lock stile positioned adjacent a lock stile of the other door when the doors are closed. A panic device is mounted on at least one of the doors for emergency opening thereof, and a retractable latch is extended between the stiles of the doors when closed, for minimizing or eliminating the unauthorized forced separation of the stiles into a position wherein the panic device can be actuated with an implement inserted from outside the entrance to release and open the door. Mechanism is included for interconnecting the latch and the panic device for retraction of the latch, when the panic device is actuated for opening the door, thus, providing both a substantially safe and secure entrance system.
[0027] U.S. Pat. No. 4,429,493 (St. Aubin) discloses an astragal housing seal and lock, for use in a double door assembly having an active door and a relatively inactive door. The astragal has a vertically extending mullion housing, which is attached to the free edge of the relatively inactive door. A vertically extending slide section is mounted on the mullion housing on the sealing side of the free edge of the inactive door. The slide section extends from the free vertical edge of the inactive door, when the active door is in the closed position. The slide section is vertically movable from an unlocked position to a locked position, wherein the slide section is moved vertically downward with respect to the mullion housing to engage the sill/threshold of the door frame, thereby preventing movement of the inactive door.
[0028] U.S. Pat. No. 4,262,450 (Anderson) discloses a sliding door structure, including an outer frame, at least one fixed and one movable door panel, and a screen door, the frame including a head having a single, inwardly extending movable door panel guiding fin and all mitered corners, which corners include integral, offset abutment structure for insuring proper alignment of the corners in assembly, weather stripping at both the top and bottom rail of both the fixed and movable door panels, bottom adjusting structure for the movable door panel, and two-member glazing structure for the door panels, capable of resisting high wind force and permitting glazing of the door panels from the inside. The frame and door panels include substantially universal and reversible members. Resilient bumpers, a weather stop, and prowler lock structure permitting locking of the sliding door structure of the movable door panel in a number of selected positions are also disclosed.
[0029] U.S. Pat. No. 4,225,163 (Hubbard, et al.) discloses a panic device actuator for a door, which includes apparatus for unlatching a door mounted in a door frame and one or more elements movable for retracting one or more door latches normally engaged with the door frame for positively locking the door. The panic actuator includes a relatively large panel having an enlarged outer face responsive to pressure applied at any area thereon for unlocking the door without a key. A mounting system is provided for supporting the panel on the door for controlled movement in a horizontal direction in continuous parallelism with the face of the door in a direction normal to the door face. A linkage is provided for interconnecting the panel and the door latching element(s) for moving the same to unlock the door latches in response to pressure movement of the panel on the door.
[0030] U.S. Pat. No. 4,204,369 (Hubbard) discloses an entrance door system, which includes an automatic astragal along an edge of a door and an operator on the door for controlling one or more latch assemblies normally engaged to latch an edge of the door with a member of a door frame in which the door is mounted. The latch assembly is mounted on the door to normally latch the door with the door frame, when the door is closed, and the latch is releasable to an unlatched condition, so that the door may be opened. The elongated astragal is mounted in parallel along the edge of the door and is guided for parallel movement between a retracted and an extended position. The door operator is effective for moving the astragal between retracted and extended positions, and the astragal is interconnected for moving the latch assembly to release the latching engagement, when the astragal is moved to the retracted position, so that the door may be opened.
[0031] U.S. Pat. No. 4,058,332 (DiFazio) discloses an astragal and flush bolt assembly to be secured to a relatively stationary member, such as a door jamb or to the edge of an inactive door of a pair of double doors or the like. The astragal assembly includes a flat metal body mounted on the edge of the stationary member and a metal stop member secured to the body along one edge thereof. The flat body includes first and second spaced apart legs extending outwardly from the stationary member, with the flat body and legs defining a channel to receive and retain a door latch bolt from the active door. The stop member prevents movement of the door in a first direction, and when the latch bolt is engaged in the channel, the channel and the latch bolt prevent the door from moving in the opposite direction. A pair of flush bolts are slidably mounted in the channel, one adjacent each end thereof, so that when the astragal assembly is utilized with double doors, the flush bolts are moved to engage the header and sill, respectively, to hold the inactive door stationary. The astragal body is secured to the stop member by a thermal barrier or thermal break structure to provide thermal insulation between the inside and the outside of the doors. The stop member also includes a weather strip to form a tight seal against the active door, and when metal doors or metal covered doors are used, the weather strip may include a magnetic member to form a seal against the active door.
[0032] U.S. Pat. No. 4,052,819 (Beischel, et al.) discloses a double door astragal, which comprises a rigid support member securable to the vertical edge portion of a normally inactive door, a rigid cover member securable in a plurality of positions relative to the rigid support member and mounted on the rigid support member with a U-shaped portion having an outer leg extending into the swinging path of the active door, and a flexible sealing member secured to the rigid support member and extending into the opening formed by the U-shaped portion of the cover member so as to contact the outside surface of the active door when the vertical edge portions of the active and inactive doors are in abutting relation, to provide an adjustable seal against weather.
[0033] U.S. Pat. No. 4,009,537 (Hubbard) discloses an automatic astragal assembly for inclusion or attachment to a door edge, comprising an elongated astragal housing mounted on the door and having an outwardly opening longitudinal recess therein, an elongated astragal slidably mounted in the recess, means supporting the astragal in the recess for upward and inward relative movement in the housing in response to lifting of the astragal from lifting means mounted on an inside surface of the door, the lifting means including a lift slide mounted on the housing for reciprocal vertical movement and having an L-shaped slot defined therein with an interconnecting horizontal and vertical section and a dead lock pin engaged in the slot and secured to the astragal for elevating the same upon lifting movement of the slide, the vertical section of the slot and the dead lock pin engaging to prevent elevation of the astragal from pressure exerted against an outer edge of the astragal tending to force the astragal horizontally into the recess.
[0034] U.S. Pat. No. 3,997,201 (DeSchaaf, et al.) discloses a latch structure for releasably locking a door to a cabinet, including switch structure for permitting operation of electrical apparatus associated therewith to be operated only when the door is in the latched closed position. The switch is hidden within the door behind the latch bolt, so as to be operated substantially only by the strike which has a preselected configuration, to effect the latching and switch operating operations. The bolt may be operated manually to release the door from the latched condition. A pivotally mounted operator is also disclosed for effecting the unlatching movement of the bolt.
[0035] U.S. Pat. No. 3,940,886 (Ellingson, Jr). discloses a door locking structure forming a panic exit device, consisting of an elongated housing recessed within the leading edge of a door structure, an operating rod including latch bolts disposed in the housing, an astragal seated within a channel formed in the leading edge of the housing, link members connecting the rod and the astragal, and operating means carried by the housing operating the rod to move the astragal inwardly and outwardly of the channel, a plurality of cam headed lug members carried by the rod, a plurality of studs corresponding to the cam members extending rearwardly of the astragal, whereby latching movement of the rods moves the cam members to engage their corresponding studs to hold the astragal in an outward or extended dead locked position.
[0036] Astragals with seals and other astragals have been disclosed. However, none of these astragals adequately satisfies the aforementioned needs.
[0037] U.S. Pat. No. 5,857,291 (Headrick) discloses an astragal with integral sealing lock block, for use with a double door installation, which includes an astragal strip secured along a vertical edge of an inactive door. A lock block is slidably disposed in at least one end of the astragal strip, and can be moved between an extended position, for securing the inactive door, and a retracted position for freeing the inactive door. The lock block has a projecting bolt receivable in a receptacle in a door frame, when the lock block is slid to its extended position. A gasket is secured to an end of the lock block, and the bolt passes through an opening in the gasket. The gasket engages and seals against the door frame, when the lock block is in its extended position. Gaskets are also provided on the sides of the lock block, for engaging and sealing against the doors of the double door installation. When the doors are closed and secured in place, the lock block and gasket assembly prevents drafts from flowing under the door installation beneath the astragal thereof.
[0038] U.S. Pat. Nos. 5,350,207 and 5,328,217 (Sanders) disclose locking astragals, for attaching to an inactive leaf of a double doorway, and in particular U.S. Pat. No. 5,350,207. Each of the locking astragals has an elongated astragal casing, which has a channel and bolt-slide assemblies mounted slidably within the channel. Each bolt-slide assembly includes a latching member and bolt. By depressing the latching member, the latching member can slide through the channel, to extend and lock the bolts into indentations in upper and lower surfaces of a door frame. The bolts may also be retracted back into the astragal, to open the inactive leaf. Each of the latching members has an integral spring, which simplifies fabrication and assembly.
[0039] U.S. Pat. No. 6,491,326 (Massey, et al) discloses a swing adaptable astragal with lockable unitary flush bolt assemblies, for double door entryways, which includes an extruded aluminum frame into which upper and lower flush bolt assemblies are slidably disposed. The flush bolt assemblies include a long metal bolt about which is injection overmolded a series of retainer guides, which ride in the frame. Locking mechanisms are also integrally overmolded onto the bolts. The frame and all components of the astragal assembly are symmetrical and reversible, so that the assembly is non-handed; that is, it can be adapted to both a right hand swing and a left-hand swing inactive door. A strike plate mounting system and bottom-sealing block are provided, and the upper end of the assembly includes means for sealing against a stop of a head jamb. Drafts at upper and lower inside corners of the doors of a double door entryway may be prevented.
[0040] U.S. Pat. No. 6,125,584 (Sanders) discloses an automatic door bottom for a hinged door, which is pivotable to be positioned over a sill when closed, the door having a hinge side and a width, the door bottom having an inverted channel having an open bottom, a length corresponding to the door width and a hinge end corresponding to the hinge side of the door; a sealing member having a length corresponding to the length of the channel, the sealing member being housed in the channel and being movable vertically downwardly into a sealing position, in which the sealing member contacts the sill when the door is closed; and a displacement mechanism installed in the channel and coupled to the sealing member, for moving the sealing member vertically into the sealing position in response to closing of the door, wherein the displacement mechanism is coupled to the sealing member at a plurality of points along the length of the sealing member, and is operative to move the end of the sealing member at the hinge side of the channel into the sealing position, prior to the remainder of the sealing member, during closing of the door.
[0041] U.S. Pat. No. 6,457,751 (Hartman) discloses a locking assembly for an astragal, which can be attached to an inactive door of a double door unit of a residence or a building. The astragal is attached to an edge of the inactive door in space between the inactive door and active door. A separate locking assembly is attached adjacent a top end of the door and also adjacent a bottom end of the door. A plug having an elongated locking bolt extending therefrom is mounted in a front end of a carriage member. Additional structure is provided for reciprocal travel of the carriage member between a locked position and an unlocked position.
[0042] U.S. Pat. No. 5,335,450 (Procton) discloses an astragal, which has an exterior aluminum extrusion and an interior wooden portion. The exterior extrusion includes a pair of rearwardly extending center walls, which form a channel for receiving the wooden interior portion. Attachments and door hardware can be installed in the wooden interior portion, while the extruded exterior acts as cladding.
[0043] U.S. Pat. No. 5,590,919 (Germano) discloses a T-astragal and sleeve for door, for use with double swinging doors, such as for french doors. The T-astragal includes a cap portion perpendicular to a base portion, wherein both the cap and base can be formed from wood, such as plywood or plastic. The T-astragal is a molding that extends the full height of the swinging doors. One side of the base portion is fixably coupled to the free end of one of the swinging doors by nails or screws. The free end of the other swinging doors is able to swing up to and against a shoulder portion formed from the cap and base portions. A metal pipe shaped sleeve having an approximate length of one foot is partially positioned along the longitudinal axis of the T-astragal molding. A bolt slides within the sleeve from a rest position to an extended position, where the extended position locks the attached door to a matching slot in the door frame.
[0044] U.S. Pat. No. 4,429,493 (St. Aubin) discloses an astragal housing seal and lock, for use in a double door assembly having an active door and a relatively inactive door. The astragal has a vertically extending mullion housing, which is attached to a free edge of the relatively inactive door. A vertically extending slide section is mounted on the mullion housing on a sealing side of the free edge of the inactive door. The slide section extends from the free vertical edge of the inactive door, when the active door is in the closed position. The slide section is vertically movable from an unlocked position to a locked position, wherein the slide section is moved vertically downward, with respect to the mullion housing, to engage the sill/threshold of the door frame, thereby preventing movement of the inactive door.
[0045] U.S. Pat. No. 4,058,332 (DiFazio) discloses an astragal and flush bolt assembly to be secured to a relatively stationary member such as a door jamb or to the edge of an inactive door of a pair of double doors or the like. The astragal assembly includes a flat metal body mounted on the edge of the stationary member and a metal stop member secured to the body along one edge thereof. The flat body includes first and second spaced apart legs extending outwardly from the stationary member, with the flat body and legs defining a channel to receive and retain a door latch bolt from the active door. The stop member prevents movement of the door in a first direction, and when the latch bolt is engaged in the channel, the channel and latch bolt prevent the door from moving in the opposite direction. A pair of flush bolts are slidably mounted in the channel, one adjacent each end thereof, so that when the astragal assembly is utilized with double doors, the flush bolts are moved to engage the header and sill, respectively, to hold the inactive door stationary. The astragal body is secured to the stop member by a thermal barrier or thermal break structure, to provide thermal insulation between the inside and the outside of the doors. The stop member also includes a weather strip to form a seal against the active door, and when metal doors or metal covered doors are used, the weather strip may include a magnetic member to form a seal against the active door.
[0046] U.S. Pat. No. 6,453,616 (Wright) discloses an astragal for use with exterior double door installations, such as french doors. When attached to the edge of a generally inactive door, the astragal provides a door stop for an active door, a seal to prevent intrusion of water, and a lock for the inactive door. The invention particularly pertains to extruded metal astragals, capable of increasing the resistance of the double door system to high wind conditions. The astragal comprises a longitudinally extending base member that has at least one longitudinally extending channel and a pair of spaced apart outwardly extending legs. At least one bolt is slidably inserted in the channel adjacent to one of the first and second ends of the channel. The astragal is attached to the door, by at least one cleat whose spaced apart arms engage the legs of the base member, providing resistance to the astragal rocking in relation to the door edge, when the doors are subject to wind forces.
[0047] U.S. Pat. No. D293,719 (Stepanian) discloses a combined astragal extrusion and seal.
[0048] For the foregoing reasons, there is a need for a self positioning astragal seal that prevents unwanted drafts, is easy to use and install in a quick, convenient, and efficient manner, is durable and long lasting, maintains its seal against drafts over time, even in situations where repeated opening and closing of the inactive door is necessary, and can be used with a variety of astragals and threshold sills, types, sizes, and shapes of threshold sills, doors, and door frames. The self positioning astragal seal should be capable of automatically positioning at least one seal at the lower end of the astragal adjacent the threshold sill, and prevent drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or of automatically positioning at least one seal at the upper end of the astragal adjacent the header, and prevent drafts at the vicinity of the header. The self positioning astragal seal should independently position itself abuttingly adjacent the sill and/or the header when the bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame. The astragal should also have a lock for locking the bolts into the extended position, and unlocking the bolts at a user's discretion, thus, provide additional security.
SUMMARY
[0049] The present invention is directed to a locking astragal with a self positioning astragal seal that automatically positions at least one seal at the lower end of an astragal adjacent the threshold sill of a door frame, and prevent drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or of automatically positions at least one seal at the upper end of the astragal adjacent the header of the door frame, and prevent drafts at the vicinity of the header. The self positioning astragal seal independently positions itself abuttingly adjacent the sill and/or the header when the astragal's bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame. The self positioning astragal seal prevents unwanted drafts, is easy to use and install in a quick, convenient, and efficient manner, is durable and long lasting, maintains its seal against drafts over time, even in situations where repeated opening and closing of the inactive door is necessary, and can be used with a variety of astragals and threshold sills, types, sizes, and shapes of threshold sills, doors, and door frames. The astragal also has a lock for locking the bolts into the extended position, and unlocking the bolts at a user's discretion, thus, provide additional security.
[0050] The locking astragal with self positioning astragal has a bolt having a bolt retracted position and a bolt extended position, spring means and a latching mechanism having a latch; the latching mechanism retracting the bolt into the bolt retracted position and compressing the spring means when the latch is retracted to a latch retracted position; the latching mechanism releasing the bolt and the spring means forcing the bolt into the bolt extended position and the latch into a latch released position when the latch is released, a self positioning astragal seal, comprising: a seal block having a catch and a hole, the bolt slidably disposed through the hole, the catch catching a portion of the bolt and holding the seal block in a seal block retracted position when the bolt is in the bolt retracted position and releasing the seal block when the bolt is in the bolt extended position; spring means forcing the seal block into a seal block extended position when the seal block is released, and an astragal lock, which locks the bolt into the bolt extended position when the astragal lock is locked and unlocks the bolt when the astragal lock is unlocked, which when unlocked allows the bolt to be moved from the bolt extended position to the bolt retracted position and from the bolt retracted position to the bolt extended position. The astragal lock has a lock cylinder, which is rotatably mounted to the astragal, the lock cylinder having an axis substantially perpendicular to the axis of the astragal bolt, and a notch, which has an axis substantially perpendicular to the axis of the lock cylinder, the notch preferably having an arcuate shape and slidably matingly accepting the astragal bolt therethrough when the astragal lock is unlocked and in an unlocked position, the lock cylinder preventing movement of the astragal bolt and locking the astragal bolt in the bolt extended position, when the lock cylinder is rotated into a locked position, which is substantially perpendicular to the unlocked position. The lock cylinder also has a stop, which limits the angular rotation of the lock cylinder to substantially ninety degrees.
[0051] An astragal having features of the present invention comprises: a bolt having a bolt retracted position and a bolt extended position; a lock having a locked position and an unlocked position, the lock locking the bolt into the bolt extended position when the bolt is in the bolt extended position and the lock is in the locked position, the lock unlocking the bolt when the lock is in the unlocked position; a seal block having a catch and a hole, the bolt slidably disposed through the hole, the catch catching a portion of the bolt and holding the seal block in a seal block retracted position when the bolt is in the bolt retracted position and releasing the seal block when the bolt is in the bolt extended position; spring means forcing the seal block into a seal block extended position when the seal block is released.
DRAWINGS
[0052] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0053] FIG. 1 is a perspective view of a locking astragal with a self positioning astragal seal, constructed in accordance with the present invention, shown locked with a bolt and the self positioning astragal seal extended;
[0054] FIG. 1A is a perspective section view of the locking astragal with the self positioning astragal seal of FIG. 1 ;
[0055] FIG. 1B is a section view of the locking astragal with the self positioning astragal seal of FIG. 1 ;
[0056] FIG. 1C is an exploded section view of the locking astragal with the self positioning astragal seal of FIG. 1 ;
[0057] FIG. 2 is a perspective view of a locking astragal with the self positioning astragal seal, shown unlocked with the bolt and the self positioning astragal seal retracted;
[0058] FIG. 2A is a perspective section view of the locking astragal with the self positioning astragal seal of FIG. 2 ;
[0059] FIG. 2B is a section view of the locking astragal with the self positioning astragal seal of FIG. 2 ;
[0060] FIG. 2C is an exploded section view of the locking astragal with the self positioning astragal seal of FIG. 2 ;
[0061] FIG. 3 is an exploded view of the locking astragal with the self positioning astragal seal and a latching mechanism;
[0062] FIG. 4 is an exploded view of selected components of the locking astragal with the self positioning astragal seal and a portion of the latching mechanism of FIG. 3 ;
[0063] FIG. 5 is an exploded view of the latching mechanism of FIG. 3 ;
[0064] FIG. 6 is a perspective view of entrance doors, comprising an inactive door, shown in a closed position, and an active door;
[0065] FIG. 7 is a perspective view of the inactive door, showing the locking astragal with the self positioning astragal seal installed on the inactive door, shown locked with the bolt and the self positioning astragal seal extended;
[0066] FIG. 8 is a section view of the locking astragal with the self positioning astragal seal, shown locked with the bolt and the self positioning astragal seal extended;
[0067] FIG. 9 is a section view of the locking astragal with the self positioning astragal seal, shown locked with the bolt and the self positioning astragal seal extended;
[0068] FIG. 10 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0069] FIG. 11 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0070] FIG. 12 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0071] FIG. 13 is another section view of the locking astragal with the self positioning astragal seal, with the bolt and the self positioning astragal seal extended;
[0072] FIG. 14 is another section view of the locking astragal with the bolt and the self positioning astragal seal, with the self positioning astragal seal extended;
[0073] FIG. 15 is a section view of the latching mechanism of FIG. 3 , along a portion of line 8 - 8 of FIG. 7 , with the bolt and the self positioning astragal seal extended;
[0074] FIG. 16 is a section view of the locking astragal with the self positioning astragal seal, along a portion of line 8 - 8 of FIG. 7 , shown locked with the bolt and the self positioning astragal seal extended;
[0075] FIG. 17 is a section view of the locking astragal with the self positioning astragal seal, shown unlocked with the bolt and the self positioning astragal seal retracted;
[0076] FIG. 18 is another section view of the locking astragal with the self positioning astragal seal, shown unlocked with the bolt and the self positioning astragal seal retracted;
[0077] FIG. 19 is an exploded view of an upper bolt and latching mechanism of the astragal of FIG. 7 ;
[0078] FIG. 20 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door;
[0079] FIG. 21 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door;
[0080] FIG. 22 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door;
[0081] FIG. 23 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door;
[0082] FIG. 24 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door;
[0083] FIG. 25 is a section view of an alternate embodiment of a locking astragal with a self positioning astragal seal, shown installed on the inactive door and also showing the active door; and
[0084] FIG. 26 is a perspective view of a locking astragal, constructed in accordance with the present invention, shown locked with a bolt extended;
[0085] FIG. 26A is a perspective section view of the locking astragal of FIG. 26 ;
[0086] FIG. 26B is a section view of the locking astragal of FIG. 26 ;
[0087] FIG. 26C is an exploded section view of the locking astragal of FIG. 26 ;
[0088] FIG. 27 is a perspective view of the locking astragal of FIG. 26 , shown unlocked with the bolt retracted;
[0089] FIG. 27A is a perspective section view of the locking astragal of FIG. 27 ;
[0090] FIG. 27B is a section view of the locking astragal of FIG. 27 ;
[0091] FIG. 27C is an exploded section view of the locking astragal of FIG. 27 ;
[0092] FIG. 28 is an exploded view of the locking astragal of FIGS. 26 and 27 and a latching mechanism; and
[0093] FIG. 29 is another exploded view of the locking astragal of FIGS. 26 and 27 and the latching mechanism of FIG. 28 ;
REFERENCE NUMERALS
[0094] These and other features, aspects, and advantages of the present invention will become better understood with regard to the references and associated reference numerals of the following description and accompanying drawings where:
1 locking astragal with self positioning astragal seal 2 lock 10 self positioning astragal seal 12 seal block 14 seal block hole 16 shoulder 18 compression spring 20 end seal 30 astragal 42 inactive door edge 44 inactive door 46 sill 48 door frame 52 elongated guide 54 elongated guide channel 56 lower bolt 58 shoulder 60 astragal bottom 74 seal block bottom 78 seal block base 80 face plate 82 guide block 84 “T” shaped member 86 compression spring guide holder 88 compression spring bottom end 90 base top 92 barrel 94 barrel extension 96 barrel extension arcuate interior 98 extension 100 extension arcuate interior 102 T top portion 104 arcuate interior 105 angled edges 106 shoulder 108 face plate reinforcement 110 face plate stop 112 guide block edge stop 114 guide block reinforcement 116 guide block stop 130 astragal recess 132 astragal extension stop 134 astragal retraction stop 136 astragal opposing side 138 astragal side portion 140 astragal side 142 side channel 144 threaded hole 146 threaded hole 148 set screw 150 angled longitudinal channel edge 152 compression spring top end 154 seal hole 156 face seal 158 face plate exterior side 160 active door edge 162 active door 164 header 166 seal peel off adhesive strip 168 face seal peel off adhesive strip 180 astragal housing 182 longitudinal channel 184 longitudinal retention guide 185 channel base 186 lockset strike 188 deadbolt strike 190 upper bolt 191 upper bolt assembly 192 lockset 194 deadbolt 196 lockset cover plate 198 deadbolt cover plate 199 screws 200 latching member 202 pull block 204 elongated connector 206 compression spring 208 slide plate 210 bolt lower portion 212 bolt mid portion 214 bolt upper portion 216 bolt slot 218 bolt hole 220 end pin 222 elongated connector hole 224 pin 226 pin 228 pull block track 230 pull block retention track 232 pull block retention track 234 pull block channel 236 pull block channel 238 pull block notch 240 pull block base 242 pull block notch 244 pull block bearing notch 246 pull block notch side 248 lever arm receiving hole 250 lever arm 252 trunnion 254 spring tail 256 latching dog 260 slide plate retraction hole 262 slide plate extension hole 264 slide plate notch 266 slide plate end tab 268 slide plate projecting tab 270 slide plate projecting notch 280 elongated guide notched recess 282 elongated guide end 284 pull block arrow marking 286 arcuate side 288 arcuate base 289 oblique angled side portion 290 longitudinally disposed side channel base wall 291 longitudinally disposed side channel side wall 292 lock mounting hole 293 lock cylinder 294 arcuate keyway 295 arcuate tab 296 lock stop 297 unlock stop 298 head 299 slot 300 alternate astragal housing 302 saw tooth recess 304 finned tail 306 foam weather strip 308 cavity 310 alternate astragal housing 312 thermal break 314 slot 320 alternate astragal 322 alternate astragal housing 324 cover 326 outer seal 328 inner seal 330 alternate astragal 332 thermal break 340 alternate astragal 342 cover element 344 saw tooth recess 346 finned tail 348 weather strip seal 349 inner seal 350 alternate astragal 352 thermal break 400 mounting shoulder 402 bearing surface 404 astragal longitudinal wall 406 lock contact area 408 unlock contact area 410 lock cylinder wall 412 bolt top contact portion 414 other bolt top portion 416 bolt portion 500 locking astragal
DESCRIPTION
[0252] The preferred embodiments of the present invention will be described with reference to FIGS. 1-29 of the drawings. Identical elements in the various figures are identified with the same reference numbers.
[0253] FIGS. 1-19 show an embodiment of the present invention, a locking astragal with self positioning astragal seal 1 , which has a lock 2 and a self positioning astragal seal 10 . The self positioning astragal seal 10 comprises a seal block 12 having a substantially centrally disposed hole 14 therethrough, a shoulder 16 , compression springs 18 , and end seal 20 , for use with an astragal 30 .
[0254] The astragal 30 is mounted to edge 42 of inactive door 44 , and the self positioning astragal seal 10 is mounted to the astragal 30 adjacent sill 46 of door frame 48 , as shown in FIGS. 6 and 7 . The astragal 30 has an elongated guide 52 having a substantially centrally disposed longitudinal channel 54 and a bolt 56 having a shoulder 58 , the bolt 56 slidably mounted therein the substantially centrally disposed longitudinal channel 54 .
[0255] The astragal seal shoulder 16 catches the bolt shoulder 58 when the bolt 56 is retracted to a retracted position, as shown in FIGS. 2, 17 , and 18 , and is released from the bolt shoulder 58 when the bolt 56 is extended to an extended position, as shown in FIGS. 1 and 7 - 16 , the compression springs 18 forcing the seal block 12 into an extended position, when the bolt 56 is in the bolt extended position. The seal block 12 is, thus, retracted to a retracted position, the astragal seal shoulder 16 catching and abutting the bolt shoulder 58 , and holding the seal block 12 in a seal block retracted position when the bolt 56 is in the bolt retracted position. The seal block 12 is extended to the seal block extended position, when the astragal seal shoulder 16 is released from the bolt shoulder 58 , the compression springs 18 forcing the seal block 12 into the seal block extended position, when the bolt 56 is in the bolt extended position. The astragal seal shoulder 16 , thus, acts as a catch, which catches the bolt shoulder 58 when the bolt 56 is retracted to the bolt retracted position, and is released from the bolt shoulder 58 when the bolt 56 is extended to the bolt extended position.
[0256] FIGS. 1 , 1 A- 1 C, 7 - 9 , and 16 show the bolt 56 locked into the bolt extended position with the lock 2 locked. FIGS. 2 , 2 A- 2 C, 17 , and 18 show the bolt 56 in the bolt retracted position with the lock 2 unlocked.
[0257] The self positioning astragal seal 10 automatically and independently adjusts itself to fit snugly and fill any gaps between bottom 60 of the astragal 30 and the sill 46 of the door frame 48 , when the bolt 56 is in the bolt extended position, thus, preventing unwanted drafts between bottom 74 of the seal block 12 and the sill 46 of the door frame 48 , the compression springs 18 forcing the seal block 12 opposingly away from the bottom 60 of the astragal 30 and forcing the end seal 20 , which is affixed to the bottom 74 of the seal block 12 , to abut the sill 46 of the door frame 48 .
[0258] The seal block 12 has base 78 , face plate 80 , and guide block 82 , which is adjacent the inactive door edge 42 , when the self positioning astragal seal 10 and the astragal are installed on the inactive door 44 and the seal block 12 is in the retracted position, the face plate 80 and the guide block 82 being substantially perpendicular to the base 78 , and substantially parallel one to the other.
[0259] The seal block 12 has substantially “T” shaped member 84 integral with the guide block 82 and compression spring guide holders 86 , which hold the compression springs 18 in place, the compression springs 18 being mounted about the compression spring holders 86 , with bottom ends 88 of the compression springs 18 abutting top 90 of the base 78 . The seal block 12 has barrel 92 integral with the guide block 82 , the barrel 92 having the substantially centrally disposed hole 14 therethrough to the bottom 74 of the seal block 12 , the bolt 56 slidable therethrough the substantially centrally disposed hole 14 , and the seal block 12 slidable about the bolt 56 . The barrel 92 has extension 94 , which is integral with the barrel 92 , having arcuate interior 96 , which is substantially collinear with the interior of the barrel 92 , and extension 98 having the shoulder 16 and arcuate interior 100 . The substantially “T” shaped member 84 has T top portion 102 , which has arcuate interior 104 , angled edges 105 , and shoulder 106 . The face plate 80 has reinforcements 108 having stops 110 . The guide block 82 has edge stops 112 and reinforcements 114 having stops 116 . The compression spring holders 86 have splines for reinforcement.
[0260] The elongated guide 52 of the astragal 30 has recesses 130 , which have extension stops 132 and retraction stops 134 at opposing ends thereof, and substantially planar opposing side 136 . The elongated guide 52 of the astragal 30 has substantially planar side portions 138 adjacent the recesses 130 , which oppose the substantially planar opposing side 136 , and sides 140 , which are substantially perpendicular to the substantially planar side portions 138 , the recesses 130 , and the substantially planar opposing side 136 . The elongated guide 52 also has opposing longitudinally disposed side channels 142 . The substantially planar side portions 138 and the substantially planar opposing side 136 have threaded holes 144 and 146 , respectively, therethrough, opposing one another, having set screws 148 therein, the set screws 148 extending across the longitudinally disposed side channels 142 . The elongated guide 52 also has angled longitudinal edges 150 atop the substantially centrally disposed longitudinal channel 54 adjacent the recesses 130 and the substantially planar side portions 138 .
[0261] The substantially “T” shaped member 84 and the face plate 80 of the seal block 12 matingly sandwich the recesses 130 and the substantially planar opposing side 136 of the astragal 30 , respectively, therebetween, and retain the seal block 12 slidably mating about the elongated guide 52 between the seal block retracted position and the seal block extended position, and vice versa.
[0262] The compression springs 18 are mounted about the compression spring holders 86 , with the bottom ends 88 of the compression springs 18 abutting the top 90 of the base 78 of the seal block 12 and top 152 of the compression springs 18 abutting the set screws 148 in the longitudinally disposed side channels 142 of the astragal 30 . The compression springs 18 are held in the longitudinally disposed side channels 142 of the astragal 30 under compression, the extension stops 132 of the astragal 30 preventing the compression springs 18 from forcing the substantially “T” shaped member 84 out of the recesses 130 .
[0263] The barrel 92 of the seal block 12 is matingly slidable about the bolt 56 of the astragal 30 , and the bolt 56 is matingly slidable therethrough the substantially centrally disposed hole 14 of the barrel 92 of the seal block 12 . The angled edges 105 of the substantially “T” shaped member 84 matingly abut the angled longitudinal edges 150 of the astragal 30 . The angled edges 105 of the substantially “T” shaped member 84 and the barrel 92 of the guide block 82 guide the seal block 12 collinearly with the angled longitudinal edges 150 of the astragal 30 and the substantially centrally disposed longitudinal channel 54 , the bolt 56 being substantially aligned with the substantially centrally disposed longitudinal channel 54 .
[0264] The extension stops 132 and the retraction stops 134 limit the extent of travel of the substantially “T” shaped member 84 , and, thus, limit the extent of travel of the seal block 12 and the end seal 20 from the seal block extended position to the seal block retracted position, respectively, the compression springs 18 forcing the seal block 12 into the extended position, other than when the seal block 12 is retracted. The seal block 12 is retracted to the retracted position, the astragal seal shoulder 16 catching and abutting the bolt shoulder 58 , and holding the seal block 12 in the seal block retracted position, when the bolt 56 is in the bolt retracted position. The seal block 12 is extended to the seal block extended position, when the astragal seal shoulder 16 is released from the bolt shoulder 58 , the compression springs 18 forcing the seal block 12 into the seal block extended position, when the bolt 56 is in the bolt extended position.
[0265] The end seal 20 has substantially centrally disposed hole 154 therethrough, which is substantially aligned collinearly with the substantially centrally disposed hole 14 of the seal block 12 , which allows the end seal 20 to slide about the bolt 56 , and vice versa. The self positioning astragal seal 10 has face seal 156 , which is affixed to exterior side 158 of the face plate 78 of the seal block 20 and abuts edge 160 of active door 162 , when the active door 162 is closed abuttingly against the inactive door 44 , thus, preventing unwanted drafts between the self positioning astragal seal 10 and the edge 160 of the active door 162 . The astragal 30 also has edge seal 163 .
[0266] The self positioning astragal seal 10 may be used with the astragal 30 adjacent the sill 46 and/or header 164 of the door frame 48 , and may be used with the inactive door 44 and/or the active door 162 . Typical installations, however, have the astragal 30 mounted to the edge 42 of the inactive door 44 , and the self positioning position astragal end seal 20 mounted to the astragal 30 adjacent the sill 46 .
[0267] The self positioning astragal seal 10 may be used with a variety of astragals but is preferably used with the astragal 30 shown in the accompanying figures. Other astragals may be modified to suit the needs of particular applications.
[0268] The end seal 20 and the face seal 156 may have adhesives covered by peel off adhesive strips 166 and 168 , respectively, the end seal 20 and the face seal 156 being fastened to the seal block 12 with the adhesives, upon removal of the adhesive strips 166 and 168 , respectively.
[0269] The astragal 30 has astragal housing 180 having longitudinal channel 182 , which has longitudinal retention guides 184 , the elongated guide 52 inserted into the longitudinal channel 182 and held in the longitudinal channel 182 by the retention guides 184 and the set screws 148 , and channel base 185 , the set screws 148 locking the elongated guide 52 into the astragal housing 180 . The astragal 30 also has lockset strike 186 , deadbolt strike 188 , and upper bolt 190 mounted to the longitudinal channel 182 of the astragal housing 180 , the bolt 56 and the upper bolt 190 being used to lock the astragal 30 , and, thus, the inactive door 44 , which the astragal 30 is affixed to, to the sill 46 and the header 164 , respectively, of the door frame 48 . The upper bolt 190 may be used with the self positioning astragal seal 10 and/or alternatively the upper bolt 190 may use an alternative sealing means. Upper bolt assembly 191 having the upper bolt 190 is installed into the longitudinal channel 182 in substantially the same manner as the elongated guide 52 . The active door 162 has lockset 192 and deadbolt 194 , which are received by lockset strike 186 , deadbolt strike 188 , respectively, on the inactive door 44 , for securing the active door 162 to the inactive door 134 when the active door 162 is closed abuttingly adjacent the inactive door 44 . The astragal housing 180 has lockset cover plate 196 and deadbolt cover plate 198 , which are mounted to the astragal housing 180 , the lockset strike 186 and the deadbolt strike 188 being fastened to the lockset cover plate 196 and the deadbolt cover plate 198 with screws 199 .
[0270] The astragal 30 has latching member 200 , pull block 202 , elongated connector 204 , compression spring 206 about the elongated connector 204 , and slide plate 208 . The bolt 56 has lower portion 210 , mid portion 212 adjacent the shoulder 58 , the mid portion 212 having a smaller diameter than the diameter of the lower portion 210 , and upper portion 214 , the upper portion 214 of the bolt 56 having substantially the same diameter as the lower portion 210 , and having a slot 216 therethrough and a hole 218 therethrough, the slot 216 and the hole 218 substantially perpendicular one to the other.
[0271] The elongated connector 204 has end pin 220 , opposing hole 222 , and pin 224 therebetween, the end pin 220 and the pin 224 substantially perpendicular to the plane of the elongated connector 204 . The elongated connector 204 is sandwiched in the slot 216 of the upper portion 214 of the bolt 56 , the hole 218 and the hole 222 aligned one with the other, the bolt 56 and the elongated connector 204 pinned one to the other with pin 226 , the pin 226 therethrough the holes 222 and 218 .
[0272] The pull block 202 has longitudinal tracks 228 , retention tracks 230 and 232 , and channels 234 and 236 , the channels 234 between the longitudinal tracks 228 and the retention tracks 230 , and the channels 236 between the longitudinal tracks 230 and the retention tracks 232 . The pull block 202 is inserted into the longitudinal channel 182 of the astragal housing 180 , the channels 234 and 236 being adjacent to the retention guides 184 of the astragal housing 180 , the retention guides 184 slidably retaining the pull block 204 in the astragal housing 180 . The pull block 202 has substantially centrally disposed notch 238 at base 240 of the pull block 202 , notch 242 adjacent and substantially perpendicular to the substantially centrally disposed notch 238 , and bearing notches 244 . The substantially centrally disposed notch 238 is adjacent to and surrounds the elongated connector 204 adjacent the end pin 220 of the elongated connector 204 ; and sides 246 of the notch 242 surround and abut the end pin 220 , thus, pinning the elongated connector 204 to the pull block 202 one to the other. The pull block 202 also has lever arm receiving hole 248 .
[0273] The latching member 200 has lever arm 250 , which has trunnions 252 protruding therefrom, spring tail 254 , and latching dog 256 .
[0274] The slide plate 208 has retraction hole 260 , extension hole 262 , notches 264 , which form end tabs 266 , and projecting tabs 268 , which form projecting notch 270 therebetween, the projecting notch 270 for matingly slidably receiving the elongated connector 204 therebetween.
[0275] The elongated guide 52 is locked into the astragal housing 180 with the set screws 148 . The elongated guide 52 has notched recesses 280 opposing the recesses 130 , the notched recesses 280 matingly receiving the end tabs 266 of the slide plate 208 therein, and adjacent ends 282 , the notches 264 of the slide plate 208 matingly receiving the ends 282 of the elongated guide 52 therein, the slide plate 208 being sandwiched and locked between the elongated guide 52 and the channel base 185 of the astragal housing 180 . The projecting notch 270 of the slide plate 208 slidably guides the elongated connector 204 , which is located in the projecting notch 270 , substantially collinear with the center line of the elongated guide 52 .
[0276] The latching member 200 is sandwiched between the pull block 202 and the slide plate 208 , with the trunnions 252 in the bearing notches 244 of the pull block 202 and the lever arm 250 extending through the lever arm receiving hole 248 of the pull block 202 , thus facilitating operator control.
[0277] The retraction hole 260 and the extension hole 262 of the latching member 200 matingly receive the latching dog 256 of the latching member 200 therein.
[0278] The latching member 200 may be retracted to a latching member retracted position, when the lever arm 250 of the pull block 202 is depressed and pushed in the direction of pull block arrow marking 284 , which pulls the elongated connector 204 in the direction of the pull block arrow marking 284 , pulls the bolt 56 into the bolt retracted position, pulls the seal block 12 into the seal block retracted position, compresses the compression springs 18 , and compresses the compression spring 206 between the pin 224 of the elongated connector 204 and the projecting tabs 268 of the slide plate 208 . When the latching member 200 is retracted to the latching member retracted position, the spring tail 254 of the latching member 200 forces the latching dog 256 into the retraction hole 260 of the slide plate 208 , thus, locking the bolt 56 into the bolt retracted position and locking the seal block 12 into the seal block retracted position.
[0279] The latching member 200 may be released into a latching member extended position from the latching member retracted position, when the lever arm 250 of the pull block 202 is depressed and released, releasing compression from the compression spring 206 between the pin 224 of the elongated connector 204 and the projecting tabs 268 of the slide plate 268 , forcing the elongated connector 204 in the direction opposing the pull block arrow marking 284 , forcing the bolt 56 into the bolt extended position, releasing compression on the compression springs 18 , which forces the seal block 12 into the seal block extended position. When the latching member 200 is released, the latching member 200 snaps into latching member extended position, the latching dog 256 snaps into the extension hole 262 of the slide plate 208 , the spring tail 254 of the latching member 200 forcing the latching dog 256 into the extension hole 262 , thus, locking the bolt 56 into the bolt extended position with the seal block 12 in the seal block extended position, the seal block 12 automatically and independently self positioned with the end seal 20 abutting the sill 46 of the door frame 48 . The latching member 200 may alternatively be pushed into the latch member extended position.
[0280] The substantially centrally disposed longitudinal channel 54 of the elongated guide 52 has arcuate sides 286 and arcuate base 288 to slidably and matingly accommodate the bolt 56 , the lower portion 210 and the upper portion 214 of which are substantially cylindrical and have substantially the same diameter. The mid portion 212 of the bolt 56 is also substantially cylindrical, but has a smaller diameter than the diameter than that of the lower portion 210 and the upper portion 214 .
[0281] The elongated guide 52 also has oblique angled side portions 289 between the substantially planar side portions 138 and the arcuate sides 286 of the substantially centrally disposed longitudinal channel 54 . The longitudinally disposed side channels 142 have base walls 290 , which oppose the arcuate sides 286 of the substantially centrally disposed longitudinal channel 54 , and side walls 291 opposingly adjacent the substantially planar opposing side 136 .
[0282] Again, FIGS. 1 , 1 A- 1 C, 7 - 9 , and 16 show the bolt 56 locked into the bolt extended position with the lock 2 locked in the locked position, and FIGS. 2 , 2 A- 2 C, 17 , and 18 show the bolt 56 in the bolt retracted position with the lock 2 unlocked in the unlocked position. The elongated guide 52 has lock mounting hole 292 therethrough one of the substantially planar side portions 138 , the adjacent one of the oblique angled side portions 289 , the adjacent one of the arcuate sides 286 of the substantially centrally disposed longitudinal channel 54 and the adjacent one of the opposing longitudinally disposed side channel base walls 290 , and through the adjacent one of the longitudinally disposed side channel side walls 291 and the substantially planar opposing side 136 . The lock 2 is mounted in the lock mounting hole 292 .
[0283] The lock 2 comprises lock cylinder 293 , the lock cylinder 293 having an arcuate keyway 294 , arcuate tab 295 having lock stop 296 and unlock stop 297 , head 298 having slot 299 , mounting shoulder 400 , and bearing surface 402 . The lock 2 is rotatably mounted in the lock mounting hole 292 , with the mounting shoulder 400 rotatably mounted about the longitudinally disposed side channel side wall 291 adjacent the lock mounting hole 292 .
[0284] The astragal 30 has longitudinal wall 404 adjacent the edge 42 of the inactive door 44 . The lock 2 is rotatably mounted and held within the locking astragal with self positioning astragal seal 1 between the longitudinal wall 404 and the longitudinally disposed side channel side wall 291 adjacent the lock mounting hole 292 . The bearing surface 402 of the lock 2 is rotatably mounted abuttingly about the longitudinal wall 404 , and the mounting shoulder 400 is rotatably mounted abuttingly about the longitudinally disposed side channel side wall 291 adjacent the lock mounting hole 292 , thus, rotatably holding the lock 2 within the locking astragal with self positioning astragal seal 1 .
[0285] The arcuate tab 295 has a substantially ninety degree arc. The lock stop 296 and the unlock stop 297 are, thus, substantially perpendicular to each other, and thus, the locked position and the unlocked position of the lock 2 are substantially perpendicular to each other. The opposing longitudinally disposed side channel base wall 290 has lock contact area 406 and unlock contact area 408 , each adjacent to and on opposing sided of the lock mounting hole 292 . The lock stop 296 contacts the lock contact area 406 of the opposing longitudinally disposed side channel base wall 290 when the lock 2 is locked, and the unlock stop 297 contacts the unlock contact area 408 of the opposing longitudinally disposed side channel base wall 290 when the lock 2 is unlocked. The slot 299 at the head 298 of the lock 2 is substantially perpendicular to the axis of the bolt 56 , when the lock 2 is locked, the lock 2 is in the locked position and the lock stop 296 contacts the lock contact area 406 of the opposing longitudinally disposed side channel base wall 290 , indicating to a user that the bolt 56 is locked in the bolt extended position. The slot 299 at the head 298 of the lock 2 is substantially parallel to the axis of the bolt 56 , when the lock 2 is unlocked, the lock 2 is in the unlocked position and the unlock stop 297 contacts the unlock contact area 408 of the opposing longitudinally disposed side channel base wall 290 , indicating to the user that the bolt 56 is unlocked and may be moved from the bolt extended position to the bolt retracted position and vice versa, or the bolt 56 may be left in either the bolt extended position or the bolt retracted position, at the user's discretion. The lock 2 may be locked or unlocked by rotating the slot 299 at the head 298 of the lock 2 substantially ninety degrees from either unlocked to locked or substantially ninety degrees from locked to unlocked.
[0286] The lock cylinder 293 has wall 410 , and the bolt 56 has bolt top contact portion 412 and other bolt top portion 414 , the bolt top contact portion 412 being adjacent the wall 410 of the lock cylinder 293 , when the lock 2 is locked. When the lock 2 is locked, the lock 2 is in the locked position and the lock stop 296 contacts the lock contact area 406 of the opposing longitudinally disposed side channel base wall 290 , the bolt top contact portion 412 of the bolt 56 is blocked by the wall 410 of the lock cylinder 293 , which prevents the bolt 56 from moving from the bolt extended position to the bolt retracted position, thus, locking the bolt 56 in the bolt extended position. When the lock 2 is unlocked, the lock 2 is in the unlocked position and the unlock stop 297 contacts the unlock contact area 408 of the opposing longitudinally disposed side channel base wall 290 , the axis of the arcuate keyway 294 is substantially parallel to the axis of the bolt 56 , the bolt 56 is unlocked, and portion 416 of the bolt 56 adjacent the arcuate keyway 294 of the lock 2 may be slidably moved through the arcuate keyway 294 , thus, allowing movement of the bolt 56 from the bolt extended position to the bolt retracted position and vice versa, or the bolt 56 may be left in either the bolt extended position or the bolt retracted position.
[0287] A screwdriver or other suitable tool may be used to lock or unlock the lock 2 , by inserting the screwdriver or other suitable tool into the slot 299 and rotating the head 298 , and, thus, the lock 2 into the locked position or the unlocked position. Other suitable means may alternatively be used to rotate the lock 2 into the locked or unlocked position. The head 298 may, in lieu of or in addition to the slot 299 , which acts as a keyway, alternatively have a socket, a keyway, a protuberance, such as, for example, having a hex head, a knob, such as a knurled knob, or other suitable means adapted to facilitate rotating the lock 2 , in which case an alan wrench, a wrench, other suitable tool, or other suitable means may be used to rotate the lock 2 into the locked or unlocked position.
[0288] The lock 2 is preferably injection molded from an engineered plastic resin that has properties to provide strength, such as an acetal, although metal, such as aluminum or steel, thermoplastics, thermosetting polymers, rubber, or other suitable materials may be used.
[0289] The astragal housing 180 and the elongated guide 52 are preferably of metal, such as aluminum or steel, thermoplastics, thermosetting polymers, rubber, or other suitable material or combination thereof.
[0290] The seal block 12 and the latching member 200 are preferably injection molded from an engineered plastic resin that has properties to provide flexural strength, such as an acetal, although other suitable materials may be used. The end seal 20 and the face seal 156 are preferably of cellular material, such as closed cell neoprene sponge, although other suitable materials may be used.
[0291] FIG. 15 shows the latching member 200 with the lever arm 250 depressed and the latching dog 256 ready to be moved to the retraction hole 260 of the slide plate 208 , which is shown after being moved in FIGS. 17 and 18 . The seal block 12 is also retracted along with the bolt 56 , when the latching dog 256 is moved into the retraction hole 260 , as shown in FIGS. 17 and 18 .
[0292] The active door 162 and the inactive door 44 are “handed” as either right hand, in which the hinges of the active door 162 are on the right side of the active door 162 as viewed from the outside of the door frame 48 and left hand if the hinges of the active door 162 are on the left side of the door frame 48 as viewed from the outside of the door frame 48 . The elongated guide 52 and the self positioning astragal seal 10 may easily be reversed from left hand to right hand, and vice versa, by merely loosening the set screws 148 , removing the elongated guide 52 with the self positioning astragal seal 10 from the longitudinal channel 182 of the astragal housing 180 , and installing the elongated guide 52 with the self positioning astragal seal 10 on the end of the astragal housing 180 opposing that from which it was removed, thus, converting the astragal 30 from one hand to the other.
[0293] FIGS. 20-25 show alternate embodiments of astragals having astragal housings that the self positioning astragal 10 may be used with, although other suitable astragals having other suitable astragal housings may be used.
[0294] FIG. 20 shows an alternate embodiment of an astragal housing 300 , which has a saw-tooth recess 302 to retain finned tail 304 of a typical wrapped foam type weather strip 306 for sealing. The astragal housing 300 also has cavity 308 .
[0295] FIG. 21 shows an alternate embodiment of an astragal housing 310 , which is substantially the same as the astragal housing 300 , except that the astragal housing 310 has thermal break 312 , for installations in climates that experience extremely cold weather, in which the astragal housing 310 is fabricated from an aluminum extrusion, or other suitable material having substantially the same properties, which would otherwise readily lose heat to the outside and result in condensation, and in some cases even the formation of ice. The thermal break 312 is created by filling cavity 308 of the astragal housing 300 with a polyurethane thermal break compound, after which it is de-bridged by milling slot 314 , thus, separating outer and inner portions of the astragal housing 310 and preventing infiltration of the cold.
[0296] FIG. 22 shows an alternate embodiment of an astragal 320 , which may be used for installation on a pair of outwsinging rather than inswinging doors, which has astragal housing 322 , cover 324 that provides overlap, and outer seal 326 , and is used on the active leaf of the pair of out swinging doors. Inner seal 328 is of greater reach as the beveled edge of the active door is reversed, creating a greater gap at its inner edge.
[0297] FIG. 23 shows an alternate embodiment of an astragal 330 , which may be used for installation on a pair of outwsinging rather than inswinging doors, which is substantially the same as the astragal housing 320 , except that the astragal 330 has thermal break 332 .
[0298] FIG. 24 shows an alternate embodiment of an astragal 340 , which may be used for installation on a pair of outwsinging rather than inswinging doors, in which cover element 342 has saw-tooth recess 344 to accommodate finned tail 346 of a wrapped foam weather strip seal 348 . Inner seal 349 is of greater reach as the beveled edge of the active door is reversed, creating a greater gap at the inner edge.
[0299] FIG. 25 shows an alternate embodiment of an astragal 350 , which may be used for installation on a pair of outwsinging rather than inswinging doors, which is substantially the same as the astragal housing 340 , except that the astragal 350 has thermal break 352 .
[0300] FIGS. 26-29 show an alternate embodiment of a locking astragal 500 , which is substantially the same as the locking astragal with self positioning astragal seal 1 , except that the self positioning astragal seal has been removed from the locking astragal 500 . The locking astragal 500 has the lock 2 , as in the locking astragal with self positioning astragal seal 1 .
[0301] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | A locking astragal with self positioning seal that automatically positions at least one seal at the lower end of an astragal adjacent the threshold sill of a door frame, and prevents drafts at the vicinity of the lower end of the astragal and the threshold sill, and/or automatically positions at least one seal at the upper end of the astragal adjacent the header of the door frame, and prevent drafts at the vicinity of the header. The self positioning seal independently positions itself abuttingly adjacent the sill and/or the header when the astragal's bolts are extended from a retracted position to an extended position and are received by the upper and/or lower apertures in the upper and/or lower portions of the door frame, the astragal having locks for locking the bolts into the extended position, and can be used with a variety of thresholds, sills, headers, doors, and door frames | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an imager that captures an image and processes the captured image.
[0003] 2. Description of the Related Art
[0004] Japanese Unexamined Patent Application Publication No. H05-95501 discloses an imager that indicates a warning when an unwanted object, i.e. a finger, is in the angle of view. In such construction, however, an object may move while a user moves a finger out of the angle of view or changes the composition of the picture.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to provide an imager that reduces the influence of an unwanted object in a photograph and releases a shutter at the right moment.
[0006] An endoscope is provided having an imaging sensor, a focusing lens, and an image processor. The imaging sensor converts an optical image to an output image signal. The focusing lens focuses on an object. The image processor calculates a contrast value based on the image signal while the focusing lens moves to focus on an object, and in the case where the image processor detects a region in which the amount of variation in the contrast value is within a predetermined range, while the focusing lens moves in a close range around a focusing point the image processor processes at least one output image in which either the image has been cropped to exclude the region, an ornament has been added to the region, or the region has been softened.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The objects and advantages of the present invention will be better understood from the following description, with references to the accompanying drawings in which:
[0008] FIG. 1 is a schematic view of an imager according to the present embodiment;
[0009] FIG. 2 shows a display that displays a through image in which an unwanted object exists;
[0010] FIG. 3 shows a display that displays a still image that has been cropped to exclude the region in which an unwanted object exists;
[0011] FIG. 4 is a flowchart of a cropping process;
[0012] FIG. 5 shows an AF search region and an unwanted object search region; and
[0013] FIG. 6 shows another pattern of an AF search region and an unwanted object search region.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention is described below with references to the embodiments shown in the drawings. An imager 10 according to the embodiment shown in FIG. 1 comprises an imaging sensor 11 , a focusing lens 12 , an image processor 13 , a release button 14 , a display 15 , a storage medium 16 , and a controller 17 .
[0015] Light reflected from an object strikes the imaging sensor 11 after passing through the focusing lens 12 , so that the imaging sensor 11 captures an optical image and converts it to an electric image signal. The image processor 13 creates image data by processing the image signal. The image data is then sent to the display 15 . The display 15 displays an image based on the image data. In the case the digital camera carries out such procedures for only one frame, the display 15 displays a through image. This is called as live view. The controller 17 controls each part of the digital camera 10 , i.e., the image processor.
[0016] When the release button 14 is depressed halfway, the image processor 13 brings an object into focus by controlling the focusing lens 12 , and calculates exposure conditions, e.g. aperture value, exposure time, etc., based on a brightness signal included in the image signal. While the focusing lens 12 is focused on an object, the image processor 13 directs the movement of the focusing lens 12 along its axis while calculating contrast values based on the brightness signal from a predetermined period. Then, when the image processor 13 determines that an object is in focus of the focusing lens 12 and the contrast value is at its maximum, the focusing lens 12 is fixed in its current position that is focused on an object.
[0017] The focusing lens 12 can focus on an object at close range from the digital camera 10 , and the range in which the focusing lens 12 moves to bring the object into focus is the close focusing range. While the focusing lens 12 moves in the close focusing range, the image processor 13 determines whether or not a region exists that has a contrast value with a variation that is within a predetermined range. In other words, the image processor 13 detects whether or not a region exists in which the amount of variation in its contrast value is less than or equal to a predetermined range. The detected region, which contains an unwanted object, is described hereinafter.
[0018] A plurality of virtual AF search regions is provided on a captured image, as shown in FIG. 5 . The image processor 13 detects the contrast values of all of these AF search regions. That is, the image processor 13 determines whether or not any of the AF search regions have a contrast value that varies within a predetermined range.
[0019] The image processor 13 detects the hue of the unwanted object region based on its contrast value and determines whether the detected hue is a predetermined hue. The predetermined hue is, for example, a flesh color or a color in the range of black to brown.
[0020] In the case that the hue of the unwanted object region is a flesh color, the image processor 13 determines that an unwanted object is in the angle of view of the focusing lens 12 . For example, when a finger of a user is in front of the focusing lens 12 , a finger captured in an image creates an unwanted object region because a finger is flesh-colored. In a captured image, a region in which an unwanted object exists is an unwanted object region. In the case that the hue of the unwanted object region is a color in the range from black to brown, the image processor 13 determines that an unwanted object is in the angle of view of the focusing lens 12 . For example, when the back of a person's head is in front of the focusing lens 12 , a head captured in an image creates an unwanted object region because the back of a head has a color in the range from black to brown.
[0021] In the case that the image processor 13 determines that a finger is in front of the focusing lens 12 , the close focusing range is a relatively short distance away from the digital camera 10 that is measured in centimeters. In the case that the image processor 13 determines that the back of a person's head is in front of the focusing lens 12 , the close focusing range is a relatively short distance away from the digital camera 10 that is measured in meters.
[0022] When the release button 14 is fully depressed, the focusing lens 12 remains focused on an object while the imaging sensor 11 captures an image under the calculated exposure conditions. Then, the image processor 13 creates image data by processing the image signal, and a still image based on the image data is displayed on the display 15 . The image file including the image data is stored in the storage medium.
[0023] In the case that the image processor 13 determines that a finger of a user or the back of a head is in front of the focusing lens 12 , the operation mode of the digital camera 10 is set to a cropping mode. In the cropping mode, the image processor 13 crops an image to exclude the unwanted object region from the captured image, displays the cropped image on the display 15 (refer to FIG. 3 ), and stores the cropped image in the storage medium 16 . For example, the unwanted object region is the hatched region shown in FIG. 2 , and the cropped region is the upper right section of the captured image that is framed by dashed lines. Note that the image processor 13 may crop the center of a captured image so as to exclude the unwanted object region. This cropping method corresponds to a zoom-up technique.
[0024] The unwanted object region and the hue is determined after the release button 14 is depressed halfway but before it is depressed completely. Image cropping can be carried out only after an image has been captured.
[0025] The cropping process is described with reference to FIG. 4 . When the digital camera is powered on, the controller 17 determines whether or not the release button 14 is depressed halfway in Step S 11 . In the case that the release button 14 is not depressed halfway, Step S 11 is repeated. Otherwise, the process continues to Step S 12 .
[0026] In Step S 12 , the image processor 13 calculates exposure conditions and directs the focusing lens 12 to focus on an object. While the focusing lens 12 is focused on an object, the image processor 13 directs the movement of the focusing lens 12 along its axis and calculates a contrast value based on the brightness signal for a predetermined period so that a hue can be determined based on the calculated contrast value.
[0027] In Step S 13 , while the focusing lens 12 moves in the close focusing range, the image processor 13 determines whether or not an unwanted object region with a contrast value that varies within a predetermined range exists. In the case that the unwanted object region exists, the process continues on to Step S 14 . Otherwise, the process jumps to Step S 16 .
[0028] In Step S 14 , the image processor 13 detects the hue of the unwanted object region based on the contrast value and determines whether the detected hue is a predetermined hue, such as a flesh color or a color in the range from black to brown, for example. In the case that the hue of the unwanted object region is a predetermined hue, the process continues on to Step S 15 . Otherwise, the process proceeds to Step S 16 .
[0029] In Step S 15 , the image process 13 sets the operation mode of the digital camera 10 to the cropping mode. In Step S 16 , the image process 13 sets the operation mode of the digital camera 10 to the normal mode that is different from the cropping mode.
[0030] In Step S 17 , the camera controller 17 determines whether or not the release button 14 is depressed completely. In the case that the release button 14 is not depressed completely, Step S 17 is repeated. Otherwise, the process continues on to Step S 18 .
[0031] In Step S 18 , while the focusing lens 12 is focused on an object the imaging sensor 11 captures an image under the calculated exposure conditions. Then, image data is created when the processor 13 processes the image signal, and a still image based on the image data is displayed on the screen 15 . The image file including the image data is stored in the storage medium. In the case that the operation mode of the digital camera 10 is set to a cropping mode, the image processor 13 crops an image to exclude an unwanted object region from the captured image, displays the cropped image on the display 15 (refer to FIG. 3 ), and stores the cropped image in the storage medium 16 .
[0032] Therefore, a still image excluding the unwanted object region is created. Note that, as a substitute for cropping, the image processor 13 may add an ornament to the unwanted object region in the process of creating a still image. The ornament may be, for example, the symbol of a heart. According to this construction, a still image is created in which a user cannot recognize the unwanted object region. As another substitute for cropping, the image processor 13 may soften an unwanted object region in the process of creating a still image.
[0033] Cropping, adding an ornament, and softening are all processes that are carried out after an image has been captured, so that the elapsed time between the moment when the release button is depressed completely and the moment of capture does not increase. Therefore, the digital camera 10 reduces the influence of an unwanted object in a photograph and releases the shutter at the right moment. Note that only one process of cropping, adding an ornament, or softening may be carried out, but two or more of these processes may also be executed for the same image.
[0034] Virtual AF search regions and unwanted object search regions may be simultaneously indicated on a captured image, as shown in FIG. 6 . The image processor 13 detects the focusing point of the focusing lens 12 based on the AF search region at the center of a captured image, because the focusing point is detected at or near the center of an image. The image processor 13 detects contrast values for each of the unwanted object search regions that are provided on the periphery of a captured image, because an unwanted object is detected at or near a periphery of a captured image. The unwanted object search regions are indicated differently from the AF search regions so that an unwanted object can be rapidly detected in a short amount of time.
[0035] Steps S 12 to S 16 may be carried out repeatedly during each period, e.g. every millisecond until the release button 14 is completely depressed, and then the appropriate operation mode of the camera 10 may be set. In the embodiment described hereinbefore, when an unwanted object disappears from the angle of view during the period between Step S 15 and S 17 , the operation mode of the digital camera 10 does not change to the normal mode. On the other hand, when an unwanted object appears in the angle of view between Steps S 16 and S 17 the operation mode of the digital camera 10 is not changed to the cropping mode. Repeating Step S 12 to S 16 effectively resolves such problems.
[0036] Although the embodiment of the present invention has been described herein with references to the accompanying drawings, obviously many modifications and changes may be made by those skilled in the art without departing from the scope of the invention.
[0037] The present disclosure relates to subject matter contained in Japanese Patent Application No. 2009-224147 (filed on Sep. 29, 2009), which is expressly incorporated herein, by reference, in its entirety. | An endoscope is provided having an imaging sensor, a focusing lens, and an image processor. The imaging sensor converts an optical image to an output image signal. The focusing lens focuses on an object. The image processor calculates a contrast value based on the image signal while the focusing lens moves to focus on an object, and in the case where the image processor detects a region in which the amount of variation in the contrast value is within a predetermined range, while the focusing lens moves in a close range around a focusing point the image processor processes at least one output image in which either the image has been cropped to exclude the region, an ornament has been added to the region, or the region has been softened. | 7 |
FIELD OF THE INVENTION
The present invention relates to novel ethylenically unsaturated crosslinking agents and to radiation curable compositions containing these agents. The invention particularly relates to ethylenically unsaturated heterocyclic crosslinking agents, to radiation curable oxygen insensitive compositions containing such agents, and to alcohol or aqueous alcohol developable imaging layers containing such compositions.
DESCRIPTION OF THE PRIOR ART
The generation of three dimensional bonding or crosslinking in a composition or coating to reduce the solubility and improve the chemical resistance of a cured product is well known. This is usually effected by the addition of a crosslinking agent to an otherwise two dimensionally polymerizable composition from which the cured product is made. Crosslinking has been produced in products from ethylenically unsaturated compositions such as acrylic compositions (e.g. a methyl methacrylate composition) by incorporation of from about 1 to about 10 percent by weight of a polyacrylic substituted compound as a crosslinking agent. It is well known that such acrylic compositions generally must be polymerized in an inert atmosphere, e.g., a nitrogen atmosphere. Otherwise, the oxygen present in air will retard or even prevent polymerization of the acrylic composition so that desired levels of polymerization cannot be achieved. At best, only a tacky, incompletely polymerized resin or a weak, low molecular weight polyacrylate resin can be obtained.
Curable, oxygen insensitive acrylic compositions are described in U.S. Pat. Nos. 3,844,916, 3,914,165 and 3,925,349. These references teach that oxygen inhibition can be avoided by incorporation of a Michael adduct of a polyacrylate and an amine having at least one amino hydrogen into acrylic compositions. The use of such an adduct in acrylic photopolymerizable compositions requires the use of a relatively high concentration of polymerization photoinitiator (3% by weight is disclosed at Col. 3, lines 50-51 of U.S. Pat. No. 3,925,349). Although such compositions are useful for coatings and inks that can be cured in the presence of oxygen, these compositions are not satisfactory for coatings that are transparent and where discoloration is undesirable since the use of large amounts of photoinitiator leads to yellowing of the cured coating.
Acrylic compositions, containing 0.5 to 10 percent triphenyl phosphine, that can be cured rapidly in an atmosphere containing 300 to 1000 ppm of oxygen are disclosed in U.S. Pat. No. 4,113,893. Since the provision of atmosphere containing oxygen in any concentration less than that found in air requires use of special equipment, the use of phosphines to obtain rapid curing is also unsatisfactory for many commercial processes.
U.S. Pat. No. 3,968,305 describes acrylic compositions comprising an aliphatic compound having three or more methacryloxy groups that can be polymerized to a crosslinked mar resistant coating. U.S. Pat. No. 4,014,771 teaches that by the addition of (1) 30 to 95 percent of the adduct of methacrylic acid and (2) either a polyglycidyl ether of an aromatic polyhydric compound or a polyglycidyl ester of an aromatic or aliphatic polycarboxylic acid to a polymethacryloxy compound such as that described in U.S. Pat. No. 3,968,305, there is obtained a composition which evidently can be polymerized without the necessity of excluding air during the polymerization.
Protective coatings produced by irradiation in the absence of air of the adduct of methacrylic acid to N-glycidylheterocyclic compounds are disclosed in U.S. Pat. Nos. 3,808,226 and 3,847,769. Polymerization of the dimethacrylic ester of N-oxyalkylated-heterocyclic compounds is disclosed in U.S. Pat. Nos. 3,821,098 and 3,852,302.
The compounds of U.S. Pat. No. 3,808,226 bear a similarity in structure to the compounds of the present application. The route of synthesis shown for those compounds can not produce the compounds of the present invention nor could the route of synthesis used in the present invention produce the compounds of that patent.
SUMMARY OF THE INVENTION
In accordance with the invention, there are provided novel ethylenically unsaturated crosslinking agents comprising poly(ethylenically unsaturated alkoxyalkyl)heterocyclic compounds and a process for their preparation. The crosslinking agents of the invention have the general formula:
A.sup.1 --Z--A.sup.2 I
in which A 1 and A 2 independently are alkoxyalkyl groups having terminal ethylenic unsaturation and having the general formula: ##STR1## in which R--O-- is a monovalent residue (formed by removal of the active hydrogen from an --OH group) of an aliphatic terminally unsaturated primary alcohol, ROH, R having the formula: ##STR2## wherein:
E is ##STR3##
a and c are independently an integer of 1 to 6,
b is zero or an integer of 1 to 6,
R 1 and R 4 are independently hydrogen or methyl,
R 5 is an aliphatic group having 1 to 15 carbon atoms (preferably alkylene of up to 15 carbon atoms) and optionally one or two catenary (i.e., backbone) oxygen atoms, or ##STR4##
a valence of m+1, and
m is an integer of 1 to 5,
R 2 is preferably hydrogen but can be ##STR5## wherein R 6 is preferably alkenyl but can be alkyl (each preferably having 2 to 5 carbon atoms) and can be substituted by a phenyl or carboxyl group and R 7 is an aliphatic group (of up to eight carbon atoms, e.g., alkyl) or aromatic group (preferably having up to 8 carbon atoms and more preferably a phenyl group) and R 7 is most preferably an acryloyloxyalkyl or a methacryloyloxyalkyl group,
R 3 is an alkylene group having 1 to 6 carbon atoms and optionally one catenary oxygen atom; and
Z is a heterocyclic group of the formula: ##STR6## wherein:
X is a divalent group which is required to complete a 5- or 6-membered heterocyclic ring, preferably X is ##STR7## wherein R 8 , R 9 , R 10 , and R 11 are independently hydrogen or lower alkyl (of 1 to 4 carbon atoms), cycloalkyl (of 3 to 6 carbon atoms) or phenyl group (of 6 to 12 carbon atoms) and A 3 is an alkoxyalkyl group as defined above for A 1 and A 2 .
The preferred compounds of Formula I are those wherein E is ##STR8## m is 2 to 5, and X is ##STR9## These compounds are preferred because they provide not only a high crosslink density, resulting in improved solvent and abrasion resistance but also excellent adhesion and flexibility. Furthermore, these compounds are water/alcohol soluble and are photocurable to tack free surfaces in the presence of atmosphere oxygen.
This invention further includes energy crosslinkable compositions particularly to photocurable compositions comprising the poly(ethylenically unsaturated alkoxyalkyl)heterocyclic compounds of the present invention and a polymerization catalyst which liberates free radicals on application of energy.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the invention can be prepared by the Lewis acid catalyzed addition of n moles of an ethylenically unsaturated primary alcohol to an epoxy-substituted heterocycle in accordance with the equation: ##STR10## wherein R, R 1 , R 3 , and Z are as defined for the compounds of Formula I, and n is 2 or 3.
Particularly, the (polyacrylyloxy)alkoxypropylheterocyclic compounds of the invention are 5- or 6-membered ring heterocyclic compounds having preferably two (but may have three) nitrogen and preferably two (but may have three) carbonyl groups, viz. ##STR11## in the ring. At least one but preferably all of the ring nitrogens are substituted by a (polyacryloyloxy)alkoxypropyl group (e.g., Formula II). The substituted heterocyclic compounds can be prepared (as shown above) by the Lewis acid catalyzed addition to a heterocyclic compound, as defined, that has one, two or three (where present) of its ring nitrogens substituted by a glycidyl group (e.g., a 2,3-epoxypropyl group) of one, two or three equivalents of a hydroxy compound that is the product of esterification of m hydroxyl groups of a polyol having (m+1) hydroxyl groups with acrylic or methacrylic acid in accordance with the equation: ##STR12## wherein R 1 , R 2 , m, R 3 and X are defined above.
The above equation illustrates the preparation where only one of the ring nitrogens has been substituted by the glycidyl group. Where two or three of the ring nitrogens have been substituted by glycidyl (as is most preferable), two or three equivalents of hydroxy compound can be added. The addition of the hydroxy compound to the glycidyl groups of the heterocyclic compound can be done in one step or in a sequence of steps in which first one and then a second and then a third glycidyl group is reacted. It is not necessary that the same hydroxy compound be used in each of the steps. Where two or more different hydroxy compounds are used, unsymmetrical compounds are obtained, that is, A 1 and A 2 (and A 3 if three nitrogens on the ring) of Formula I are different. Mixtures of hydroxy compounds can also be used. It is to be expected, however, when two or more hydroxy compounds are used, whether in a sequence of steps or in a one-step mixture, the product obtained will be a mixture of (polyacryloyloxy)alkoxypropylheterocyclic compounds. All, however, are useful in the present invention, particularly when at least about 30% by weight of the polymerizable coating composition is a heterocyclic compound having at least two glycidyl groups reacted with hydroxy compounds in which m in Formula I is at least three; that is, the hydroxy compound to be reacted with the glycidyl group of the heterocyclic compound is preferably a tri- or higher acryloyloxy or methacryloyloxy-hydroxy compound.
The polyglycidyl heterocyclic intermediates useful in the preparation of any and all of the compounds of the present invention are disclosed in U.S. Pat. Nos. 3,808,226 and 4,071,477. Preferably, the reaction is performed in solution. However, it also can be performed in the absence of solvent. Generally, a solution of an epoxy-substituted heterocycle can be added incrementally (over a period of time ranging from a few minutes to several hours) to a mixture of (1) an ethylenically unsaturated primary alcohol (or mixtures of ethylenically unsaturated primary alcohols), (2) an inhibitor for thermal polymerization, and (3) a Lewis acid while maintaining the temperature of the mixture at 50° to 120° C., preferably about 80° to 100° C., until the disappearance of the epoxy group, as indicated by chemical titration or nuclear magnetic resonance spectrometric analysis. Heating the mixture for from 2 to 40 hours usually suffices to complete the reaction, after which volatiles are removed by vacuum distillation.
The compounds of Formula II can then be acylated by reaction with an acylating agent, preferably an acyl halide, an acyl anhydride, or an isocyanate that contains polymerizable ethylenically unsaturated groups. Preferred acylated compounds have the Formula: ##STR13## wherein R, R 1 , R 3 , R 6 , R 7 , z, m and n are as defined for Formula I.
Exemplary acylating agents include acid chlorides such as acetyl chloride, propionyl chloride, valeryl chloride, dodecanyl chloride, acrylolyl chloride, methacryloyl chloride, alpha-chloroacryloyl chloride, crotyl chloride, benzoyl chloride, phenylacetyl chloride, 2,4-dichlorophenylacetyl chloride; and the corresponding carboxylic acids and anhydrides; other anhydrides include the anhydrides of dicarboxylic acids such as maleic anhydride, succinic anhydride, methylenesuccinic anhydride, phthalic anhydride, and 3-chlorophthalic anhydride; and organic isocyanates such as methyl isocyanate, ethyl isocyanate, n-butyl isocyanate, phenyl isocyanate, 4-t-butyl isocyanate, acryloyloxyethyl isocyanate, methacryloyloxyethyl isocyanate, 4-methacryloyloxybutyl isocyanate, 4-acryloylphenyl isocyanate and 4-vinylphenyl isocyanate.
The compounds of Formulas III and IV of the invention are prepared by addition of a suitable acylating agent to the compound II, e.g. an organic acid anhydride or halide or an organic isocyanate.
Suitable ethylenically unsaturated primary alcohols for use in the preparation of the compounds of the invention are the hydroxylalkyl acrylates having the formula: ##STR14## in which R 4 , R 5 , m and c are the same as defined for compounds of Formula I. Included among suitable hydroxyalkyl acrylates are the monoacrylate and monomethacrylate esters of aliphatic diols such as ethyleneglycol, propyleneglycol, butyleneglycol, hexamethyleneglycol, diethyleneglycol, and dimethylolcyclohexane; the diacrylates and dimethacrylates of aliphatic triols such as trimethylolmethane, 1,1,1-trimethylolpropane, 1,2,3-trimethylolpropane; the triacrylates and trimethacrylates of aliphatic tetrols such as pentaerythritol, 1,1,2,2-tetramethylolethane and 1,1,3,3-tetramethylopropane; the tetraacrylates and tetramethacrylates of polyols such as dipentaerythritol and 1,1,1,2,2-pentamethylolethane; and the pentaacrylates and pentamethacrylates of polyols such as tripentaerythritol and hexamethylolethane.
Other suitable ethylenically unsaturated primary alcohols for use in the preparation of the compounds of the invention are the hydroxyalkenes having the formula: ##STR15## in which R 4 , R 5 , m, d, b, and c are the same as defined for compounds of Formula I. Included among suitable hydroxyalkenes are allyl alcohol, methallyl alcohol, allyloxyethyl alcohol, 2-allyloxymethylpropanol (from dimethylolethane), and 2,2-di(allyloxymethyl)butanol (from trimethylolpropane).
Polymerization initiators suitable for use in the crosslinkable compositions of the invention are compounds which liberate or generate a free-radical on addition of energy. Such initiators include peroxy, azo, and redox systems each of which are well known and are described frequently in polymerization art, e.g. Chapter II of Photochemistry, by Calvert and Pitts, John Wiley & Sons (1966). Included among free-radical initiators are the conventional heat activated catalysts such as organic peroxides and organic hydroperoxides; examples are benzoyl peroxide, tertiary-butyl perbenzoate, cumene hydroperoxide, azobis(isobutyronitrile) and the like. The preferred catalysts are photopolymerization initiators which facilitate polymerization when the composition is irradiated. Included among such initiators are acyloin and derivatives thereof, such as benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin isobutyl ether, and α-methylbenzoin; diketones such as benzil and diacetyl, etc.; organic sulfides such as diphenyl monosulfide, diphenyl disulfide, decyl phenyl sulfide, and tetramethylthiuram monosulfide; S-acyl dithiocarbamates, such as S-benzoyl-N,N-dimethyldithiocarbamate; phenones such as acetophenone, α,α,α-tribromacetophenone, α,α-diethoxyacetophenone, 2,2-dimethoxy-2-phenylacetophenone, o-nitro-α,α,α-tribromacetophenone benzophenone, and p,p'-tetramethyldiaminobenzophenone; aromatic iodonium and aromatic sulfonium salts; sulfonyl halides such as p-toluenesulfonyl chloride, 1-naphthalenesulfonyl chloride, 2-naphthalenesulfonyl chloride, 1-3benzenedisulfonyl chloride, 2,4-dinitrobenzenesulfonyl bromide and p-acetamidobenzenesulfonyl chloride. Normally the initiator is used in amounts ranging from about 0.01 to 5% by weight of the total polymerizable composition. When the quantity is less than 0.01% by weight, the polymerization rate becomes extremely low. If the initiator is used in excess of 5% by weight, no correspondingly improved effect can be expected. Thus, addition of such greater quantity is economically unjustified. Preferably, about 0.25 to 1.0% of initiator is used in the polymerizable compositions.
The crosslinkable compositions of the invention are preferably diluted with an ethylenically unsaturated monomer. Suitable ethylenically unsaturated monomers include methyl methacrylate, ethyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate, styrene, 2-chlorostyrene, 2,4-dichlorostyrene, acrylic acid, acrylamide, acrylonitrile, t-butyl acrylate, methyl acrylate, butyl acrylate, 2-(N-butylcarbamyl)ethyl methacrylate and 2-(N-butylcarbamyl)ethyl methacrylate and 2-(N-ethylcarbamyl) ethyl methacrylate. Other diluting monomers that can be incorporated into the composition of the invention include 1,4-butylene dimethacrylate or acrylate, ethylene dimethacrylate, hexanediol diacrylate or dimethacrylate, glyceryl diacrylate or methacrylate, glyceryl triacrylate or trimethacrylate, pentaerythritol triacrylate or trimethacrylate, pentaerythritol tetraacrylate or tetramethacrylate, diallyl phthalate, dipentaerythritol pentaacrylate, neopentylglycol triacrylate and 1,3,5-tri(2-methacryloxyethyl)-s-triazine.
The crosslinkable composition can also contain a viscosity modifier or binder. Generally, up to about 50 percent by weight of a compatible polymer is used. Preferably, the polymer is an acrylic polymer such as poly(acrylic acid), a poly(methacrylic acid), poly(methyl methacrylate), poly(vinyl chloride), poly(vinyl acetate, poly(vinyl butyral) and the like. Other polymers include polyethers, polyesters, polylactones, polyamides, polyurethanes, cellulose derivatives, polysiloxanes and the like.
The compositions of the invention can also include a variety of addenda utilized for their known purpose, such as stabilizers, inhibitors, lubricants, flexibilizers, pigments, carbon black, dyes, reinforcing fillers such as finely divided silica, non-reinforcing fillers such as diatomaceous earth, metal oxides, asbestos, fiberglass, glass bubbles, talc, etc. Fillers can generally be used in proportions up to about 200 percent by weight of the curable components but preferably are used up to about 50 percent by weight. Where the polymerizing energy is radiation, it is desirable that the addenda be transparent to the radiation.
The compositions of the invention are prepared by simply mixing (under "safe light" conditions if the composition is to be sensitized to visible light) the polymerization catalyst and sensitizer (where used), the poly(ethylenically unsaturated alkoxyalkyl)heterocyclic compound, diluting monomers, binders and addenda. Inert solvents may be employed if desired when effecting this mixture. Examples of suitable solvents are methanol, ethanol, acetone, acetonitrile and includes any solvent which does not react with the components of the mixture.
Utility
The crosslinkable compositions of the invention can be used as adhesives, caulking and sealing compositions, casting and molding compositions, potting and encapsulating compositions, impregnating and coating compositions, etc., depending on the particular combination of components. Where the polymerization catalyst is a photoinitiator, the composition can be a composition for in situ curing because of this insensitivity to oxygen.
The photopolymerizable compositions are particularly suitable for applications in the field of protective coatings and graphic arts because of their superior abrasion-resistance and adhesion to many rigid, resilient and flexible substrates such as metals, plastics, rubber, glass, paper, wood, and ceramics; their excellent resistance to most solvents and chemicals; their excellent flexibility and weatherability; and their capability for forming high resolution images. Among such uses are water or water/alcohol developable resists for chemical milling, gravure images, offset plates, stencil making, screenless lithography, particulate binders as in microtaggants, relief printing plates, printed circuits, electron beam curing adhesives, radiation and protective coatings for glass, metal surfaces and the like. Priming layers may be used if desired, and in some cases may be necessary.
The photopolymerization of the compositions of the invention occurs on exposure of the compositions to any source of radiation emitting actinic radiation at a wavelength within the ultraviolet and visible spectral regions. Suitable sources of radiation include mercury, xenon, carbon arc and tungsten filament lamps, sunlight, etc. Exposures may be from less than about 1 second to 10 minutes or more depending upon the amounts of the particular polymerizable materials and photopolymerization catalyst being utilized and depending upon the radiation source, distance from the source, and the thickness of the coating to be cured. The compositions may also be polymerized by exposure to electron beam irradiation. Generally speaking, the dosage necessary is from less than 1 megarad to 100 megarad or more. One of the major advantages with using electron beam curing is that highly pigmented compositions can be effectively cured at a faster rate than by mere exposure to actinic radiation.
These and other features of the present invention will be shown in the following Examples.
EXAMPLE 1
Preparation of 1,3-Bis(3-[2,2,2-(triacryloyloxymethyl)ethoxy 2-hydroxypropyl]-5,5-dimethyl-2,4-imidizolidinedione ##STR16##
Compound A
Pentaerythritol triacrylate (44.3 g, 0.1 m, hydroxyl equivalent weight of 443), 0.025 g 4-methoxyphenol, and 0.4 g borontrifluoride etherate were charged into a 250 ml three-necked round bottom flask equipped with mechanical stirrer, pressure equalizing dropping funnel, reflux condenser, and a CaSO 4 drying tube. (It is to be noted that most commercially available pentaerythritol triacrylate is contaminated with acrylated impurities.). The reaction flask was heated to 60° C. and 13.8 g of 1,3-bis(2,3-epoxypropyl)-5,5-dimethyl-2,4-imidizolidinedione (0.1 m epoxide equivalency) in 5 ml chloroform was added dropwise over 45 minutes. After the addition, the reaction flask temperature was raised to 85° C. and stirred for 11.5 hours. After this time, titration of an aliquote for unreacted epoxide indicated that the reaction was greater than 99% complete. The chloroform was removed by vacuum distillation leaving as residue a viscous liquid that contains predominently compounds of the structure of Compound A. Photocurable impurities introduced with the pentaerythritol triacrylate can be removed by trituration with diethyl ether.
A mixture of the liquid and 2% by weight of the photopolymerization initiator 2,2-dimethoxy-2-phenylacetophenone was coated onto 12 μm polyester film and dried to provide a 2.5 μm layer. The layer was then cured in a UV Processor, Model No. CC 1202 N/A (manufactured by Radiation Polymer Co.) after one pass at 12 m/min. (40 feet/min.) under an 80 watts/cm (200 watts/inch) medium pressure mercury lamp. The cured layer exhibited 95-100% cross-hatch adhesion, 2-7% Taber Haze, 13-16% haze in the Gardner Falling Sand Abrader (i.e., tested according to ASTM Designation D1003-64(Procedure A)) and excellent resistance to abrasion by steel wool. The layer was unaffected by treatment with ethanol, acetone, ethyl acetate, toluene, hexane, aqueous sodium hydroxide and 10% aqueous hydrochloric acid.
EXAMPLES 2-3
Preparation of 1,3-Bis[3-(2-acryloyloxyethoxy)-2-hydroxypropyl]-5,5-dimethyl-2,4-imidizolidinedione
Compound B
Distilled hydroxyethyl acrylate (46.4 g, 0.4 m), 0.065 g 4-methoxyphenol, and 1.0 g borontrifluoride etherate were charged into a 250 ml three-necked round bottom flask equipped with mechanical stirrer, pressure equalizing dropping funnel, reflux condenser, and CaSO 4 drying tube. The reaction flask was heated to 60° C. and 55.2 g 1,3-bis(2,3-epoxypropyl)-5,5-dimethyl-2,4-imidizolidenedione in 10 ml chloroform was added dropwise over 30 minutes. The reaction flask temperature was raised to 75° C. for 11 hours. At this time titration of residual epoxide groups indicated that the reaction was 97% complete. The volatiles were removed by vacuum distillation leaving as residue a liquid.
A layer of the compound containing 2% of 2,2-dimethoxy-2-phenylacetophenone was prepared and cured as in Example 1. The cured layer had chemical resistance similar to that of the layer of Example 1.
The analogous dimethacryloyl derivative (Compound C) was prepared in a similar manner utilizing 2-hydroxyethyl methacrylate in place of 2-hydroxyethyl acrylate. Layers prepared and cured with Compound C in the same manner as with Compound B had characteristics similar to those layers formed from Compound B.
EXAMPLE 4
Preparation of 1-[3-(2-acryloyloxyethoxy)-2-hydroxypropyl]-3[3-(2-acryloyloxyethoxy)-2-[[3-carboxyacryloyloxy]]propyl]-5,5-dimethyl-2,4-imidizolidinedione
Compound D
Compound B (10.0 g, 0.025 m from Example 2) and 2.4 g maleic anhydride were charged into a 100 ml three-necked round bottom flask equipped with mechanical stirrer, reflux condenser, and CaSO 4 drying tube. The reaction was heated at 80° C. for six hours. At this time the reaction was terminated to yield a viscous slightly yellow liquid displaying a strong, broad infrared spectral absorbance centered at 3000 cm -1 , characteristic for carboxylic acids.
A layer of this material containing 2% of 2,2-dimethoxy-2-phenylacetophenone was prepared as in Example 1. This layer was cured to insolubility with a Hanovia 3D960 mercury arc lamp in 60 seconds. The sample was 6 cm from the light source.
EXAMPLES 5-10
Various amounts of Compounds A and B were mixed with trimethylolpropanetriacrylate (TMPTA) and 2% by weight of the photopolymerization initiator of Example 1 added. Each mixture was diluted with an equal weight of acetone and coated onto 12 μm polyester film and dried. The dried coating was 2.5 μm thick. On exposure in air at a distance of 6 cm the radiation from a 100 watt Hanovia 3D690 lamp and the time measured at which each become insoluble in acetone. The data obtained is recorded in Table I.
TABLE I______________________________________Exp. Composition Cure TimeNo. Compound (%) TMPTA (Sec.)______________________________________4 None 100 6005 A (17) 83 806 A (28) 72 607 A (50) 50 508 A (100) 0 109 B (100) 0 30______________________________________
By reference to Table I it can be seen that TMPTA requires 10 minutes to reach insolubility and that with the addition of 17% of Compound A (from Example 1) the cure time is reduced to 80 seconds and with increasing amounts of A, the composition cures faster until at 100% A, the composition under the stated conditions cures in only 10 seconds. Comparable results can be obtained with Compound B.
EXAMPLE 11
A layer, 2.5 μm in thickness, of Compound B containing 2% of the photopolymerization catalyst of Example 1 on 12 μm polyester film was prepared as described in Example 1. A patterned template was placed over the layer and exposed in the UV Processor to one pass at 12 m/min. of an 80 watts/cm lamp. The exposed sheet was washed with cold water leaving an image having excellent resolution.
EXAMPLE 12
One part polyacrylic acid, one part compound A from Example 1, five parts water, five parts ethanol and 0.02 parts of the photopolymerization catalyst of Example 1 were mixed together to form a solution. A layer 5.0 m in thickness of this solution was coated onto 12 m polyester as described in Example 1. A patterned template was placed over the layer and exposed by a Hanovia 3D690 mercury arc lamp at a distance of 6 cm for two minutes. The exposed sheet was developed with cold water leaving an image having excellent resolution.
PREPARATION OF COMPOUND E ##STR17##
Compound A (20.4 g from Example 1) and 10.6 ml dry tetrahydrofuran were dissolved in a 250 ml 3-necked round bottom flask equipped with a magnetic stirrer, reflux condenser, pressure equalizing dropping funnel and CaSO 4 drying tube. 5.7 g phenylisocyanate was added dropwise over the course of five minutes. The reaction was terminated after stirring for twenty hours at room temperature. The lack of an isocyanate infrared absorption band indicates the reaction of the isocyanate to be quantitative.
A layer of this material containing 2% of the photopolymerization catalyst of Example 1 was prepared as in Example 1. This layer was cured to insolubility with a Hanovia 3D690 mercury arc lamp in 15 seconds. The sample was 6 cm from the light source.
Preparation of 1,3-Bis[3-(2-allyloxyethoxy)-2-hydroxypropyl]-5,5-dimethyl-2,4-imidizolidinedione ##STR18##
COMPOUND F
2-allyloxyethanol (20.43 g, 0.1 m), 0.03 g 4-methoxyphenol, and 0.30 g borontrifluoride etherate were charged into a 250 ml three-necked round bottom flask equipped with mechanical stirrer, pressure equalizing dropping funnel, reflux condenser and CaSO 4 drying tube. The reaction flask temperature was heated to 80° C. and 13.8 g 1,3-bis(2,3-epoxypropyl)-5,5-dimethyl-2,4-imidizolidinedione in 4.5 g chloroform was added dropwise over 30 minutes. The reaction was maintained at 80° for 17 hours. At this time titration of residual epoxide groups indicated that the reaction was 99% complete. The chloroform was removed by vacuum distillation leaving as residue a colorless liquid.
EXAMPLE 15
Into a 250 ml three-necked round bottom flask equipped with mechanical stirrer, pressure equalizing dropping funnel, reflux condenser, and calcium sulfate drying tube were charged 103.0 g pentaerythritol triacrylate (hydroxy equivalent weight of 515), 23.2 g 2-hydroxyethyl acrylate (0.2 m), 0.08 g 4-methoxyphenol, and 1.0 g borontrifluoride etherate. The reaction flask was heated to 75° C. and 55.2 g (0.40 m epoxy equivalency) 1,3-bis(2,3-epoxypropyl)-5,5-dimethyl-2,4-imidizolidinedione in 20 ml chloroform was added dropwise over one hour. After the addition, the reaction flask temperature was raised to 88° C. and stirred for 18.0 hours. At this time, titration of an aliquote for unreacted epoxide indicated the reaction was greater than 99% complete. The volatiles were removed by vacuum distillation leaving a viscous liquid which contains a mixture of bis(triacryloyl)-, bis(monoacryloyl)-, and the unsymmetrical monoacryloyl-triacryloyl-imidizolidinedione, and impurities, introduced with the pentaerythritol triacrylate.
A layer of the reaction product of Example 15, prepared to contain 2% Irgacure 651 and cured as described in Example 1, had abrasion and chemical resistance characteristics similar to those of the layer of Example 1. | Ethylenically unsaturated crosslinking agents and polymerizable monomers are disclosed. These agents contain a heterocyclic nucleus and are capable of forming oxygen insensitive, radiation curable systems. | 2 |
TECHNICAL FIELD
This invention relates generally to non-contact measurement systems for monitoring a web of material, and, more particularly, to an ultrasonic apparatus and method for diagnosing printing press web breakage while minimizing the effect of web wrinkles on the detection process which utilizes an ultrasonic transmitter and at least two ultrasonic receivers.
BACKGROUND OF THE INVENTION
Measurement systems, particularly ultrasonic measurement systems, are widely used in the printing industry to monitor characteristics of a web of paper ("web") passing through machinery such as a printing press. Ultrasonic technology is popular because of its reliable operation in the often dusty and dirty printing plant environment.
The principles of operation of ultrasonic measurement systems are well-known. When ultrasonic energy (i.e., a frequency higher than the audible range, or above 20 kHz) is incident on an object such as a web, part of the energy is reflected, part is transmitted and part is absorbed. Measuring the time between transmission of the energy and return of the reflected energy (the "return echo"), makes it possible to determine the distance from the ultrasonic transmitter and/or receiver to the web.
One important function of an ultrasonic measurement system for a printing press is to detect web breaks by checking for the absence or presence of a web within a certain distance from the measurement system. A typical ultrasonic web break detection system generates an emergency shutdown signal if the web is determined to be absent. The web is judged to be absent when no return echo is received by an ultrasonic receiver within certain amount of time, or if the time for receipt of the return echo indicates that the web has traveled outside of acceptable tolerances. Conversely, if there is a return echo within an acceptable time, the measurement system considers the web to be present and does not generate an emergency shutdown signal.
When a web breaks, the web is often directed back into the printing press, where it becomes entangled in the press rolls, resulting in substantial down-time and repair expenses. When a web break is detected it is often desirable to deploy a press protection device which stops the printing presses and severs and/or re-directs the web at various points. Accordingly, a false web breakage alarm could cause significant and unnecessary delay and expense.
Two well known ultrasonic web break detection systems used in the printing industry include the sonic web break detector disclosed in U.S. Pat. No. 5,036,706 to Gnuechtel et. al. and the model 1127 ultrasonic web break detector manufactured by Baldwin Web Controls. Such systems detect the presence or absence of a web within certain tolerances which vary with the speed of the web.
Web break detectors generally mount directly to a printing press, perpendicular to the plane of the web, within a few inches of the web's surface. Known web break detectors typically comprise a pair of piezoelectric transducers functioning in opposite ways, i.e., one transducer transmits ultrasonic energy at a predetermined amplitude, frequency and phase angle and a second transducer receives a return echo of the transmitted energy. The transmitter transducer and the receiver transducer together comprise a sonic head, and are typically tilted toward each other at a slight angle, for example, 5 to 10 degrees.
The transmission and reception of sonic energy by the sonic head is typically coordinated by a controller module, which causes the transmitter to emit a short burst of sonic energy every few milliseconds and, if the web is present, looks for the receiver to detect a return echo of sonic energy within a certain time, for example 300 to 780 microseconds, after the beginning of the transmission of the energy burst.
In addition, when the web is present, the receiver must generally show the presence of a return echo from the web for a certain number of consecutive transmit signals. The number of absent return echo signals tolerated is dependent on web speed, and decreases as web speed increases. Thus, the number of return echo absences functions as a filter which helps to ameliorate the possibility of the detection system issuing an emergency shutdown signal because of web flutter or small holes in the web.
Further, if a web is present, the controller module may continuously monitor the strength of the return echo to determine whether the receiver transducer has become dirty--covered with ink or paper dust, for example. A two-transducer sonic head will not function properly if the receiver transducer is too dirty.
Often, a single controller synchronizes multiple web break detection systems, each detection system having one or more sonic heads, so that the timing of sonic energy transmission and reception for each sonic head is synchronized. Synchronizing detection systems which are in close proximity to each other eliminates interference in the detection of return echoes which would result if timing were not precisely synchronized.
Typical ultrasonic web break detection systems utilizing a single transmitter-receiver transducer pair per sonic head suffer from the problem of mistaking harmless web angles and wrinkles in the web, which cause marked degradation of the return echo signal, for actual web breaks, thereby shutting down machinery and severing and redirecting webs unnecessarily.
Past systems have attempted to solve the false web breakage alarm problem caused by wrinkles by connecting the processed signals from two sonic heads in parallel logic, so that each sonic head must detect the absence of the web before an emergency shutdown signal is generated.
Parallel logic connection of the sonic heads suffers from various disadvantages, however. First, space within a detection system is wasted with two sonic heads essentially functioning as one detection unit. Second, cost and complexity are increased, where one transmitter transducer and associated electronics must be utilized for each receiver transducer, then both transmitter transducers must be synchronized to prevent interference between the adjacent transducer pairs. Third, the controller module must perform the same web detection analysis for each receiver transducer input. This wastes controller inputs and increases web break detection times, thus creating the potential for more serious press jams. For example, when two sonic heads are connected in parallel, a small web tear at only one edge (i.e., under only one sonic head), often referred to as an "edge tear", will not result in press shutdown until the tear travels further across the web. This is because, when connected in parallel logic, both sonic heads must detect a web break before an emergency shutdown signal is generated.
Accordingly, one object of the invention is to minimize false web breakage alarms resulting primarily from web wrinkles and secondarily from angular web distortions.
Another object is to reduce a number of components necessary to detect web breakage and prevent false web breakage alarms resulting from web wrinkles.
A further object is to increase reliability of web breakage detection systems.
A still further object of the invention is to decrease web tear detection time.
SUMMARY OF THE INVENTION
According to the present invention, the foregoing objects and advantages are attained by a method of minimizing an effect of a web wrinkle during web break detection including periodically transmitting a burst of energy for a period of time, the burst of energy being reflected off the web and producing an echo signal; receiving a portion of the echo signal by a first transducer and a second transducer; determining strengths of the portions of the echo signal received by the first and second transducers; comparing the strengths to determine which portion of the echo signal is stronger; and analyzing the strongest echo signal to determine the presence of a web break.
In accordance with another embodiment of the present invention, an apparatus for detecting a position of a web of material traversing a machine for feeding the web comprises a housing for storing three transducers; a first transducer adapted to periodically emit a burst of energy for a period of time, the burst of energy being reflected off an object and producing an echo signal; a second transducer adjacent to the first transducer, adapted to receive a portion of the echo signal; and a third transducer adjacent to the first transducer, adapted to receive another portion of the echo signal.
Other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following description of the preferred embodiment of the invention which has been shown and described by way of illustration, as the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a typical multiple printing unit heat set press system.
FIG. 2a illustrates a cut-away side view of an ultrasonic detection module for diagnosing printing press web breakage according to the preferred embodiment of the present invention.
FIG. 2b illustrates a cut-away side view of a detector bar for housing up to four detection modules according to the preferred embodiment of the present invention.
FIG. 3 illustrates the principle of operation of the ultrasonic detection module for diagnosing printing press web breakage while reducing false web break alarms according to the preferred embodiment of the present invention.
FIGS. 4 and 4A-4C are a schematic electrical diagram of the ultrasonic detection module according to the preferred embodiment of the present invention.
FIG. 5 illustrates the difference in phase angle of a return echo signal received by a left receiver transducer and a return echo received by a right receiver transducer of a detection module according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings, wherein like numerals designate like components, FIG. 1 illustrates a typical multiple printing unit heat set press system. As shown, the press may include multiple printing units 10A-10D, each having one or more blanked impression cylinder combinations 5 employed in the printing process. When the printing units 10A-10D are running, the blanked cylinders 5 feed a continuous paper web 30 through the printing units 10A-10D, from an infeed unit 2 upstream from the printing units 10A-10D and then through a web dryer unit 35 and a chill unit 40 downstream of the printing units 10A-10D.
Web break detection systems 15, which may be ultrasonic systems, are located at various points in the system above web 30 to detect when the web 30 breaks. As shown, a web break 42 has occurred in the dryer unit 35.
FIG. 2a illustrates a cut-away side view of an ultrasonic detection module 50 for diagnosing printing press web breakage according to the preferred embodiment of the present invention. The detection module 50 may be molded plastic, and have dimensions of approximately 4.5 inches long by approximately 1.7 inches high.
The detection module 50 may be adjustably located in a detector bar 130, as illustrated in FIG. 2b, which may be extruded aluminum. The detector bar 130 may have a channel 132 sufficiently long to hold up to four detection modules 50 arranged in series logic in slot positions 134a, b, c and d, respectively. Stocking the detector bar with four modules 50 allows for accurate web detection at both full and half-web conditions. The detector module 50 has approximately the same dimensions as a Baldwin model 1127 sonic head, and thus slots 134a, b, c or d may house either detector modules 50 or prior sonic heads such as the Baldwin 1127 model.
Referring again to FIG. 2a, a flange 51 may facilitate the insertion and removal of detection module 50 to and from the detector bar 130. A base side 58 of the detector module 50 fits into the detector bar channel 132. The detector bar 130 is mounted to a printing press via brackets (not shown) such that a detection side 60 of the detector module 50 is oriented toward the web 136, perpendicular to the plane of the web, nominally about 2.5 inches from the web's surface.
Three dimensionally-identical piezoelectric transducers 62, 64 and 66 are housed within individual transducer housings 52, 54 and 56. The transducers 62, 64 and 66 may be cylindrical, the center of each transducer being approximately 1.2 inches from its neighbor, and may be composed of a can containing a piezoceramic-driven aluminum membrane. Each can may in turn be encased in a rubber boot.
Suitable transducers are commercially available from Motorola, product numbers KSN6541A and KSN6540A and from S. Square Enterprise Co., Ltd., Taiwan, Product Nos. RE455ET/R180 or RE400ET/R180. A transducer which oscillates at 45.5 kHz, 40 kHz or another frequency may be utilized.
A transmitter transducer 62 may reside in transducer housing 52, held in place by transducer supports 52a and 52b. The transmitter transducer 62 may emit a short burst of four pulses, for example 77 microseconds long, of 45.5 kHz sonic energy toward the web every 10 milliseconds.
One receiver transducer 64 may reside in transducer housing 54 supported by transducer supports 54a and 54b, while a second receiver transducer 66, which is approximately 2.4 inches from the first receiver transducer, may reside in transducer housing 56, secured by transducer supports 56a and 56b. The receiver transducers 64, 66 detect the presence of a return echo of the transmitted sonic energy.
The transmitter transducer 62 is generally perpendicular to the plane of the web, while the receiver transmitters 64, 66 may be tilted toward the transmitter transducer 62 at a slight angle, for example, 10 degrees. Three cone-shaped horns 53, 57 and 59, which may be integral with the molded plastic of the detection module 50, counteract cross-talk between the transducers 62, 64 and 66. The center horn 57 associated with the transmitter transducer 62 is shorter than horns 53 and 59 associated with the receiver transducers 64, 66 so that, among other things, transmitted sonic energy radiates a wide beam. The beam width may be approximately 60 degrees, whereas past two-transducer sonic heads having angled transmitter transducers emitted total beam widths of only 45 degrees.
The receiver transducers 64, 66 are typically immediately active upon transmission of a burst of sonic energy by the transmitter transducer 62. To detect the presence of the web, a receiver transducer 64, 66 generally must detect a leading edge of a return echo of the transmitted sonic energy from 300 to 780 microseconds after initial transmission of the sonic energy toward the web.
Measuring the amount of time elapsed between initial transmission of sonic energy by the transmitter transducer 62 and detection of the leading edge of the return echo by the receiver transducer 64, 66, and knowing the speed of sound in air, makes it possible to calculate the distance of the web from the detection module 50. This calculation may be performed by a system controller (not shown) such as the Baldwin Web Controls model 1127 controller using well-known methods. The web is considered present if it is found to be within certain distances, for example, 1 to 4 inches, from the detection module 50. If the web is not detected within 1 to 4 inches of the module 50, an emergency shutdown signal is sent to the printing presses (depicted in FIG. 1) by the web system controller (discussed further below).
Connector port 55 allows the detector module 50 to be remotely connected to the system controller via a cable (not shown), which supplies communication between the detection module 50 and the system controller.
The system controller is responsible, for example, for (1) generating control signals which cause the transmitter transducer 62 to periodically emit bursts of sonic energy, (2) accepting and analyzing the return echo signals detected by the receiver transducer 64, 66, and (3) for determining whether the web is or is not present beneath the detector module 50 based on the analysis performed on the return echo signals.
A web is considered to be absent by the controller when there are no return echo signals from the web (within a given distance, such as 1 inch to 4 inches) for a certain number of consecutive transmit signals, the number of tolerated return echo absences being dependent on web speed. The methods for processing return echo signals based on web speed to determine web presence or absence are well-known to those skilled in the art.
The frequency of false web break alarms which occur because of web wrinkles is reduced by using the preferred embodiment of the detection module constructed and oriented as described in connection with FIG. 2, the principle of operation of which is graphically illustrated in FIG. 3.
Return echo signal strength 75, i.e., a direct current magnitude of a return echo signal, is plotted against wrinkle distance from a centerline point 73 directly beneath a transmitter transducer, for both a left receiver transducer 70 and a right receiver transducer 72, the left and right receiver transducers being positioned approximately 2.4 inches apart, as a web wrinkle with a height of 0.43 inches passes from left to right under the ultrasonic detection module.
The graph 75 demonstrates that the left and right transducer receivers in different locations from the same transmitter have signal losses (and therefore absent return echo signals) as the wrinkle changes position. For example, while the right receiver transducer 72 maintains a relative signal strength of about 5.5 when the wrinkle is near the left of the detection module, the left receiver transducer signal strength drops to about 1. Conversely, as the wrinkle travels toward to the right side of the detection module, the left receiver transducer maintains a signal strength of approximately 5.5, while the right receiver transducer signal strength drops to about 1.
A similar situation results when the web is tilted side-to-side, and, as will be appreciated by one skilled in the art, the principles of the present invention which apply to reducing false web break alarms resulting from web wrinkles are also applicable to reducing the false alarms which occur because of web angles.
The loss of signal detected by the receiver transducer nearest to the wrinkle may explained by, for example, two general principles of wave mechanics. First, a rise in the web height because of the wrinkle creates an obstruction in the path of the return echo signals--the wrinkle thus blocks most of the return echo signals from being detected by the receiver transducer closest to the wrinkle. Second, the wrinkle causes a phase angle of the return echo signals to shift such that signal cancellation with the transmitted sonic energy results.
Thus, it is seen that the effect of web wrinkles on the web break detection process may be reduced by comparing the return echo signal strengths detected by the left and right receiver transducers prior to the system controller performing analysis of the return echo signals. Then, only the stronger of the left or right receiver transducer signal must be analyzed by the controller to determine whether the web is or is not present beneath the detector module.
The use of two receiver transducers in the manner described herein increases detector module reliability over prior systems having one transmitter transducer and one receiver transducer. For example, one receiver transducer which breaks or becomes blocked by dirt will not affect the continued operation of a detector module according to the present invention because a second receiver transducer will continue to detect web breaks in a manner comparable to prior two-transducer systems.
As will further be recognized by one skilled in the art, the three-transducer detector module according to the present invention eliminates the need for parallel logic connection of detection modules. Thus, web edge tears are quickly detected.
FIG. 4 is a schematic electrical diagram of the ultrasonic detection module according to the preferred embodiment of the present invention. The electronics are designed to be used with a Baldwin Web Controls model 1127 system controller, which utilizes well-known methods for providing a 4-pulse signal to a transmitter transducer, and for digitally processing the return echo signals detected by a receiver transducer.
Circuitry 80 associated with the transmitter transducer 81 of the preferred embodiment of the detection module described in connection with FIG. 2 receives an input 82 from the system controller (not shown) and is fed via resistor 83 to dual emitter followers 84, 85. The dual emitter followers 84, 85, via coupling capacitor 86 drive the transmitter transducer 81 at its low impedance resonance point, series resonating with inductor 87 and capacitor 88.
Circuitry 90a is associated with a first receiver transducer 91a, and identical circuitry 90b is associated with a second receiver transducer 91b, both transducers 91a and 91b being constructed and oriented according to the preferred embodiment of the detection module described in connection with FIG. 2.
The inputs from receiver transducers 91a,b are fed to capacitors 92a,b and resistors 93a,b. The capacitor-resistor combinations discriminate against lower frequency interference. Operational amplifier stages 94a,b, along with their associated capacitors 95a,b and resistors 96a,b, provide some gain along with impedance transformation. Stages 97a,b including operational amplifiers 98a,b and their associated components beginning with resistors 99a,b comprise two-pole bandpass filters centered at the transmitter transducer's frequency. Stages 97a,b also provide gain. The outputs of stages 97a,b serve as inputs to stages 118a,b, which provide large, adjustable gain.
At this point, the return echo-signals detected by each receiver transducer could be added together and processed by the system controller. The addition method is not preferred, however, because, as illustrated in FIG. 5, the signals from the left receiver transducer 70 and the right receiver transducer 72 may be out of phase. As shown, the signals are 180 degrees out of phase, so that simple addition of the signal magnitudes would be impossible, and could lead to unsatisfactory web detection.
Thus, it is preferred that stages 119a,b plus 100a,b perform full-wave rectification of the signals, so that absolute magnitudes or direct current values of the return echo signals detected by each receiver transducer are obtained. The rectified signals represent the relative strengths of the signals. Components 101a,b and 102a,b provide filtering.
The rectified and filtered signals are impedance transformed by operational amplifier stages 103a,b and their associated components. Then, each signal is fed into a comparator stage 104, which drives analog switch 105. The analog switch 105 selects the stronger of the two signals. The strongest signal is fed to a final amplifier stage 106 via capacitor 107 and resistor 108. Capacitor 109 provides stabilization. Stage 106 drives dual emitter followers 110, 111, the output 112 of which is capable of driving long cables (not shown) for connecting the detection module to the system controller.
It will be apparent that other and further forms of the invention may be devised without departing from the spirit and scope of the appended claims, it being understood that this invention is not to be limited to the specific embodiments shown. | An apparatus for detecting breakage of a web of material traversing a machine for feeding the web, and a method for the same. The apparatus includes a housing for mounting three transducers, a first transducer adapted to periodically emit a burst of energy for a period of time, the burst of energy being reflected off an object and producing an echo signal. A second transducer adjacent to the first transducer receives a portion of the echo signal, and a third transducer also adjacent to the first transducer receives another portion of the echo signal. The strongest portion of the echo signal is used to detect whether the web is broken. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Japanese Patent Application Nos. 2011-148094, filed Jul. 4, 2011; 2012-050933, filed Mar. 7, 2012; and 2012-146881, filed Jun. 29, 2012; each incorporated herein in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to a positive electrode active material, to a positive electrode for an electric device, and to an electric device. Specifically, the positive electrode active material of the present invention is suitably used as a positive electrode active material of a lithium ion secondary battery or a lithium ion capacitor, which serves as an electric device. Moreover, the electric device of the present invention is suitably used, for example, as an electric device for a vehicle such as an electric vehicle, a fuel cell vehicle and a hybrid electric vehicle.
BACKGROUND
[0003] In recent years, in order to cope with the air pollution and the global warming, it is sincerely desired that the emission amount of carbon dioxide be reduced. In the automobile industry, expectations are centered on such reduction of the emission amount of carbon dioxide by introduction of the electric vehicle (EV) and the hybrid electric vehicle (HEV). Therefore, development of an electric device such as a secondary battery for driving a motor, the electric device serving as a key for practical use of these vehicles, is assiduously pursued.
[0004] As the secondary battery for driving a motor, a lithium ion secondary battery having high theoretical energy attracts attention, and at present, development thereof rapidly progresses. In general, the lithium ion secondary battery has a configuration in which a positive electrode, a negative electrode and an electrolyte located therebetween are housed in a battery casing. Note that the positive electrode is formed by coating a surface of a current collector with positive electrode slurry containing a positive electrode active material, and the negative electrode is formed by coating a surface of a negative electrode current collector with negative electrode slurry containing a negative electrode active material.
[0005] In order to enhance capacity characteristics, output characteristics and the like of the lithium ion secondary battery, selection of the respective materials is extremely important.
[0006] Heretofore, a non-aqueous electrolyte secondary battery has been proposed, which has a hexagonal layered rock salt structure belonging to the space group R-3m, and contains Li in the 3b site in which transition metal is contained (for example, refer to Japanese Patent Unexamined Publication No. 2007-242581). This lithium-nickel-manganese composite oxide is represented by a formula Li[Li x Ni y Mn z ]O 2−a . Then, in the formula, x ranges: 0<x<0.4; y ranges: 0.12<y<0.5; z ranges: 0.3<z<0.62; and a ranges: 0≦a<0.5, which satisfy the following relationships: x>(1−2y)/3; ¼≦y/z≦1.0; and x+y+z=1.0.
[0007] Moreover, heretofore, a cathode composition for a lithium ion battery has been proposed, which has a formula (a) Li y M 1 (1−b) Mn b ]O 2 or a formula (b) Li x [M 1 (1−b) Mn b ]O 1.5+c (for example, refer to Japanese Patent Unexamined Publication No. 2004-538610). Note that, in the formulae, the following relationships are satisfied, which are: 0≦y<1; 0<b<1; and 0<c<0.5, and M 1 denotes one or more types of metal elements. However, in the case of the formula (a), M 1 is metal elements other than chromium. Then, this composition has a single-phase form having an O3 crystal structure that does not cause phase transition to the spinel structure when a cycle operation of a predetermined complete charge/discharge cycle is performed.
SUMMARY
[0008] With the non-aqueous electrolyte secondary battery described in Japanese Patent Unexamined Publication No. 2007-242581, there has been a problem that a high capacity cannot be maintained since a crystal structure of the lithium-nickel-manganese composite oxide represented by the formula Li[Li x Ni y Mn z ]O 2−a is not stabilized.
[0009] Moreover, in the examination by the inventors of the present invention, even in a lithium ion battery using the cathode composition for a lithium ion battery, which is described in Japanese Patent Unexamined Publication No. 2004-538610, there has been a problem that a discharge capacity, a discharge operation voltage and initial rate characteristics are not sufficient.
[0010] The present invention has been made in consideration of the problems as described above, which are inherent in the conventional technology. Then, it is an object of the present invention to provide a positive electrode active material for an electric device, which is capable of exerting excellent initial charge/discharge efficiency while maintaining a high capacity by maintaining a high reversible capacity. It is another object of the present invention to provide a positive electrode for an electric device, which uses the positive electrode active material for an electric device, and to provide an electric device.
[0011] A positive electrode active material for an electric device according to an aspect of the present invention contains a first active material and a second active material. The first active material is composed of a transition metal oxide represented by compositional formula (1):
[0000] Li 1.5 [Ni a Co b Mn c [Li] d ]O 3 (1)
[0000] wherein Li is lithium, Ni is nickel, Co is cobalt, Mn is manganese, O is oxygen, a, b, c and d satisfy relationships: 0<d<0.5; a+b+c+d=1.5; and 1.0<a+b+c<1.5.
[0012] The second active material is composed of a spinel-type transition metal oxide represented by compositional formula (2) and having a crystal structure belonging to a space group Fd-3m:
[0000] LiM a′ Mn 2−a′ O 4 (2)
[0000] wherein Li is lithium, M is at least one metal element with a valence of 2 to 4, Mn is manganese, O is oxygen, and a′ satisfies a relationship: 0≦a′<2.0.
[0013] Then, a content ratio of the first active material and the second active material satisfies, in a mass ratio, a relationship represented by expression (3):
[0000] 100:0<M A :M B <0:100 (3)
[0000] wherein M A is a mass of the first active material and M B is a mass of the second active material.
BRIEF DESCRIPTION OF DRAWINGS
[0014] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
[0015] FIG. 1 is a schematic cross-sectional view showing an example of a lithium ion secondary battery according to an embodiment of the present invention;
[0016] FIG. 2 is a graph showing charge/discharge curves of the respective examples and comparative examples in a first embodiment;
[0017] FIG. 3 is a graph showing initial charge/discharge efficiencies of the respective examples and comparative examples in the first embodiment; and
[0018] FIG. 4 is a graph explaining a definition of a change rate of a spinel structure.
DESCRIPTION OF EMBODIMENTS
[0019] A description is made in detail of a positive electrode active material for an electric device according to the present invention, of a positive electrode for an electric device, which uses the positive electrode active material, and an electric device. Here, the positive electrode active material for an electric device according to the present invention is applicable, for example, as a positive electrode active material of a lithium ion secondary battery as an electric device. Accordingly, the description of the above is made in detail while taking, as examples, the positive electrode active material for a lithium ion secondary battery, and the lithium ion secondary battery.
First Embodiment
[0020] First, a description is made of a positive electrode active material for a lithium ion secondary battery according to a first embodiment of the present invention. The positive electrode active material for a lithium ion secondary battery according to the first embodiment contains a first active material composed of a transition metal oxide represented by compositional formula (1). Moreover, the above-described positive electrode active material contains a second active material composed of a spinel-type transition metal oxide, which is represented by compositional formula (2), and has a crystal structure belonging to the space group Fd-3m:
[0000] Li 1.5 [Ni a Co b Mn c [Li] d ]O 3 (1)
[0000] where, in the formula (1), Li is lithium, Ni is nickel, Co is cobalt, Mn is manganese, and O is oxygen. Moreover, a, b, c and d satisfy relationships: 0<d<0.5; a+b+c+d=1.5; and 1.0<a+b+c<1.5.
[0000] LiM a′ Mn 2−a′ O 4 (2)
[0000] where, in the formula (2), Li is lithium, M is at least one metal element with a valence of 2 to 4, Mn is manganese, and O is oxygen. Moreover, a′ satisfies a relationship: 0≦a′<2.0.
[0021] Moreover, the positive electrode active material for a lithium ion secondary battery according to this embodiment is one in which a content ratio of the first active material and the second active material satisfies a relationship, which is represented by expression (3), in a mass ratio:
[0000] 100:0<M A :M B <0:100 (3)
[0000] where, in the expression (3), M A is a mass of the first active material, and M B is a mass of the second active material.
[0022] In the case where the positive electrode active material as described above is used for the lithium ion secondary battery, the positive electrode active material is capable of exerting excellent initial charge/discharge efficiency while maintaining a high capacity by maintaining a high reversible capacity. Accordingly, the positive electrode active material is suitably used for the positive electrode for the lithium ion secondary battery. As a result, the lithium ion secondary battery can be suitably used as a lithium ion secondary battery for a drive power supply or auxiliary power supply of a vehicle. Besides, the lithium ion secondary battery is also sufficiently applicable as a lithium ion secondary battery oriented for a mobile instrument such as a cellular phone.
[0023] Here, in the case where d does not satisfy 0<d<0.5 in compositional formula (1), a crystal structure of the first active material is not stabilized in some case. On the contrary, in the case where d satisfies 0<d<0.5, the first active material is likely to become a layered transition metal oxide belonging to the space group C2/m. Note that, by the fact that the first active material is the layered transition metal oxide belonging to the space group C2/m, and further, is mixed with the above-described second active material, an irreversible capacity in an initial period is reduced more, whereby it is made possible to maintain the high reversible capacity.
[0024] Moreover, in compositional formula (1), in the case where d is 0.1 or more, that is to say, in the case where d satisfies 0.1≦d<0.5, a composition of the first active material is less likely to be approximate to Li 2 MnO 3 , and the charge/discharge becomes easy, and accordingly, this is preferable. Moreover, in the case where d is 0.45 or less, that is to say, in the case where d satisfies 0<d≦0.45, a charge/discharge capacity of the positive electrode active material per unit weight can be set at 200 mAh/g or more, which is higher than in the existing layered positive electrode active material, and accordingly, this is preferable. Note that, from the above-described viewpoint, in compositional formula (1), in the case where d satisfies 0.1≦d≦0.45, the charge/discharge capacity can be increased while facilitating the charge/discharge, and accordingly, this is particularly preferable.
[0025] Moreover, in compositional formula (1), preferably, a+b+c satisfies 1.05≦a+b+c≦1.4. Here, in general, it is known that, from viewpoints of enhancing material purity and enhancing electron conductivity, nickel (Ni), cobalt (Co) and manganese (Mn) contribute to a capacity and output characteristics of the lithium ion secondary battery. Then, by the fact that a+b+c satisfies 1.05≦a+b+c≦1.4, the respective elements are optimized, and the capacity and the output characteristics can be enhanced more. Hence, in the case where the positive electrode active material containing the first active material that satisfies this relationship is used for the lithium ion secondary battery, then the high reversible capacity is maintained, whereby it is made possible to exert the excellent initial charge/discharge efficiency while maintaining the high capacity.
[0026] Note that, if the relationships: a+b+c+d=1.5; and 1.0<a+b+c<1.5 are satisfied in compositional formula (1), then values of a, b and c are not particularly limited. However, preferably, a satisfies 0<a<1.5. Note that, in the case where a does not satisfy a≦0.75, since nickel is contained in the positive electrode active material within a range of d described above under a condition where nickel (Ni) is divalent, the crystal structure of the first active material is not stabilized in some case. Note that, in the case where a satisfies a≦0.75, the first active material is likely to become the layered transition metal oxide belonging to the space group C2/m in terms of the crystal structure.
[0027] Moreover, in compositional formula (1), preferably, b satisfies 0≦b<1.5. However, in the case where b does not satisfy b≦0.5, then the crystal structure is not stabilized in some case since nickel is contained in the positive electrode active material within the range of d described above under the condition where nickel (Ni) is divalent, and further, since cobalt (Co) is contained in the positive electrode active material. Note that in the case where b satisfies b≦0.5, the first active material is likely to become the layered transition metal oxide belonging to the space group C2/m in terms of the crystal structure.
[0028] Moreover, in compositional formula (1), preferably, c satisfies 0<c<1.5. However, in the case where c does not satisfy c≦1.0, nickel and cobalt are contained in the positive electrode active material within the range of d described above under the condition where nickel is divalent. Moreover, manganese (Mn) is contained in the positive electrode active material within the range of d described above under a condition where manganese is tetravalent. Therefore, the crystal structure of the positive electrode active material is not stabilized in some case. Note that, in the case where c satisfies c≦1.0, the first active material is likely to become the layered transition metal oxide belonging to the space group C2/m in terms of the crystal structure.
[0029] Furthermore, in compositional formula (1), preferably, the relationship: a+b+c+d=1.5 is satisfied from a viewpoint of stabilizing the crystal structure of the first active material.
[0030] Moreover, in compositional formula (2), in the case where a′ does not satisfy 0≦a′<2.0, then in terms of the crystal structure, the second active material does not become the spinel-type transition metal oxide belonging to the space group Fd-3m. Note that, in the case where a′ is 0.2 or less, that is, in the case where a′ satisfies 0≦a′≦0.2, the charge/discharge capacity of the positive electrode active material per unit weight can be set at 200 mAh/g or more, which is higher than in the existing layered positive electrode active material, and accordingly, this is preferable.
[0031] Furthermore, in compositional formula (2), M is at least one metal element with a valence of 2 to 4. As suitable examples of the metal element as described above, for example, nickel (Ni), cobalt (Co), zinc (Zn) and aluminum (Al) can be mentioned. In the positive electrode active material, these may be each contained singly, or two or more thereof may be contained in combination.
[0032] Moreover, in the lithium ion secondary battery of this embodiment, the content ratio of the first active material and the second active material satisfies the relationship, which is represented by expression (3), in the mass ratio. However, from a viewpoint of enabling exertion of superior initial charge/discharge efficiency, preferably, the content ratio satisfies a relationship represented by expression (4). Moreover, from the viewpoint of enabling the exertion of the superior initial charge/discharge efficiency, more preferably, the content ratio satisfies a relationship represented by expression (5):
[0000] 100:0<M A :M B <0:100 (3)
[0000] 100:0<M A :M B <50:50 (4)
[0000] 100:0<M A :M B <85:15 (5)
[0000] wherein M A is the mass of the first active material and M B is the mass of the second active material.
[0033] At the present point of time, in the positive electrode active material of this embodiment, it is considered that effects thereof are obtained by a mechanism which is described as below. However, even a case where the effects are obtained without depending on the mechanism which is described as below is incorporated within the scope of the present invention.
[0034] First, in the positive electrode active material of this embodiment, it is considered necessary that there coexist: the first active material that has the crystal structure containing extra lithium (Li), which is irreversible; and the second active material that has the crystal structure having a defect or a site, into which lithium is insertable. That is to say, when there coexist the first active material and the second active material, which are as described above, then at least a part of the extra lithium, which is irreversible, in the first active material is inserted into the defect or site of the second active material, into which lithium is insertable, and an amount of such irreversible lithium is reduced. In such a way, the high reversible capacity can be maintained, and the high capacity can be maintained. Moreover, the following is considered. Specifically, even if the amount of the irreversible lithium is reduced, the first active material that has the crystal structure containing the extra lithium is contained, and accordingly, the initial charge/discharge efficiency is enhanced.
[0035] Moreover, in the case where the mechanism for inserting the lithium, the mechanism being as mentioned above, is considered, preferably, the first active material and the second active material are arranged close to each other. Hence, preferably, particles of the first active material and particles of the second active material are mixed with each other, and the first active material and the second active material are contained in a state where the particles of both thereof are brought into contact with each other; however, the state of the first active material and the second active material is not limited to this, and may be non-uniform. For example, the first active material and the second active material may be arranged so as to be stacked on each other. That is to say, in the positive electrode of the lithium ion secondary battery, a layer containing the first active material and a layer containing the second active material may be stacked on each other in a state of being brought into direct contact with each other. In the case where the mechanism for inserting the lithium, the mechanism being as mentioned above, is considered, it is considered that, preferably, the first active material is arranged on a current collector side to be described later, and the second active material is arranged on an electrolyte layer side to be described later.
[0036] Next, while referring to the drawings, a description is made in detail of the positive electrode for the lithium ion secondary battery according to the embodiment of the present invention and of the lithium ion secondary battery according thereto. Note that dimensional ratios in the drawings, which are incorporated by reference in the following embodiments, are exaggerated for convenience of explanation, and are different from actual ratios in some case.
[Configuration of Lithium Ion Secondary Battery]
[0037] FIG. 1 shows the lithium ion secondary battery according to the embodiment of the present invention. Note that the lithium ion secondary battery as described above is called a laminate-type lithium ion secondary battery.
[0038] As shown in FIG. 1 , the lithium ion secondary battery 1 of this embodiment has a configuration in which a battery element 10 attached with a positive electrode lead 21 and a negative electrode lead 22 is enclosed in an inside of an exterior body 30 formed of a laminated film. Then, in this embodiment, the positive electrode lead 21 and the negative electrode lead 22 are drawn out in opposite directions to each other from the inside of the exterior body 30 to an outside thereof. Note that, though not shown, the positive electrode lead and the negative electrode lead may be drawn out in the same direction from the inside of the exterior body to the outside thereof. Moreover, the positive electrode lead and the negative electrode lead, which are as described above, can be attached onto positive electrode current collectors and negative electrode current collectors, which are to be described later, for example, by ultrasonic welding, resistance welding and the like.
[Positive Electrode Lead and Negative Electrode Lead]
[0039] The positive electrode lead 21 and the negative electrode lead 22 are composed, for example, of a metal material such as aluminum (Al), copper (Cu), titanium (Ti), nickel (Ni), alloys thereof and stainless steel (SUS). However, the metal material is not limited to these, and materials, which have been heretofore known in public and are used as the leads for the lithium ion secondary battery, can be used.
[0040] Note that, as the positive electrode lead and the negative electrode lead, those formed of the same material may be used, or those formed of different materials may be used. Moreover, as in this embodiment, the leads, which are prepared separately, may be connected to the positive electrode current collectors and the negative electrode current collectors, or alternatively, the leads may be formed by individually extending the respective positive electrode current collectors and the respective negative electrode current collectors, which are to be described later. Although not shown, preferably, the positive electrode lead and the negative electrode lead on portions of being taken out from the exterior body are coated with heat-resistant and insulating thermal shrinkage tubes and the like so as not to affect products (for example, automotive components, and in particular, electronic components and the like) by causing a current leakage and so on by contacting peripheral instruments, wires and the like.
[0041] Moreover, though not shown, current collector plates may be used for the purpose of taking a current to an outside of the battery. The current collector plates are electrically connected to the current collectors and the leads, and are taken out to an outside of the laminated film as an outer package material of the battery. A material that composes the current collector plates is not particularly limited, and a highly electrically conductive material, which is known in public and has heretofore been used as current collector plates for the lithium ion secondary battery, can be used. As such a constituent material of the current collector plates, for example, a metal material such as aluminum (Al), copper (Cu), titanium (Ti), nickel (Ni), alloys thereof, and stainless steel (SUS) is preferable, and from viewpoints of light weight, corrosion resistance and high conductivity, aluminum, copper or the like is more preferable. Note that, for the positive electrode current collector plate and the negative electrode current collector plate, the same material may be used, or different materials may be used.
[Exterior Body]
[0042] Preferably, the exterior body 30 is formed, for example, of a film-like outer package material from viewpoints of miniaturization and weight reduction. However, the exterior body is not limited to this, and a material, which has been heretofore known in public and is used for the exterior body for the lithium ion secondary battery, can be used. That is to say, a metal can case can also be applied.
[0043] Note that, from a viewpoint of being excellent in output enhancement and cooling performance, and of being suitably usable for a battery for a large instrument such as an electric vehicle and a hybrid electric vehicle, a polymer-metal composite laminated film excellent in thermal conductivity can be mentioned as the exterior body. More specifically, an exterior body can be suitably used, which is formed of a laminated film with a three-layer structure composed by stacking polypropylene as a thermocompression layer, aluminum as a metal layer and Nylon as an outer protection layer on one another in this order.
[0044] Note that, in place of the above-mentioned laminated film, the exterior body may be composed of another structure, for example, a laminated film that does not have a metal material, a polymer film such as polypropylene, a metal film or the like.
[0045] Here, a general configuration of the exterior body can be represented by a stacked structure of the outer protection layer/the metal layer/the thermocompression layer. However, in some case, the outer protection layer is composed of plural layers, and the thermocompression layer is composed of plural layers. Note that it is sufficient if the metal layer functions as an impermeable barrier film, and not only aluminum foil but also stainless steel foil, nickel foil, plated iron foil and the like can be used. However, as the metal layer, the aluminum foil, which is thin, lightweight and excellent in workability, can be suitably used.
[0046] Configurations usable as the exterior body are listed below in the format of (outer protection layer/metal layer/thermocompression layer): Nylon/aluminum/unstretched polypropylene; polyethylene terephthalate/aluminum/unstretched polypropylene; polyethylene terephthalate/aluminum/polyethylene terephthalate/unstretched polypropylene; polyethylene terephthalate/Nylon/aluminum/unstretched polypropylene; polyethylene terephthalate/Nylon/aluminum/Nylon/unstretched polypropylene; polyethylene terephthalate/Nylon/aluminum/Nylon/polyethylene; Nylon/polyethylene/aluminum/straight-chain low-density polyethylene; polyethylene terephthalate/polyethylene/aluminum/polyethylene terephthalate/low-density polyethylene; polyethylene terephthalate/Nylon/aluminum/low-density polyethylene/unstretched polypropylene; and the like.
[Battery Element]
[0047] As shown in FIG. 1 , the battery element 10 has a configuration in which positive electrodes 11 , electrolyte layers 13 and negative electrodes 12 are stacked on one another. Here, in each of the positive electrodes 11 , positive electrode active material layers 11 B are formed on both of main surfaces of a positive electrode current collector 11 A, and in each of the negative electrodes 12 , negative electrode active material layers 12 B are formed on both of main surfaces of a negative electrode current collector 12 A. At this time, the positive electrode active material layer 11 B, which is formed on one of the main surfaces of the positive electrode current collector 11 A in one positive electrode 11 , and the negative electrode active material layer 12 B, which is formed on one of the main surfaces of the negative electrode current collector 12 A in the negative electrode adjacent to the one positive electrode 11 , face each other while interposing the electrolyte layer 13 there between. In such a way, pluralities of the positive electrodes, the electrolyte layers and the negative electrodes are stacked on one another in this order.
[0048] In such a way, the positive electrode active material layer 11 B, the electrolyte layer 13 and the negative electrode active material layer 12 B, which are adjacent to one another, compose one single cell layer 14 . Hence, the lithium ion secondary battery 1 of this embodiment becomes one, in which a plurality of the single cell layers 14 are stacked on one another, and are thereby electrically connected in parallel to one another. Note that each of the positive electrodes and the negative electrodes may be one, in which each of the active material layers is formed on one of the main surfaces of each current collector. In this embodiment, for example, on a negative electrode current collector 12 a located on an outermost layer of the battery element 10 , the negative electrode active material layer 12 B is formed on only one surface thereof.
[0049] Moreover, though not shown, on outer circumferences of the single cell layers, there may be provided insulating layers for insulating the positive electrode current collectors and the negative electrode current collectors, which are adjacent to each other, from each other. Preferably, the insulating layers as described above are formed of a material, which holds an electrolyte contained in the electrolyte layers and the like, and prevents liquid leakage of the electrolyte to the outer circumferences of the single cell layers. Specifically, usable are: general-purpose plastics such as polypropylene (PP), polyethylene (PE), polyurethane (PUR), polyamide-based resin (PA), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF) and polystyrene (PS); thermoplastic olefin rubber; and the like. Moreover, silicone rubber can also be used.
[Positive Electrode Current Collector and Negative Electrode Current Collector]
[0050] The positive electrode current collectors 11 A and the negative electrode current collectors 12 A are composed of an electrically conductive material. A size of the current collectors can be determined in response to a usage purpose of the battery. For example, if the current collectors are used for a large battery for which a high energy density is required, then the current collectors with a large area are used. A thickness of the current collectors is not particularly limited, either. In usual, the thickness of the current collectors approximately ranges from 1 to 100 μm. A shape of the current collectors is not particularly limited, either. In the battery element 10 shown in FIG. 1 , besides current collector foil, those with a mesh pattern (expand grid and the like) and the like can be used. Note that, in the case where a thin film alloy as an example of the negative electrode active material is directly formed on the negative electrode current collectors 12 A by the sputtering method and the like, it is desirable to use the current collector foil.
[0051] Such a material that composes the current collectors is not particularly limited. For example, metal can be employed, and resin can be employed, in which an electrically conductive filler is added to an electrically conductive polymer material or a non-electrically conductive polymer material. Specifically, as metal, there are mentioned aluminum (Al), nickel (Ni), iron (Fe), stainless steel (SUS), titanium (Ti), copper (Cu) and the like. Besides these, it is preferable to use a clad material of nickel and aluminum, a clad material of copper and aluminum, a plated material in which these metals are combined with one another, and the like. Moreover, the metal may be foil in which aluminum is coated on a surface of metal. Among them, aluminum, stainless steel, copper and nickel are preferable from viewpoints of the electron conductivity, a battery operation potential and the like.
[0052] Moreover, as the electrically conductive polymer material, for example, there are mentioned polyaniline, polypyrrole, polythiophene, polyacetylene, polyparaphenylene, polyphenylene vinylene, polyacrylonitrile, polyoxadiazole and the like. Such electrically conductive polymer materials have sufficient conductivity even if the electrically conductive filler is not added thereto, and accordingly, are advantageous in a point of facilitation of the manufacturing process or of weight reduction of the current collectors.
[0053] As the non-electrically conductive polymer material, for example, there are mentioned polyethylene (PE: high-density polyethylene (HDPE), low-density polyethylene (LDPE) and the like), polypropylene (PP), polyethylene terephthalate (PET), polyether nitrile (PEN), polyimide (PI), polyamide imide (PAI), polyamide (PA), polytetrafluoroethylene (PTFE), styrene-butadiene rubber (SBR), polyacrylonitrile (PAN), polymethyl acrylate (PMA), polymethyl methacrylate (PMMA), polyvinylidene chloride (PVC), polyvinylidene fluoride (PVDF), polystyrene (PS), and the like. Such non-electrically conductive polymer materials have excellent potential resistance and solvent resistance.
[0054] According to needs, the electrically conductive filler can be added to the electrically conductive polymer material or the non-electrically conductive polymer material, which is described above. In particular, in the case where resin that serves as a base material of the current collectors is composed of only the non-conductive electrically polymer, the electrically conductive filler becomes necessarily essential in order to impart the conductivity to the resin. As long as being a material having the conductivity, the electrically conductive filler can be used without receiving limitations in particular. For example, as a material excellent in conductivity, potential resistance or lithium ion barrier properties, there are mentioned metal, electrically conductive carbon and the like.
[0055] As the metal to be used as the electrically conductive filler, there can be mentioned at least one metal selected from the group consisting of nickel (Ni), titanium (Ti), aluminum (Al), copper (Cu), platinum (Pt), iron (Fe), chromium (Cr), tin (Sn), zinc (Zn), indium (In), antimony (Sb) and potassium (K). Moreover, alloys or metal oxides, which contain these metals, can also be mentioned as preferred examples.
[0056] Moreover, as a preferred example of the electrically conductive carbon, there can be mentioned at least one selected from the group consisting of acetylene black, Vulcan, Black Pearl, carbon nanofiber, Ketjen Black, carbon nanotube, carbon nano-horn, carbon nano-balloon and fullerene. A loading amount of the electrically conductive filler is not particularly limited as long as being an amount by which sufficient conductivity can be imparted to the current collectors, and in general, approximately ranges from 5 to 35% by mass. However, the current collectors are not limited to these, and materials, which have been heretofore known in public and are used as the current collectors for the lithium ion secondary battery, can be used.
[Positive Electrode Active Material Layer]
[0057] The positive electrode active material layer 11 B contains, as the positive electrode active material, the positive electrode active materials for a lithium ion secondary battery according to the above-mentioned first embodiment and to a second embodiment to be described later. Then, the positive electrode active material 11 B may contain a binder or an electric conducting additive according to needs.
[0058] Note that, as long as effects of the present invention are exerted, the positive electrode active material may contain another positive electrode active material in addition to the positive electrode active materials for a lithium ion secondary battery according to the first embodiment and the second embodiment. As such another positive electrode active material, for example, a lithium-containing compound is preferable from viewpoints of the capacity and the output characteristics. As the lithium-containing compound as described above, for example, there are mentioned: a composite oxide containing lithium and a transition metal element; a phosphate compound containing lithium and the transition metal element; and a sulfate compound containing lithium and the transition metal element. However, from a viewpoint of obtaining higher capacity and output characteristics, such a lithium-transition metal composite oxide is particularly preferable. As a matter of course, the positive electrode active material layer containing, as the positive electrode active material, only at least one of the positive electrode active materials for a lithium ion secondary battery according to the first embodiment and the second embodiment is also incorporated within the scope of the present invention.
[0059] As a specific example of the composite oxide containing lithium and the transition metal element, a lithium cobalt composite oxide (LiCoO 2 ), a lithium nickel composite oxide (LiNiO 2 ), a lithium nickel cobalt composite oxide (LiNiCoO 2 ) and the like are mentioned. Moreover, as specific examples of the phosphate compound containing lithium and the transition metal element, a lithium iron phosphate compound (LiFePO 4 ), a lithium iron manganese phosphate compound (LiFeMnPO 4 ) and the like are mentioned. Note that, for such a purpose of stabilizing structures of these composite oxides, those in which other elements are partially substituted for the transition metals can also be mentioned.
[0060] The binder is not particularly limited; however, the following materials are mentioned. For example, there are mentioned thermoplastic polymers such as: polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyether nitrile (PEN), polyacrylonitrile (PAN), polyimide (PI), polyamide (PA), cellulose, carboxymethyl cellulose (CMC), an ethylene-vinyl acetate copolymer, polyvinylidene chloride (PVC), styrene-butadiene rubber (SBR), isoprene rubber, butadiene rubber, ethylene-propylene rubber, an ethylene-propylene-diene copolymer, a styrene-butadiene-styrene block copolymer and a hydrogen-added product thereof, and a styrene-isoprene-styrene block copolymer and a hydrogen-added product thereof. Moreover, there are mentioned fluorine resins such as polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), a tetrafluoroethylene-hexafluoropropylene copolymer (FEP), a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), an ethylene-tetrafluoroethylene copolymer (ETFE), polychlorotrifluoroethylene (PCTFE), an ethylene-chlorotrifluoroethylene copolymer (ECTFE), and polyvinyl fluoride (PVF). Furthermore, there are mentioned: vinylidene fluoride-based fluorine rubber such as vinylidene fluoride-hexafluoropropylene-based fluorine rubber (VDF-HFP-based fluorine rubber), vinylidene fluoride-hexafluoropropylene-tetrafluoroethylene-based fluorine rubber (VDF-HFP-TEF-based rubber), vinylidene fluoride-pentafluoropropylene-based fluorine rubber (VDF-PFP-based fluorine rubber), vinylidene fluoride-pentafluoropropylene-tetrafluoroethylene-based fluorine rubber (VDF-PFT-TFE-based fluorine rubber), vinylidene fluoride-perfluoromethyl vinyl ether-tetrafluoroethylene-based rubber (VDF-PFMVE-TFE-based fluorine rubber), and vinylidene fluoride-chlorotrifluoroethylene-based fluorine rubber (VDF-CTFE-based fluorine rubber); epoxy resin; and the like. Among them, more preferably, the binder is polyvinylidene fluoride, polyimide, styrene-butadiene rubber, carboxymethyl cellulose, polypropylene, polytetrafluoroethylene, polyacrylonitrile, and polyamide. These preferred binders are excellent in heat resistance, further have extremely wide potential windows, are stable at both of the positive electrode potential and the negative electrode potential, and are usable for the positive electrode active material layer and the negative electrode active material layer. However, the binder is not limited to these, and materials, which are known in public and have been heretofore used as the binder for the lithium ion secondary battery, can be used. These binders may be each used singly, or two or more thereof may be used in combination.
[0061] An amount of the binder contained in the positive electrode active material layer is not particularly limited as long as the binder can bind the positive electrode active material. However, the amount of binder is preferably 0.5 to 15% by mass, more preferably 1 to 10% by mass with respect to the positive electrode active material layer.
[0062] The electric conducting additive is one to be blended in order to enhance the conductivity of the positive electrode active material layer. As the electric conducting additive, for example, there can be mentioned carbon materials such as: carbon black including acetylene black; graphite; and vapor deposited carbon fiber. When the positive electrode active material layer contains the electric conducting additive, an electron network in the inside of the positive electrode active material layer is formed effectively, and such containing of the electric conducting additive can contribute to the enhancement of the output characteristics of the battery. However, the electric conducting additive is not limited to these, and materials, which have been heretofore known in public and are used as the electric conducting additives for the lithium ion secondary battery, can be used. These electric conducting additives may be each used singly, or two or more thereof may be used in combination.
[0063] Moreover, an electrically conductive binder, which has functions of the above-described electric conducting additive and binder in combination, may be used in place of these electric conducting additive and binder, or may be used in combination with one or both of these electric conducting additive and binder. As the electrically conductive binder, for example, commercially available TAB-2 made by Hohsen Corporation can be used.
[0064] Furthermore, it is suitable that a density of the positive electrode active material layer be 2.5 g/cm 3 or more to 3.0 g/cm 3 or less. In the case where the density of the positive electrode active material layer is 2.5 g/cm 3 or more, weight (filler content) thereof per unit volume is increased, whereby it is made possible to enhance the discharge capacity. Moreover, in the case where the density of the positive electrode active material layer is 3.0 g/cm 3 or less, reduction of a void amount of the positive electrode active material layer is prevented, whereby permeability of a non-aqueous electrolysis solution and diffusivity of lithium ions can be enhanced.
[Negative Electrode Active Material Layer]
[0065] The negative electrode active material layer 12 B contains, as the negative electrode active material, a negative electrode material capable of absorbing and releasing lithium, and may contain a binder and an electric conducting additive according to needs. Note that, as the binder and the electric conducting additive, those mentioned above can be used.
[0066] As the negative electrode material capable of absorbing and releasing lithium, for example, there can be mentioned carbon materials such as graphite (natural graphite, artificial graphite and the like) as high crystalline carbon, low crystalline carbon (soft carbon, hard carbon), carbon black (Ketjen black, acetylene black, channel black, lamp black, oil furnace black, thermal black and the like), fullerene, carbon nanotube, carbon nanofiber, carbon nano-horn, and carbon fibril. Note that the carbon materials include one containing 10% by mass or less silicon nanoparticles. Moreover, there can be mentioned: simplexes of elements which make alloys with lithium, the elements including silicon (Si), germanium (Ge), tin (Sn), lead (Pb), aluminum (Al), indium (In), zinc (Zn), hydrogen (H), calcium (Ca), strontium (Sr), barium (Ba), ruthenium (Ru), rhodium (Rh), iridium (Ir), palladium (Pd), platinum (Pt), silver (Ag), gold (Au), cadmium (Cd), mercury (Hg), gallium (Ga), thallium (Tl), carbon (C), nitrogen (N), antimony (Sb), bismuth (Bi), oxygen (O), sulfur (S), selenium (Se), tellurium (Te), chlorine (Cl) and the like; and oxides (silicon monoxide (SiO), SiO x (0<x<2), tin dioxide (SnO 2 ), SnO x (0<x<2), SnSiO 3 and the like), carbides (silicon carbide (SiC) and the like) and the like, which contain these elements. Furthermore, metal materials such as lithium metal and lithium-transition metal composite oxides such as lithium-titanium composite oxides (lithium titanate: Li 4 Ti 5 O 12 ) can be mentioned. However, the negative electrode active material is not limited to these, and materials, which have been heretofore known in public and are used as the negative electrode active material for the lithium ion secondary battery, can be used. These negative electrode active materials may be each used singly, or two or more thereof may be used in combination.
[0067] Moreover, in this embodiment, suitably, the carbon material is made of a graphite material, which is coated with an amorphous carbon layer, and does not have a scale shape. Moreover, suitably, a BET specific surface area of the carbon material is 0.8 m 2 /g or more to 1.5 m 2 /g or less, and a tap density thereof 0.9 g/cm 3 or more to 1.2 g/cm 3 or less. The carbon material made of the graphite material, which is coated with an amorphous carbon layer, and does not have a scale shape, is preferable since lithium ion diffusivity to a graphite-layered structure is high. Moreover, if the BET specific surface area of the carbon material as described above is 0.8 m 2 /g or more to 1.5 m 2 /g or less, then such a capacity retention ratio can be further enhanced. Furthermore, if the tap density of the carbon material as described above is 0.9 g/cm 3 or more to 1.2 g/cm 3 or less, then weight (filler content) thereof per unit volume can be enhanced, and the discharge capacity can be enhanced.
[0068] Furthermore, in this embodiment, suitably, a BET specific surface area of the negative electrode active material layer, which at least contains the carbon material and the binder, is 2.0 m 2 /g or more to 3.0 m 2 /g or less. By the fact that the BET specific surface area of the negative electrode active material layer is 2.0 m 2 /g or more to 3.0 m 2 /g or less, the permeability of the non-aqueous electrolysis solution can be enhanced, the capacity retention ratio can be further enhanced, and generation of gas owing to decomposition of the non-aqueous electrolysis solution can be suppressed.
[0069] Moreover, in this embodiment, suitably, a BET specific surface area of the negative electrode active material layer, which at least contains the carbon material and the binder, the BET specific surface area being obtained after the negative electrode active material layer is pressure-molded, 2.01 m 2 /g or more to 3.5 m 2 /g or less. The BET specific surface area of the negative electrode active material layer thus already press-molded is set at 2.01 m 2 /g or more to 3.5 m 2 /g or less, whereby the permeability of the non-aqueous electrolysis solution can be enhanced, the capacity retention ratio can be further enhanced, and the generation of gas owing to the decomposition of the non-aqueous electrolysis solution can be suppressed.
[0070] Furthermore, in this embodiment, suitably, an increment of the BET specific surface area concerned before and after the negative electrode active material layer, which at least contains the carbon material and the binder, is pressure-molded, is 0.01 m 2 /g or more to 0.5 m 2 /g or less. In such a way, the BET specific surface area after the negative electrode active material layer is pressure-molded can be set at 2.01 m 2 /g or more to 3.5 m 2 /g or less, whereby the permeability of the non-aqueous electrolysis solution can be enhanced, the capacity retention ratio can be further enhanced, and the generation of gas owing to the decomposition of the non-aqueous electrolysis solution can be suppressed.
[0071] Moreover, a thickness of each of the active material layers (each active material layer on one on the surfaces of each current collector) is not particularly limited, either, and knowledge heretofore known in public about the battery can be referred to as appropriate. An example of the thickness is mentioned. In usual, the thickness of each active material layer approximately ranges from 1 to 500 μm, preferably 2 to 100 μm in consideration of the usage purpose of the battery (output is regarded important, energy is regarded important, and so on), and of ion conductivity.
[0072] Moreover, in the case where optimum particle diameters are different among the respective active materials in the event of developing the effects individually intrinsic to the active materials, the active materials just need to be mixed and used while setting the optimum particle diameters in the event of developing the effects individually intrinsic thereto. Accordingly, it is not necessary to uniform the particle diameters of all of the active materials.
[0073] For example, in the case of the positive electrode active materials of the first and second embodiments and other positive electrode active materials, mean particle diameters thereof just need to be substantially the same as a mean particle diameter of the positive electrode active material contained in the existing positive electrode active material layer, and is not particularly limited. The mean particle diameter just needs to preferably range from 1 to 20 μm from the viewpoint of the output enhancement. Note that “the particle diameter” stands for a maximum distance among distances, each of which is between arbitrary two points on outlines of the active material particles (observed surfaces) observed by using observing means such as a scanning electron microscope (SEM) and a transmission electron microscope (TEM). As a value of “the mean particle diameter”, a value is employed, which is calculated as a mean value of particle diameters of particles observed in several to several ten visual fields by using the observing means such as the scanning electron microscope and the transmission electron microscope. Particle diameters and mean particle diameters of the other constituent components can also be defined in a similar way.
[0074] However, the mean particle diameters are never limited to the range as described above, and may go out of this range as long as the functions and effects of this embodiment can be developed effectively.
[Electrolyte Layer]
[0075] As the electrolyte layer 13 , for example, there can be mentioned: one in which an electrolysis solution is held in a separator; and one in which a layer structure is formed by using a polymer gel electrolyte and a solid polymer electrolyte. Moreover, one in which a laminated structure is formed by using a polymer gel electrolyte and a solid polymer electrolyte can be mentioned.
[0076] Preferably, the electrolysis solution is one, which is usually used in the lithium ion secondary battery. Specifically, the electrolysis solution has a form in which a supporting salt (lithium salt) is dissolved into an organic solvent. As the lithium salt, for example, there can be mentioned at least one lithium salt selected from inorganic acid anion salts such as lithium hexafluorophosphate (LiPF 6 ), lithium tetrafluoroborate (LiBF 4 ), lithium perchlorate (LiClO 4 ), lithium hexafluoarsenate (LiAsF 6 ), lithium hexafluorotantalate (LiTaF 6 ), lithium tetrachloroaluminate (LiAlCl 4 ) and lithium decachlorodecaborate (Li 2 B 10 Cl 10 ), and the like. Moreover, there can be mentioned at least one lithium salt selected from organic acid anion salts such as lithium trifluoromethane sulfonate (LiCF 3 SO 3 ), lithium bis(trifluoromethanesulfonyl)imide (Li(CF 3 SO 2 ) 2 N) and lithium bis(pentafluoroethanesulfonyl)imide (Li(C 2 F 5 SO 2 ) 2 N), and the like. Among them, lithium hexafluorophosphate (LiPF 6 ) is preferable. Moreover, as the organic solvent, for example, there can be used at least one organic solvent selected from the group consisting of cyclic carbonates, fluorine-containing cyclic carbonates, chain carbonates, fluorine-containing chain carbonates, aliphatic carboxylate esters, fluorine-containing aliphatic carboxylate esters, γ-lactones, fluorine-containing γ-lactones, cyclic ethers, fluorine-containing cyclic ethers, chain ethers and fluorine-containing chain ethers. As the cyclic carbonates, for example, propylene carbonate (PC), ethylene carbonate (EC) and butylene carbonate (BC) can be mentioned. Moreover, as the fluorine-containing cyclic carbonates, for example, fluoroethylene carbonate (FEC) can be mentioned. Furthermore, as the chain carbonates, for example, there can be mentioned dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), methyl propyl carbonate (MPC), ethyl propyl carbonate (EPC) and dipropyl carbonate (DPC). Moreover, as the aliphatic carboxylate esters, for example, methyl formate, methyl acetate and ethyl propionate can be mentioned. Moreover, as the γ-lactones, for example, γ-butyrolactone can be mentioned. Furthermore, as the cyclic ethers, for example, tetrahydrofuran, 2-methyltetrahydrofuran, 1,4-dioxane can be mentioned. Moreover, as the chain ethers, for example, 1,2-ethoxyethane (DEE), ethoxymethoxyethane (EME), diethylether, 1,2-dimethoxyethane and 1,2-dibutoxyethane can be mentioned. Besides the above, nitriles such as acetonitrile and amides such as dimethylformamide can be mentioned. These can be each used singly, or two or more thereof can be used in combination.
[0077] Moreover, an additive may be added to the electrolysis solution. As the additive, there can be mentioned: an organic sulfone-based compound such as a sultone derivative and cyclic sulfonate ester; an organic disulfone-based compound such as a disultone derivative and cyclic disulfonate ester; a vinylene carbonate derivative; an ethylene carbonate derivative; an ester derivative; a divalent phenol derivative; an ethylene glycol derivative; a terphenyl derivative; a phosphate derivative; and the like. Each of these forms a coating film on the surface of the negative electrode active material, and accordingly, the generation of the gas in the battery is reduced, and the enhancement of the capacity retention ratio can be further enhanced.
[0078] As the organic sulfone-based compound serving as the additive, for example, 1,3-propane sulfone (saturated sultone) and 1,3-propene sultone (unsaturated sultone) can be mentioned. Moreover, as the organic disulfone-based compound, for example, methane disulfonic acid methylene can be mentioned. Furthermore, as the vinylene carbonate derivative, for example, vinylene carbonate (VC) can be mentioned. Moreover, as the ethylene carbonate derivative, for example, fluoroethylene carbonate (FEC) can be mentioned. Furthermore, as the ester derivative, for example, there can be mentioned 4-biphenylyl acetate, 4-biphenylyl benzoate, 4-biphenylyl benzyl carboxylate and 2-biphenylyl propionate can be mentioned. Moreover, as the divalent phenol derivative, for example, 1,4-diphenoxy benzene and 1,3-diphenoxy benzene can be mentioned. Furthermore, as the ethylene glycol derivative, for example, there can be mentioned 1,2-diphenoxy ethane, 1-(4-biphenylyloxy)-2-phenoxyethane and 1-(2-biphenylyloxy)-phenoxy ethane. Moreover, as the terphenyl derivative, for example, there can be mentioned o-terphenyl, m-terphenyl, p-terphenyl, 2-methyl-o-terphenyl and 2,2-dimethyl-o-terphenyl. Furthermore, as the phosphate derivative, for example, triphenyl phosphate can be mentioned.
[0079] As the separator, for example, there can be mentioned a microporous membrane, a porous flat plate, and further, nonwoven fabric, which are made of polyolefin such as polyethylene (PE) and polypropylene (PP).
[0080] As the polymer gel electrolyte, one can be mentioned, which contains an electrolysis solution and a polymer that composes the polymer gel electrolyte in a ratio heretofore known in public. For example, from viewpoints of the ion conductivity and the like, desirably, a content of the electrolysis solution is approximately set at several % by mass to 98% by mass.
[0081] The polymer gel electrolyte is one in which the above-described electrolysis solution usually used in the lithium ion secondary battery is contained in the solid polymer electrolyte having the ion conductivity. However, the polymer gel electrolyte is not limited to this, and also includes one in which a similar electrolysis solution is held in a polymer skeleton that does not have the lithium ion conductivity. As a polymer, which is used for the polymer gel electrolyte and does not have the lithium ion conductivity, for example, polyvinylidene fluoride (PVdF), polyvinyl chloride (PVC), polyacrylonitrile (PAN), polymethyl methacrylate (PMA) and the like are usable. However, the polymer is not limited to these. Note that polyacrylonitrile (PAN), polymethyl methacrylate (PMA) and the like belong, if anything, to a category of materials in which the ion conductivity is hardly present, and accordingly, can also be said to be polymers having the above-described ion conductivity. However, here, polyacrylonitrile and polymethyl methacrylate are illustrated as such polymers which do not have the lithium ion conductivity.
[0082] As the solid polymer electrolyte, for example, those can be mentioned, which have a configuration formed by dissolving the above-described lithium salts into polyethylene oxide (PEO), polypropylene oxide (PPO) and the like, and do not contain the organic solvent. Hence, in the case where the electrolyte layer is composed of the solid polymer electrolyte, there is no concern about the liquid leakage from the battery, and reliability of the battery can be enhanced.
[0083] Preferably, a thickness of the electrolyte layer is thin from a viewpoint of reducing internal resistance. The thickness of the electrolyte layer is usually 1 to 100 μm, preferably 5 to 50 μm.
[0084] Note that a matrix polymer of the polymer gel electrolyte or the solid polymer electrolyte can develop excellent mechanical strength by forming a crosslinked structure. In order to form the crosslinked structure, a polymerizable polymer for forming the polymer electrolyte just needs to be subjected to polymerization treatment such as thermal polymerization, ultraviolet polymerization, radiation polymerization and electron beam polymerization by using an appropriate polymerization initiator. Note that, as the polymerizable polymer, for example, polyethylene oxide and polypropylene oxide can be mentioned.
[Manufacturing Method of Lithium Ion Secondary Battery]
[0085] Next, a description is made of an example of a manufacturing method of the lithium ion secondary battery according to this embodiment mentioned above.
[0086] First, the positive electrode is fabricated. For example, in the case of using a granular positive electrode active material, the positive electrode active material is mixed with the electric conducting additive, the binder and a viscosity adjusting solvent according to needs, whereby positive electrode slurry is prepared. Subsequently, this positive electrode slurry is coated on the positive electrode current collector, and is dried and pressure-molded, whereby the positive electrode active material layer is formed.
[0087] Moreover, the negative electrode is fabricated. For example, in the case of using a granular negative electrode active material, the negative electrode active material is mixed with the electric conducting additive, the binder and the viscosity adjusting solvent according to needs, whereby negative electrode slurry is prepared. Thereafter, this negative electrode slurry is coated on the negative electrode current collector, and is dried and pressure-molded, whereby the negative electrode active material layer is formed.
[0088] Subsequently, the positive electrode lead is attached to a plurality of the positive electrodes, in addition, the negative electrode lead is attached to a plurality of the negative electrodes, and thereafter, the positive electrodes, the separators and the negative electrodes are stacked on one another. Moreover, one in which these are stacked on one another is sandwiched by polymer-metal composite laminated sheets, and outer circumferential edge portions of the polymer-metal composite laminated sheets, each of which excludes one side, are heat-sealed, whereby a bag-like exterior body is formed. Thereafter, the above-described electrolysis solution is prepared, is injected from an opening portion of the exterior body to an inside thereof, and is sealed by heat-sealing the opening portion of the exterior body. In such a way, the laminate-type lithium ion secondary battery is completed.
Example 1
[0089] A description is made below in more detail of this embodiment by examples and comparative examples; however, the present invention is not limited to these examples.
Example 1-1
Preparation of First Active Material
[0090] The first active material (solid solution) was synthesized by the composite carbonate method. Specifically, as starting materials, sulfates of nickel, cobalt and manganese were used, and ion exchange water was added to the respective types of sulfates, whereby the respective types of aqueous sulfate solutions, in each of which a concentration was 2 mol/L, were prepared. Subsequently, the respective types of aqueous sulfate solutions were weighed so that nickel, cobalt and manganese could achieve a predetermined molar ratio, followed by mixing thereof, whereby an aqueous solution of the mixed sulfates was prepared.
[0091] Moreover, while stifling the aqueous solution of the mixed sulfates by a magnetic stirrer, an aqueous sodium carbonate (Na 2 CO 3 ) solution was dropped into the aqueous solution of the mixed sulfates, and Ni—Co—Mn composite carbonate was precipitated. Note that, during a period while the aqueous sodium carbonate (Na 2 CO 3 ) solution was being dropped, pH of the aqueous solution of the mixed sulfates was adjusted to 7 by using an aqueous ammonia solution with a concentration of 0.2 mol/L, which served as a pH regulating agent. Moreover, the composite carbonate thus obtained was aspirated and filtrated, was washed, was dried at 120° C. for 5 hours, and was calcined at 500° C. for 5 hours, whereby the Ni—Co—Mn composite oxide was obtained.
[0092] Moreover, in order that a predetermined molar ratio could be achieved, the obtained composite oxide was added with a little excess amount of lithium hydroxide (LiOH.H 2 O), followed by pulverization and mixing. Thereafter, a resultant mixture was baked at 900° C. for 12 hours in the atmosphere, and was rapidly cooled by using liquid nitrogen, whereby Li 1.5 [Ni 0.25 Co 0.10 Mn 0.85 [Li] 0.3 ]O 3 as the first active material for use in this example was obtained. Note that, with regard to Li 1.5 [Ni 0.25 Co 0.10 Mn 0.85 [Li] 0.3 ]O 3 thus obtained, a=0.25, b=0.10, c=0.85, and d=0.3 in compositional formula (1).
Preparation of Second Active Material
[0093] The second active material was synthesized by the solid reaction method. Specifically, lithium carbonate and manganese oxide were used as starting materials. Subsequently, in order that lithium and manganese can establish a predetermined molar ratio, lithium carbonate and manganese oxide were weighed, pulverized and mixed with each other. Thereafter, a resultant mixture was baked at 1000° C. for 12 hours, and was further subjected to annealing treatment at 500° C. for 12 hours in an oxygen atmosphere, whereby LiMn 2 O 4 as the second active material for use in this example was obtained. With regard to LiMn 2 O 4 , a′=0 in compositional formula (2).
<Preparation of Positive Electrode Active Material>
[0094] Powder of 85 mass parts of the first active material and power of 15 mass parts of the second active material were mixed with each other, whereby the positive electrode active material of this example was obtained.
<Fabrication of Positive Electrode>
[0095] 85 mass parts of the positive electrode active material of this example, 7 mass parts of acetylene black and 3 mass parts of graphite which served as the electric conducting additives, and 5 mass parts of polyvinylidene fluoride, which served as the binder, were kneaded with one another. Then, to this kneaded product, N-methyl-2-pyrrolidone (NMP) was added and mixed, whereby positive electrode slurry was prepared. Next, on aluminum foil as the current collector, the obtained positive electrode slurry was coated so that an amount of the active material could be 10 mg per unit area of 100 mm 2 , and was vacuum-dried at 120° C., whereby the positive electrode of this example was obtained. Note that the positive electrode was formed into a circular shape with a diameter of 15 mm.
<Fabrication of Lithium Ion Secondary Battery>
[0096] The positive electrode of this example and the negative electrode made of metal lithium were allowed to face each other, and two separators were arranged there between. Note that a material of the separators was polypropylene, and a thickness thereof was set at 20 μm. Subsequently, such a stacked body of the negative electrode, the separators and the positive electrode was arranged on a bottom side of a coin cell. Moreover, a gasket for keeping insulating properties between the positive electrode and the negative electrode was mounted, an electrolysis solution to be described below was injected by using syringe, a spring and a spacer were stacked, and an upper side of the coin cell was superimposed and crimped, whereby hermetic sealing was made. In such a way, the lithium ion secondary battery of this example was obtained.
[0097] Note that a standard of the above-described coin cell was CR2032, and stainless steel (SUS316) was used as a material thereof. Moreover, as the electrolysis solution, one was used, in which lithium hexafluorophosphate (LiPF 6 ) as the supporting salt was dissolved into an organic solvent so that a concentration thereof could be 1 mol/L. Moreover, as the organic solvent, one was used, in which ethylene carbonate (EC) and diethyl carbonate (DEC) were mixed with each other in a ratio of EC:DEC=1:2 (volume ratio).
<Evaluation of Charge/Discharge Characteristics of Lithium Ion Secondary Battery>
[0098] For the obtained lithium ion secondary battery, charge/discharge was performed at a constant current rate (rate of 1/12 C) by the constant current charge/discharge method in which the charge was continued until a maximum voltage of the battery became 4.8V and the discharge was continued until a minimum voltage of the battery became 2.0V. That is to say, the charge/discharge was performed under such conditions as shown in Table 1. At this time, an initial charge capacity and an initial discharge capacity were measured, and the initial charge/discharge efficiency was calculated. Obtained results are shown in Table 2, FIG. 2 and FIG. 3 together with a part of specifications.
[0000]
TABLE 1
Repeat
Measurement
Voltage (V)
Current
count
temperature
Upper
Lower
rate
Time
(number
State
(K)
limit
limit
(C)
(h)
Mode
of times)
Charge
300
4.8
—
1/12
12
Constant
10
current
Discharge
300
—
2.0
1/12
12
Constant
10
current
[0000]
TABLE 2
Initial
First
Second
charge/
active
active
Initial charge
discharge
material
material
(mAh/g)
efficiency
Table 2
(mass %)
(mass %)
Charge
Discharge
(%)
Example 1-1
85
15
278
251
90.3
Example 1-2
90
10
298
266
89.3
Example 1-3
95
5
311
271
87.1
Comparative
100
0
370
282
76.2
example 1-1
<Structure Analysis of First Active Material and Second Active Material>
[0099] For samples (powders) as parts of the obtained first active material and second active material, powder X-ray diffraction measurement was performed by using an X-ray diffraction device. Note that, as the X-ray diffraction device, MXP18VAHF made by Bruker AXS (former Mac Science) GmbH) was used. Moreover, with regard to measurement conditions, a voltage was set at 40 kV, a current was set at 200 mA, and an X-ray wavelength was set at Cu-Kα.
[0100] As a result of comparing the obtained results with data of a standard sample, the first active material and the second active material were the layered transition metal oxide in which the crystal structure belonged to the space group C2/m, and the spinel-type transition metal oxide in which the crystal structure belonged to the space group Fd-3m, respectively.
Example 1-2, Example 1-3 and Comparative example 1-1
[0101] In the preparation of the positive electrode active material of Example 1-1, the mixture ratio of the first active material and the second active material was changed as shown in Table 2. Except for the above, similar operations to those of Example 1-1 were repeated, whereby positive electrode active materials, positive electrodes and lithium ion secondary batteries of the respective examples were obtained. Then, in a similar way to Example 1-1, evaluations of the charge/discharge characteristics of the lithium ion secondary batteries were performed. Obtained results are shown in Table 2, FIG. 2 and FIG. 3 .
[0102] FIG. 2 shows charge/discharge curves of the respective examples. It was able to be confirmed that the capacity around 2.7V was increased in order from Example 1-1 to Example 1-2, and further, from Example 1-2 to Example 1-3. This is considered to be because, since the second active material (LiMn 2 O 4 ) is the spinel-type transition metal oxide in which the crystal structure belongs to the space group Fd-3m, lithium is inserted into the second active material. Moreover, it was able to be confirmed that the charge capacity of each of Examples 1-1 to 1-3 was reduced more than in Comparative example 1-1 by the fact that the first active material (Li 1.5 [Ni 0.25 Co 0.10 Mn 0.85 [Li] 0.3 ]O 3 ) and the second active material (LiMn 2 O 4 ) were mixed with each other.
[0103] In this connection, values obtained by dividing the initial discharge capacities of the respective examples by the initial charge capacities thereof, that is, [initial charge/discharge efficiency (%) (initial discharge capacity/initial charge capacity×100)] were summarized in FIG. 3 . Note that, under illustrations of the respective examples, the content ratios (M A :M B ) of the first active material and the second active material are shown in the mass ratio. While the initial charge/discharge efficiency of Comparative example 1-1 was 76.2%, the initial charge/discharge efficiencies of the respective Examples were 85% or more. Hence, it was confirmed that an initial irreversible capacity was reduced by the second active material as the spinel-type transition metal oxide in which the crystal structure belongs to the space group Fd-3m and the first active material composed of the transition metal oxide were mixed with each other. Then, following this, it was made possible to enhance the initial charge/discharge efficiency while maintaining a high capacity by maintaining a high reversible capacity.
[0104] Moreover, the reason why the initial charge/discharge efficiency was able to be enhanced as described above while maintaining the high capacity by reducing the initial irreversible capacity and maintaining the high reversible capacity is also considered to be that the range of d is set as: 0<d≦0.45, and that the range of a′ is set as: 0≦a′<2.0. Furthermore, the reason why the initial charge/discharge efficiency was able to be enhanced as described above while maintaining the high capacity is also considered to be that the content ratio (M A :M B ) of the first active material and the second active material is set so as to satisfy the relationships of expression (4) and expression (5).
Second Embodiment
[0105] Next, a description is made of a positive electrode active material for a lithium ion secondary battery according to a second embodiment of the present invention. In a similar way to the first embodiment, the positive electrode active material of this embodiment is a positive electrode active material containing a first active material and a second active material.
[0106] Then, the first active material (solid solution lithium-containing transition metal oxide) in this embodiment is represented by compositional formula (6):
[0000] Li 1.5 [Ni a Co b Mn c [Li] d ]O 3 (6)
[0000] wherein Li is lithium, Ni is nickel, Co is cobalt, Mn is manganese, and O is oxygen. Moreover, a, b, c and d satisfy relationships: 0.1≦d≦0.4; a+b+c+d=1.5; and 1.1≦a+b+c≦1.4.
[0107] Moreover, the first active material in this embodiment includes: a layered structure region, which is changed to a spinel structure by performing the charge or the charge/discharge in a potential range of 4.3V or more to 4.8V or less; and a layered structure region, which is not changed to the spinel structure thereby.
[0108] Furthermore, in the first active material in this embodiment, when a spinel structure change ratio in the case where Li 2 MnO 3 in the layered structure region to be changed is entirely changed to LiMn 2 O 4 with the spinel structure is defined as 1, the spinel structure change ratio is 0.25 or more to less than 1.0.
[0109] Moreover, the second active material (lithium-containing transition metal oxide) in this embodiment is represented by compositional formula (7):
[0000] LiM a′ Mn 2−a′ O 4 (7)
[0000] wherein Li is lithium, M is at least one selected from the group consisting of aluminum (Al), magnesium (Mg) and chromium (Cr), Mn is manganese, and O is oxygen. Moreover, a′ satisfies a relationship: 0≦a′<0.5. The second active material has the spinel structure in a similar way to the first embodiment.
[0110] In the case where the positive electrode active material as described above is used for the lithium ion secondary battery, the positive electrode active material concerned is capable of realizing excellent discharge operation voltage and initial rate characteristics while maintaining a high discharge capacity. Therefore, the positive electrode active material is suitably used for the positive electrode for the lithium ion secondary battery and for the lithium ion secondary battery. Moreover, the positive electrode active material as described above exhibits a high capacity retention ratio particularly in a potential range of 3.0V or more to 4.5V or less. As a result, the positive electrode active material can be suitably used for such a lithium ion secondary battery for a drive power supply of a vehicle or for an auxiliary power supply thereof. Besides the above, the positive electrode active material is also sufficiently applicable for a lithium ion secondary battery for a home appliance or a mobile instrument.
[0111] Note that the “charge” refers to an operation of increasing a potential difference between electrodes continuously or step wise. Moreover, the “charge/discharge” refers to an operation of reducing the potential difference between the electrodes continuously or stepwise after the operation of increasing the potential difference between the electrodes continuously or stepwise, or refers to an operation of appropriately repeating these operations.
[0112] Here, in the first active material, preferably, in compositional formula (6), a, b, c and d satisfy the relationships: 0.1≦d≦0.4; a+b+c+d=1.5; and 1.1≦a+b+c≦1.4. In this case, the crystal structure in the first active material is stabilized.
[0113] Moreover, preferably, the first active material includes: the layered structure region, which is changed to the spinel structure by performing the charge or the charge/discharge in the potential range of 4.3V or more to 4.8V or less; and the layered structure region, which is not changed to the spinel structure thereby. In this case, it is made possible to realize both of the high discharge capacity and the high capacity retention ratio. Specifically, as will be described later, it is important to expose once or more the positive electrode, which contains the first active material, to a potential plateau section around 4.5V or more.
[0114] Moreover, in the case where the spinel structure change ratio mentioned above is 0.25 or more to less than 1.0 in the first active material, it is made possible to realize the high discharge capacity and capacity retention ratio and the excellent initial rate characteristics.
[0115] Here, in this specification, the “spinel structure change ratio” defines a ratio in which Li 2 MnO 3 with the layered structure in the first active material is changed to LiMn 2 O 4 with the spinel structure by performing the charge or the charge/discharge in such a predetermined potential range (4.3 to 4.8V). Then, when the spinel structure change ratio in the case where Li 2 MnO 3 with the layered structure in the first active material is entirely changed to LiMn 2 O 4 with the spinel structure is defined as 1. Specifically, the spinel structure change ratio is defined in the following expression.
[0000]
[
Spinel
structure
change
ratio
(
K
)
]
=
[
Actual
capacity
of
plateau
region
]
[
Theoretical
capacity
(
Vs
)
caused
by
Li
2
MnO
3
in
first
active
material
]
×
[
Composition
ratio
(
x
)
of
Li
2
Mb
O
3
in
first
active
material
]
[
Math
.
1
]
[0116] A description is made of the definition of the “spinel structure change ratio” by taking the case as shown in FIG. 4 as an example. In FIG. 4 , with regard to a battery assembled by using the positive electrode that uses the first active material as the positive electrode active material, a state where the battery is charged to 4.5V from an initial state A before the charge is started is defined as a charge state B. Furthermore, a state where the battery is charged to 4.8V from the charge state B through the plateau region is defined as an overcharge state C, and a state where the battery is discharged to 2.0V is defined as a discharge state D. Then, for the “actual capacity of plateau region” in the expression described above, an actual capacity of the first active material in the plateau region of FIG. 4 just needs to be measured. Note that, specifically, the plateau region is a region from 4.5V to 4.8V, and is a region caused by the fact that the crystal structure is changed. Therefore, an actual capacity V BC of the battery in a region BC from the charge state B to the overcharge state C corresponds to the actual capacity of the plateau region.
[0117] Moreover, in the first active material of compositional formula (6), an actual capacity V AB of a region AB from the initial state A to the charge state B where the battery is charged to 4.5V corresponds to a product of the composition ratio (y) of LiMO 2 as the layered structure region and a theoretical capacity (V L ) of LiMO 2 . Moreover, the actual capacity V BC from the charge state B where the battery is charged to 4.5V to the overcharge state C where the battery is charged to 4.8V corresponds to a product of the composition ratio (x) of Li 2 MnO 3 as the spinel structure region and a theoretical capacity (V s ) of Li 2 MO 3 . Therefore, when an actual capacity (V T ) measured from the initial state A to such a predetermined plateau region is defined as (V T =V AB +V BC ), the spinel structure change ratio can be calculated by using the following expression since relationships: V AB =y×(V L ); and V BC =x×(V s )×K are established. Note that M in compositional formula LiMO 2 is at least one selected from the group consisting of nickel (Ni), cobalt (Co) and manganese (Mn).
[0000]
[
Spinel
structure
change
ratio
(
K
)
]
=
[
Actual
capacity
(
VT
)
measured
to
plateau
region
]
-
[
Theoretical
capacity
(
VL
)
caused
by
LiMO
2
in
first
active
material
]
×
[
Composition
ratio
(
y
)
of
LiMO
2
in
first
active
material
]
[
Theoretical
capacity
(
Vs
)
caused
by
Li
2
MnO
3
in
first
active
material
]
×
[
Composition
ratio
(
x
)
of
Li
2
Mn
O
3
in
first
active
material
]
[
Math
.
2
]
[0118] Furthermore, the “composition ratio of Li 2 MnO 3 in first active material” can be calculated from compositional formula (6) for the first active material. Specifically, in a first active material (1) in Example 2-1 to be described later, a compositional formula thereof is represented as: Li 1.5 [Ni 0.45 Mn 0.85 [Li] 0.20 ]O 3 (a+b+c+d=1.5, d=0.20, a+b+c=1.30). In this case, the composition ratio of Li 2 MnO 3 becomes 0.4, and the composition ratio of LiNi 1/2 Mn 1/2 O 2 becomes 0.6.
[0119] Note that whether or not the layered structure region and the spinel structure region are present in the first active material can be determined based on whether or not there are special peaks in the layered structure and the spinel structure, which are observed by the X-ray diffraction analysis. Moreover, the ratio of the layered structure region and the spinel structure region can be determined from the capacity measurement/calculation as mentioned above.
[0120] Moreover, suitably, the first active material in this embodiment satisfies relationships: 0.15≦d≦0.25; a+b+c+d=1.5; and 1.25≦a+b+c≦1.35 in compositional formula (6). The positive electrode active material of the first active material as described above is capable of realizing the excellent discharge operation voltage and initial rate characteristics while maintaining the higher discharge capacity.
[0121] Moreover, preferably, the first active material in this embodiment satisfies the relationships: 0.15≦d≦0.25; a+b+c+d=1.5; and 1.25≦a+b+c≦1.35 in compositional formula (6). Then, more suitably, the spinel structure change ratio obtained by performing the charge or the charge/discharge in the predetermined potential range is 0.65 or more to 0.85 or less. The positive electrode active material containing the first active material as described above is capable of realizing the excellent discharge operation voltage and initial rate characteristics while maintaining the higher discharge capacity. This is also considered to be because the stability of the crystal structure is excellent.
[0122] Moreover, in the first active material in this embodiment, preferably, a BET specific surface area thereof is 0.8 m 2 /g or more to 10.0 m 2 /g or less, and a 50%-penetration particle diameter (median diameter, D50) thereof is 20 μm or less. The BET specific surface area and the 50%-penetration particle diameter are set in such ranges as described above, whereby the first active material is capable of realizing the excellent discharge operation voltage and initial rate characteristics while maintaining the high discharge capacity, the high capacity retention ratio and the high initial charge/discharge efficiency. That is to say, in the case where the BET specific surface area is 0.8 m 2 /g or more, diffusivity of the lithium ions from an inside of a bulk in the crystal structure is suppressed from being lowered, whereby it is made possible to realize the high initial charge/discharge efficiency and the excellent initial rate characteristics. Moreover, in the case where the BET specific surface area is 10.0 m 2 /g or less, and the 50%-penetration particle diameter is 20 μm or less, the capacity retention ratio can be suppressed from being lowered.
[0123] Next, by taking an example, a description is made in detail of a production method of the first active material in the positive electrode active material according to an embodiment of the present invention.
[0124] As a production method of a precursor of the first active material, the carbonate method (composite carbonate method) can be applied. Specifically, first, as starting materials, the respective sulfates, nitrates or the like of nickel (Ni), cobalt (Co) and manganese (Mn) are prepared, predetermined amounts thereof are weighed, and an aqueous mixed solution thereof is prepared.
[0125] Subsequently, to this aqueous mixed solution, ammonia water is dropped until pH thereof can become 7, and further, an aqueous sodium carbonate (Na 2 CO 3 ) solution is dropped, and Ni—Co—Mn composite carbonate is precipitated. Note that, during a period while the aqueous Na 2 CO 3 solution is being dropped, pH of the aqueous mixed solution is held at 7 by using ammonia water.
[0126] Then, the precipitated composite carbonate is aspirated and filtrated, is washed, is thereafter dried, and is calcined. With regard to drying conditions, the composite carbonate just needs to be dried at 100 to 150° C. for 2 to 10 hours (for example, at 120° C. for 5 hours) in the atmosphere; however, the drying conditions are not limited to this range. With regard to calcining conditions, the composite carbonate just needs to be calcined at 360 to 600° C. for 3 to 10 hours (for example, at 500° C. for 5 hours) in the atmosphere; however, the calcining conditions are not limited to this range.
[0127] Furthermore, such powder thus calcined is added with a little excess amount of lithium hydroxide (LiOH.H 2 O), followed by mixing. Thereafter, a resultant mixture is baked, whereby the precursor of the first active material can be prepared. With regard to baking conditions, for example, the resultant mixture just needs to be baked at 700 to 1000° C. (for example, 800 to 900° C.) for approximately 3 to 20 hours (for example, 12 hours). Note that, preferably, after being baked, the resultant mixture is rapidly cooled by using liquid nitrogen. This is because such rapid cooling using liquid nitrogen and the like, which is performed after baking, is preferable for reactivity and cycle stability.
[0128] Then, the first active material of this embodiment can be obtained by performing oxidation treatment for the above-described precursor. As the oxidation treatment, for example, there can be mentioned: (1) charge/discharge in predetermined potential range; (2) oxidation by oxidizing agent corresponding to charge; (3) oxidation using redox mediator; and the like. Here, (1) charge or charge/discharge in predetermined potential range specifically refers to charge or charge/discharge from a low potential range in which a large change of the crystal structure of the first active material is not brought about from the beginning. Moreover, as (2) oxidizing agent, for example, halogens of bromine, chlorine and the like can be mentioned.
[0129] Here, a relatively simple method among the above-described (1) to (3) oxidation treatments is an oxidation treatment method of the above-described (1). Then, as the oxidation treatment of (1), effective is charge or charge/discharge, which is performed so that the potential cannot exceed a predetermined maximum potential, after the battery is fabricated by using the precursor of the first active material, which is obtained as mentioned above, that is, effective is charge/discharge pretreatment in which the potential is regulated. Note that the charge or the charge/discharge may be performed so that the potential cannot exceed the predetermined maximum potential after the electrode or a structure corresponding to the electrode is fabricated by using the precursor of the first active material, which is obtained as mentioned above. In such a way, such a positive electrode active material, in which the high discharge capacity and the capacity retention ratio are realized, can be obtained.
[0130] As such a charge/discharge pretreatment method in which the potential is regulated, desirably, the charge/discharge is performed for 1 to 30 cycles under conditions where a maximum potential (upper limit potential of the charge/discharge, which is converted to lithium metal) in a predetermined potential range for lithium metal as a counter electrode becomes 4.3V or more to 4.8V or less. Desirably, the charge/discharge is performed for 1 to 30 cycles under conditions where the maximum potential becomes, more preferably, 4.4V or more to 4.6V or less. The oxidation treatment by the charge/discharge is performed within the above-described range, whereby the high charge capacity and capacity retention ratio can be realized. In particular, since the capacity is increased after the above-described oxidation treatment (charge/discharge pretreatment in which the potential is regulated), a particularly remarkable capacity retention ratio can be developed effectively in the case where the charge or the charge/discharge is performed while setting the maximum potential at approximately 4.8V. Note that the above-described potential converted to the lithium metal corresponds to a potential, which takes, as a reference, a potential shown by the lithium metal in the electrolysis solution in which the lithium ions is dissolved by 1 mol/L.
[0131] Moreover, after the charge/discharge within the above-described predetermined potential range for the lithium metal as the counter electrode is performed for 1 to 30 cycles, desirably, the maximum potential of the predetermined potential range of the charge/discharge is further increased stepwise. In particular, in the case of using the battery to a capacity with such a potential as high as 4.7V and 4.8V vs. Li, the maximum potential of such a charge/discharge potential in the oxidation treatment is increased stepwise, whereby durability of the electrode can be improved even in oxidation treatment for a short time.
[0132] In the event of increasing the maximum potential (upper limit potential) of the charge/discharge stepwise, the number of cycles required for the charge/discharge in each step is not particularly limited; however, effectively, is within a range of 1 to 10 times. Moreover, in the event of increasing the maximum potential of the charge/discharge stepwise, the total number of charge/discharge cycles in the oxidation treatment process, that is, the number of times, which is obtained by summing up the number of cycles required for the charge/discharge in each step, is not particularly limited; however, effectively, is within a range of 4 times to 20 times.
[0133] Moreover, in the event of increasing the maximum potential of the charge/discharge stepwise, a gain (increase margin) of the potential in each step is not particularly limited; however, effectively, is 0.05V to 0.1V.
[0134] Furthermore, in the event of increasing the maximum potential of the charge/discharge stepwise, effectively, a final maximum potential (termination maximum potential) is set at 4.6 to 4.9V. However, the termination maximum potential is not limited to the above-described range, and the charge/discharge pretreatment may be performed up to a higher termination maximum potential if the above-described effects can be exerted.
[0135] A minimum potential of the predetermined potential range of the charge/discharge is not particularly limited, and is 2V or more to less than 3.5V, more preferably, 2V or more to 3V or less for the lithium metal as the counter electrode. The oxidation treatment (charge/discharge pretreatment in which the potential is regulated) by the charge or the charge/discharge is performed within the above-described range, whereby the high charge capacity and capacity retention ratio can be realized. Note that the potential (V) of the above-described charge/discharge refers to a potential per single cell.
[0136] Moreover, a temperature of the electrode that performs the charge/discharge as the oxidation treatment (charge/discharge pretreatment in which potential is regulated; electrochemical pretreatment) can be set arbitrarily as long as the functions and effects of the present invention are not damaged. Note that, from a viewpoint of economy, desirably, the oxidation treatment is performed at room temperature (25° C.) at which special heating and cooling are not required. Meanwhile, from viewpoints that a larger capacity can be developed, and that it is possible to enhance the capacity retention ratio by short-time charge/discharge treatment, desirably, the oxidation treatment is performed at a temperature higher than the room temperature.
[0137] Furthermore, a process to which the oxidation treatment (charge/discharge pretreatment; electrochemical pretreatment) is applied is not particularly limited. For example, the oxidation treatment as described above can be performed as described above in the state where the battery is configured or in the electrode or in the configuration corresponding to the electrode. That is to say, the oxidation treatment may be applied in any of the state of the powder of the positive electrode active material, the configuration of the electrode, and the assembly of the battery in combination with the negative electrode. The application of the oxidation treatment to the battery can be carried out by applying oxidation treatment conditions in consideration of a potential profile of an electric capacity of the negative electrode to be combined with the positive electrode concerned.
[0138] Here, the case of the state where the battery is configured is superior to implementation of the oxidation treatment for each electrode or for each configuration corresponding to the electrode in that the oxidation treatment for many electrodes can be performed once and collectively. Meanwhile, in the case of performing the oxidation treatment for each of the electrodes or for each of the configurations corresponding to the electrode, it is easier to control the conditions for the oxidation potential and the like than in the state of configuring the battery. Furthermore, such a method of performing the oxidation treatment for each of the electrodes is excellent in that variations in degree of oxidation to the individual electrodes are less likely to occur.
[0139] Note that the oxidizing agent for use in the oxidation treatment method of (2) described above is not particularly limited, and for example, halogens of bromine, chlorine and the like can be used. These oxidizing agents may be each used singly or may be used in combination. With regard to the oxidation by the oxidizing agent, for example, fine particles of the first active material are dispersed into a solvent into which the first active material is not dissolved, and the oxidizing agent is blown into a dispersion solution concerned, whereby the first active material can be gradually oxidized.
[0140] Moreover, in compositional formula (7) for the second active material, in the case where M is at least one selected from the group consisting of aluminum (Al), magnesium (Mg) and chromium (Cr), and a′ satisfies the relationship: 0≦a′<0.5, the second active material can take a stable spinel structure.
[0141] Moreover, in the second active material in the positive electrode active material of this embodiment, preferably, a BET specific surface area thereof is 0.2 m 2 /g or more to 3.0 m 2 /g or less, and a 50%-penetration particle diameter (median diameter, D50) thereof is 20 μm or less.
[0142] The BET specific surface area and the 50%-penetration particle diameter are set in such ranges as described above, whereby the second active material is capable of realizing the excellent discharge operation voltage and initial rate characteristics while maintaining the high discharge capacity and charge/discharge efficiency. For example, in the case where the BET specific surface area is 0.2 m 2 /g or more, the diffusivity of the lithium ions from the inside of the bulk in the crystal structure is suppressed from being lowered, whereby it is made possible to realize the high initial charge/discharge efficiency and the excellent initial rate characteristics. Moreover, for example, in the case where the BET specific surface area is 3.0 m 2 /g or less, and the 50%-penetration particle diameter is 20 μm or less, the capacity retention ratio can be suppressed from being lowered.
[0143] Furthermore, in the positive electrode active material of this embodiment, preferably, the first active material and the second active material satisfy a relationship of the following expression (8):
[0000] 0<M B /(M A +M B )<0.45 (8)
[0000] wherein M A is a mass of the first active material and M B is a mass of the second active material.
[0144] The relationship between the first active material and the second active material is set in such a range as described above, whereby it is made possible to realize the excellent discharge operation voltage and initial rate characteristics while maintaining the higher discharge capacity. Moreover, the initial charge/discharge efficiency also becomes excellent.
[0145] Specific configurations of the positive electrode for the lithium ion secondary battery, which uses the positive electrode active material according to this embodiment of the present invention, and of the lithium ion secondary battery concerned, and in addition, a manufacturing method of the lithium ion secondary battery concerned are similar to those of the first embodiment, and accordingly, a detailed description thereof is omitted.
Example 2
[0146] A description is made below in more detail of this embodiment by examples and comparative examples; however, the present invention is not limited to these examples.
Example 2-1
Synthesis of First Active Material (1)
[0147] The first active material (1) was synthesized by using the composite carbonate method. As starting materials, sulfates of nickel (Ni) and manganese (Mn) were used, and an aqueous nickel sulfate solution and an aqueous manganese sulfate solution, in each of which a concentration was 2 mol/L, were prepared. As a precipitant, an aqueous sodium carbonate solution with a concentration of 2 mol/L was used, and as a pH regulating agent, an aqueous ammonia solution with a concentration of 0.2 mol/L was used.
[0148] Next, the aqueous nickel sulfate solution and the aqueous manganese sulfate solution were mixed with each other so that nickel and manganese could be mixed in a ratio of a compositional formula shown below, whereby an aqueous composite sulfate solution was prepared. Then, the above-described aqueous sodium carbonate solution was dropped into the aqueous composite sulfate solution stirred by a magnetic stirrer, whereby a precursor was precipitated. Thereafter, the precursor was aspirated and filtrated, and a precipitate deposited on filter paper was dried, whereby a precursor of composite hydroxide was obtained.
[0149] Thereafter, the obtained precursor of the composite hydroxide and lithium carbonate were mixed with each other in a predetermined molar ratio. Then, after being calcined at 500° C., a resultant mixture was baked at 800° C. to 1000° C. for 12 hours to 24 hours in the atmosphere, whereby a target sample was obtained.
<Composition of First Active Material (1)>
[0150] Li 1.5 [Ni 0.45 Mn 0.85 [Li] 0.20 ]O 3 Compositional formula:
[0000] ( a+b+c+d= 1.5 , d= 0.20 , a+b+c= 1.30)
Synthesis of Second Active Material
[0151] The second active material was synthesized by the solid phase method. As starting materials, manganese oxide, lithium carbonate and aluminum hydroxide were used. Predetermined amounts of the manganese oxide, the lithium carbonate and the aluminum hydroxide were weighed so as to achieve a ratio of the following compositional formula, and the manganese oxide, the lithium carbonate and the aluminum hydroxide were mixed with one another by using an agate mortar and a pestle. Then, an obtained mixture was baked at 1000° C. for 12 hours in the atmosphere, and was thereafter subjected to annealing treatment at 600° C. for 10 hours under an oxygen atmosphere, whereby a target sample was obtained.
<Composition of Second Active Material>
[0152] LiAl 0.1 Mn 1.9 O 4 Compositional formula:
<Preparation of Slurry for Positive Electrode>
[0153] 5.5 mass parts of the binder were dissolved into 49.5 mass parts of NMP, whereby a binder solution was prepared. Next, 55.0 mass parts of the binder solution were added to mixed powder of 5.5 mass parts of the electric conducting additive and 100 mass parts of the positive electrode active material, a resultant was kneaded by a planetary mixer, and thereafter, 24.5 mass parts of NMP were added to an kneaded product, whereby slurry for the positive electrode was obtained. A solid content concentration of the obtained slurry for the positive electrode was 60% by mass. Note that, as the planetary mixer, HIVIS MIX Model 2P-03 made by PRIMIX Corporation was used.
<Composition of Slurry for Positive Electrode>
[0154] Positive electrode active material: first active material (1) 75 mass parts, second active material 25 mass parts
[0155] Electric conducting additive: scale-like graphite 2.0 mass parts, acetylene black 3.5 mass parts
[0156] Binder: polyvinylidene fluoride (PVDF) 5.5 mass parts
[0157] Solvent: N-methylpyrrolidone (NMP) 74 mass parts
<Coating/Drying of Slurry for Positive Electrode>
[0158] On one surface of a current collector composed of aluminum foil with a thickness of 20 μm, the obtained slurry for the positive electrode was coated by a bar coater. Subsequently, this current collector coated with the slurry for the positive electrode was dried at 120 to 130° C. for 10 minutes on a hot plate, and an amount of NMP remaining in the positive electrode active material layer was set at 0.02% by mass or less.
<Press of Positive Electrode>
[0159] The obtained sheet-like positive electrode was press-molded by using a roll press, followed by cutting. In such a way, a positive electrode C1 was obtained, in which weight of the positive electrode active material layer on one surface was approximately 3.5 mg/cm 2 , a thickness thereof was approximately 50 μm, and a density thereof was 2.70 g/cm 3 .
<Drying of Positive Electrode>
[0160] Next, by using this positive electrode C1, drying treatment was performed in a vacuum drying furnace. Specifically, after the positive electrode C1 was placed in an inside of the drying furnace, a pressure of the inside was reduced (to 100 mm Hg (1.33×10 4 Pa)) at room temperature (25° C.), and air in the drying furnace was removed. Subsequently, while flowing nitrogen gas through the inside, temperature was raised to 120° C. at a rate of 10° C./min., and at 120° C., the pressure was reduced one more time. Then, the positive electrode C1 was held for 12 hours while leaving nitrogen in the furnace evacuated, and thereafter, the temperature was dropped to the room temperature, whereby a positive electrode C11 was obtained. Note that a flow rate at which the nitrogen gas was flown through the inside of the furnace was set at 100 cm 3 /min.
<Fabrication of Lithium Ion Secondary Battery>
[0161] The positive electrode C11 fabricated in Example 2-1 was punched to a diameter of φ15 mm. Thereafter, before fabricating the battery, the positive electrode C11 was dried one more time at 100° C. for 2 hours by a vacuum dryer. Moreover, the porous membrane of polypropylene, the coin cell members and the like were used after being dried in advance at the room temperature for 24 hours or more in a glove box with an argon gas atmosphere.
[0162] Then, in the glove box with the argon gas atmosphere, the positive electrode and the negative electrode made of the metal lithium were allowed to face each other, and two separators were arranged there between. Note that a material of the separators thus used is polypropylene, and a thickness thereof is 20 μm.
[0163] Subsequently, such a stacked body of the negative electrode, the separators and the positive electrode was arranged on a bottom side of a coin cell (CR2032, material: stainless steel (SUS316)). Furthermore, a gasket for keeping the insulating properties between the positive electrode and the negative electrode was mounted, and 150 μL of an electrolysis solution to be described below was injected by using a syringe. Thereafter, a spring and a spacer were stacked, and an upper side of the coin cell was superimposed and crimped, whereby hermetic sealing was made. In such a way, the lithium ion secondary battery was fabricated. Note that a standard of the above-described coin cell was CR2032, and stainless steel (SUS316) was used as a material thereof. Moreover, as the electrolysis solution, one was used, in which lithium hexafluorophosphate (LiPF 6 ) as the supporting salt was dissolved into an organic solvent so that a concentration thereof could be 1 mol/L. Moreover, as the organic solvent, one was used, in which ethylene carbonate (EC) and diethyl carbonate (DEC) were mixed with each other in a ratio of EC:DEC=1:2 (volume ratio). Note that a special additive and the like were not added to the electrolysis solution concerned.
[0164] Thereafter, the above-described battery element was set on a cell attachment jig for evaluation, and the positive electrode lead and the negative electrode lead were attached to the respective tab end portions of the battery element, and then a test was carried out.
<Electrochemical Pretreatment>
[0165] First, the charge and discharge of the above-described lithium ion secondary battery were performed. The charge was performed by the constant current and constant voltage charge (CCCV) method, in which the charge was performed at a rate of 0.1 C until the maximum voltage of the battery became 4.2V, and thereafter, the maximum voltage was held for approximately 24 hours. Moreover, the discharge was performed by the constant current discharge (CC) method, in which the discharge was performed at a rate of 1.0 C until the minimum voltage of the battery became 2.5V.
[0166] Next, as shown in Table 3, a constant current charge/discharge cycle, in which the charge was performed at a rate of 0.1 C until the maximum voltage became 4.5V, and thereafter, the discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out twice (Pattern 1). Next, a constant current charge/discharge cycle, in which the charge was performed at a rate of 0.1 C until the maximum voltage became 4.6V, and thereafter, the discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out once (Pattern 2). Furthermore, a constant current charge/discharge cycle, in which the charge was performed at a rate of 0.1 C until the maximum voltage became 4.7V, and thereafter, the discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out once (Pattern 3). Subsequently, a constant current charge/discharge cycle, in which the charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out once (Pattern 4). Finally, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out once (Pattern 5). All of the patterns were performed at the room temperature. In such a way as described above, a lithium ion secondary battery of this example was obtained.
[0000]
TABLE 3
Repeat count
State
Lower limit
Upper limit
Current
Time
Mode
(number
Pattern
(—)
voltage (V)
voltage (V)
rate (C)
(h)
(—)
of times)
1
charge
—
4.5
0.1
15
CC
2
discharge
2.0
—
0.1
15
CC
2
charge
—
4.6
0.1
15
CC
1
discharge
2.0
—
0.1
15
CC
3
charge
—
4.7
0.1
15
CC
1
discharge
2.0
—
0.1
15
CC
4
charge
—
4.8
0.1
15
CC
1
discharge
2.0
—
0.1
15
CC
5
charge
—
4.8
0.1
15
CCCV
1
discharge
2.0
—
0.1
15
CC
Example 2-2
[0167] In the composition of the slurry for the positive electrode, such a content ratio of the first active material (1) was set at 50 mass parts, and such a content ratio of the second active material was set at 50 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Example 2-3
[0168] In the composition of the slurry for the positive electrode, the content ratio of the first active material (1) was set at 25 mass parts, and the content ratio of the second active material was set at 75 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Example 2-4
Synthesis of First Active Material (2)
[0169] The first active material (2) was synthesized by using the composite carbonate method. As starting materials, sulfates of nickel (Ni) cobalt (Co) and manganese (Mn) were used, and an aqueous nickel sulfate solution, an aqueous cobalt sulfate solution and an aqueous manganese sulfate solution, in each of which a concentration was 2 mol/L, were prepared. As a precipitant, an aqueous sodium carbonate solution with a concentration of 2 mol/L was used, and as a pH regulating agent, an aqueous ammonia solution with a concentration of 0.2 mol/L was used.
[0170] Next, the aqueous nickel sulfate solution, the aqueous cobalt sulfate solution and the aqueous manganese sulfate solution were mixed with one another so that nickel, cobalt and manganese could be mixed in a ratio of a compositional formula shown below, whereby an aqueous composite sulfate solution was prepared. Then, the aqueous sodium carbonate solution was dropped into the aqueous composite sulfate solution stirred by a magnetic stirrer, whereby a precursor was precipitated. Thereafter, the precursor was aspirated and filtrated, and a precipitate deposited on filter paper was dried, whereby a precursor of composite hydroxide was obtained.
[0171] Thereafter, the obtained precursor of the composite hydroxide and lithium carbonate were mixed with each other in a predetermined molar ratio. Then, a resultant mixture was calcined at 500° C., and was then baked at 800° C. to 1000° C. for 12 hours to 24 hours in the atmosphere, whereby a target sample was obtained.
<Composition of First Active Material (2)>
[0172] Li 1.5 [Ni 0.25 Co 0.25 Mn 0.75 [Li] 0.25 ]O 3 compositional formula:
[0000] ( a+b+c+d= 1.5 , d= 0.20 , a+b+c= 1.25)
[0173] In the composition of the slurry for the positive electrode, such a content ratio of the first active material (2) was set at 75 mass parts, and such a content ratio of the second active material was set at 25 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Example 2-5
[0174] In the composition of the slurry for the positive electrode, the content ratio of the first active material (2) was set at 50 mass parts, and the content ratio of the second active material was set at 50 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Example 2-6
[0175] In the composition of the slurry for the positive electrode, the content ratio of the first active material (2) was set at 25 mass parts, and the content ratio of the second active material was set at 75 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Comparative Example 2-1
[0176] In the composition of the slurry for the positive electrode, the content ratio of the first active material (1) was set at 100 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Comparative Example 2-2
[0177] In the composition of the slurry for the positive electrode, the content ratio of the first active material (2) was set at 100 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
Comparative Example 2-3
[0178] In the composition of the slurry for the positive electrode, the content ratio of the second active material was set at 100 mass parts. Except for the above, similar operations to those of Example 2-1 were repeated, whereby a lithium ion secondary battery of this example was obtained.
[0179] Specifications of the positive electrode active materials of Examples 2-1 to 2-6 and Comparative examples 2-1 to 2-3 are shown in Table 4.
[0000]
TABLE 4
Positive electrode active material
First active material
Second active material
50%-pene-
50%-pene-
Rate
Spinel
BET
tration
BET
tration
character-
structure
specific
particle
specific
particle
Discharge
Charge/
istics
change
surface
diameter
Content
surface
diameter
Content
MB/
capacity
discharge
Average
(2.5 C/
Type
ratio (K)
area
(D50)
ratio
area
(D50)
ratio
(MA +
(0.1 C)
efficiency
voltage
0.1 C)
(—)
(—)
(m 2 /g)
(μm)
(%)
(m 2 /g)
(μm)
(%)
MB)
(mAh/g)
(%)
(V)
(%)
Example
A1
0.86
1.38
6.40
75
0.73
10.30
25
0.25
230.8*
87.6*
3.73*
79.3*
2-1
Example
A1
0.86
1.38
6.40
50
0.73
10.30
50
0.50
187.1*
90.7*
3.76*
81.5*
2-2
Example
A1
0.86
1.38
6.40
25
0.73
10.30
75
0.75
153.2*
91.1
3.78
83.7*
2-3
Example
A2
0.84
2.60
6.20
75
0.73
10.30
25
0.25
226.2*
86.7*
3.71*
78.5*
2-4
Example
A2
0.84
2.60
6.20
50
0.73
10.30
50
0.50
183.4*
89.8*
3.74*
80.7*
2-5
Example
A2
0.84
2.60
6.20
25
0.73
10.30
75
0.75
150.1*
90.2
3.76
82.9*
2-6
Comparative
A1
0.86
1.38
6.40
100
—
0
0
235.5
84.3
3.68
76.7
example 2-1
Comparative
A2
0.84
2.60
6.20
100
—
0
0
220.8
83.3
3.65
72.7
example 2-2
Comparative
—
—
—
—
0
0.73
10.30
100
1
120.5
94.1
3.81
85.1
example 2-3
[Performance Evaluation]
<Discharge Capacity and Average Voltage>
[0180] For the lithium ion secondary batteries of the above-described respective examples, as shown in Table 5, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out twice. At this time, a discharge capacity and average voltage of each of the batteries were measured and calculated. Note that, in the present invention, the discharge operation voltage was evaluated by the average voltage. Obtained results are shown in Table 4 in combination.
[0000]
TABLE 5
Repeat count
State
Lower limit
Upper limit
Current
Time
Mode
(number
Pattern
(—)
voltage (V)
voltage (V)
rate (C)
(h)
(—)
of times)
1
charge
—
4.8
0.1
15
CCCV
2
discharge
2.0
—
0.1
15
CC
<Charge/Discharge Efficiency>
[0181] Moreover, for the lithium ion secondary battery of each of the above-described examples, the charge capacity and the discharge capacity were measured in the electrochemical pretreatment and the main charge/discharge cycle. At this time, the charge/discharge efficiency was calculated from a ratio of the discharge capacity in the final discharge in the main charge/discharge cycle with respect to a total sum of: a difference of the charge capacity in the charge/discharge cycle at the time of the electrochemical pretreatment; a difference of the charge capacity in the main charge/discharge cycle; and the charge/discharge capacity in the final charge. That is to say, the charge/discharge efficiency (%) is represented by [discharge capacity in final discharge in main charge/discharge cycle]/[total sum of difference of charge capacity in charge/discharge cycle at time of electrochemical pretreatment, difference of charge capacity in main charge/discharge cycle and charge/discharge capacity in final charge]. Obtained results are shown in Table 4 in combination.
<Rate Characteristics>
[0182] For the lithium ion secondary battery of each of the above-described examples, charge/discharge cycles shown in Table 6 were implemented. First, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out twice (Pattern 1). Next, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 0.5 C until the minimum voltage became 2.0V, was carried out twice (Pattern 2). Furthermore, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 1 C until the minimum voltage became 2.0V, was carried out twice (Pattern 3). Thereafter, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 2.5 C until the minimum voltage became 2.0V, was carried out twice (Pattern 4). Finally, a cycle, in which the constant current and constant voltage charge was performed at a rate of 0.1 C until the maximum voltage became 4.8V, and thereafter, the constant current discharge was performed at a rate of 0.1 C until the minimum voltage became 2.0V, was carried out twice (Pattern 5). All of the patterns were performed at the room temperature.
[0183] At this time, the charge capacity of the battery in each of the rates was measured, whereby the capacity retention ratio was calculated. Then, the initial rate characteristics were calculated from a ratio of the capacity retention ratio at the rate of 2.5 C with respect to the capacity retention ratio at the rate of 0.1 C. Obtained results are shown in Table 4 in combination.
[0000]
TABLE 6
Repeat count
State
Lower limit
Upper limit
Current
Time
Mode
(number
Pattern
(—)
voltage (V)
voltage (V)
rate (C)
(h)
(—)
of times)
1
charge
—
4.8
0.1
15
CCCV
2
discharge
2.0
—
0.1
15
CC
2
charge
—
4.8
0.1
15
CCCV
2
discharge
2.0
—
0.5
15
CC
3
charge
—
4.8
0.1
15
CCCV
2
discharge
2.0
—
1.0
15
CC
4
charge
—
4.8
0.1
15
CCCV
2
discharge
2.0
—
2.5
15
CC
5
charge
—
4.8
0.1
15
CCCV
2
discharge
2.0
—
0.1
15
CC
[0184] From Table 4, it is understood that, in comparison with Comparative example 2-1 to Comparative example 2-3, Example 2-1 to Example 2-6 are capable of realizing the excellent discharge operation voltage and initial rate characteristics while maintaining the high discharge capacity. In particular, in the results shown in Table 4, results affixed with “*” show those improved more than arithmetic mean values corresponding to a mixture ratio of the first active material and the second active material, the arithmetic mean values being obtained from the result of Comparative example 2-1 or Comparative example 2-2. At the present point of time, it is considered that Example 2-1 and Example 2-4 are particularly excellent.
[0185] Moreover, the reason why Examples 2-1 and 2-4, in particular Example 2-1, are capable of realizing the excellent discharge operation voltage and initial rate characteristics while maintaining the high discharge capacity in comparison with Comparative example 2-1 to Comparative example 2-3 is also considered to be that Examples 2-1 and 2-4 satisfy the relationship of expression (8).
[0186] Note that, with regard to the first active material taken out by disassembling the lithium ion secondary battery of each of the examples, it was confirmed that the first active material concerned had the layered structure region and the spinel structure region based on the presence of the special peaks in the layered structure and the spinel structure, which were observed by the X-ray diffraction analysis (XRD). Moreover, with regard to the second active material taken out by disassembling the lithium ion secondary battery of each of the examples, it was confirmed that the second active material concerned had the layered structure region based on the presence of the special peak in the layered structure, which was observed by the X-ray diffraction analysis (XRD).
[0187] Note that these structures may be confirmed by the electron beam diffraction analysis, and the composition of each of the examples can be confirmed, for example, an inductively coupled plasma emission analyzer (ICP emission analyzer).
[0188] The description has been made above of the present invention by the embodiments and the example; however, the present invention is not limited to these, and is modifiable in various ways within the scope of the spirit of the present invention.
[0189] That is to say, in the above-described embodiments and examples, the lithium ion secondary battery is illustrated as the electric device; however, the present invention is not limited to this, and can also be applied to other types of secondary batteries, and further, to a primary battery. Moreover, the present invention can be applied not only to such batteries but also to a lithium ion capacitor. That is to say, the positive electrode for an electric device according to the present invention and the electric device according thereto just need to be those, each of which includes the predetermined first active material and second active material as the positive electrode active material, and other constituents are not particularly limited.
[0190] For example, the present invention can be applied not only to the above-mentioned laminate-type battery but also to forms and structures, which have been heretofore known in public, and include a button-type battery and a can-type battery. Moreover, for example, the present invention can be applied not only to the above-mentioned stack-type (flat-type) battery but also to a roll-type (cylinder-type) battery and the like.
[0191] Moreover, for example, in terms of an electric connection form in the lithium ion secondary battery, the present invention can be applied not only to the above-mentioned battery of the type in which the parallel connection is made in an inside but also to a bipolar battery and the like. That is to say, the present invention can also be applied to a battery of a type in which a series connection is made in an inside. Note that, in general, a battery element in the bipolar battery has a configuration, in which a plurality of bipolar electrodes and a plurality of electrolyte layers are stacked on each other, each of the bipolar electrodes having a negative electrode active material layer formed on one surface of a current collector, and a positive electrode active material layer formed on other surface thereof.
INDUSTRIAL APPLICABILITY
[0192] In accordance with the present invention, there are allowed to coexist: the first active material that has the crystal structure containing extra lithium, which is irreversible; and the second active material that has the crystal structure having the defect or the site, into which lithium is insertable. Therefore, there can be provided: the positive electrode active material for an electric device, which is capable of exerting the excellent initial charge/discharge efficiency while maintaining the high capacity by maintaining the high reversible capacity; and the positive electrode for an electric device, and the electric device, each of which uses the positive electrode active material. | A positive electrode active material is provided for an electric device that contains a first active material comprising a transition metal oxide represented by formula (1): Li1.5[NiaCobMnc[Li]d]O3 (where a, b, c, and d satisfy the relationships: 0<d<0.5; a+b+c+d=1.5; and 1.0<a+b+c<1.5); and a second active material comprising a spinel transition metal oxide that has a crystal structure assigned to the space group Fd-3m, represented by formula (2): LiMa′Mn2−a′O4 (where M indicates at least one metal element having an atomic valence of 2-4, and a′ satisfies the relationship 0=a′<2.0). The fraction content of the first and second active material by mass ratio satisfies the relationship (3): 100:0 A:MB A indicates the mass of the first active material and MB indicates the mass of the second active material). | 2 |
REFERENCE TO RELATED APPLICATION
This application is a continuation of International Application No. PCT/BR00/00025, filed Feb. 23, 2000, now abandoned, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the chemical synthesis of a melanocyte stimulating hormone (α-MSH) analogue containing a stable amino acid-type free radical (spin probe or spin label) that maintains entirely the biological activity of the native hormone. This maintenance of α-MSH biological potency and the presence of the paramagnetic spin label in its structure allow this analogue to be studied through electron paramagnetic resonance (also known as EPR or RPE, depending on the language used, English or Portuguese) and contains relevant potentialities for several additional applications in the biochemical-medical fields, related to the investigation of several already known physiological effects of this hormone.
2. Technical Background and Prior Art
The melanocyte stimulating hormone (α-MSH) seems to be involved in several physiologic processes in higher animals (e.g. The Melanotropic Peptides, Vaudry, H & Eberle, N, eds., New York, 1993). Among these processes one may mention the effect upon the fetal growth, behavior, inflammation (e.g. Drugs of the Future, 15, 41[1990]), obesity [Nature 385, 165 (1997)], erectile function, [J. Urol. 160, 389 (1998)], etc. No matter what, the more relevant effect of this hormone considered as a neuroimunemodulator, is related with the skin darkening effect (The Melanotropic Peptides, New York, [1993]).
The skin darkening of mammals and of other animals is basically controlled by the amount of melanin, a biological compound synthesized from the amino acid tyrosine and mediated by the enzyme tyrosinase. The melanin molecules are stored inside granules of cellular structures denominated melanocytes, and it has been observed that the more aggregated these granules in the cells are, the clearer the individual's skin will become. The control of this granular aggregation in the organism is carried out by a compound known as melatonin (N-acetyl-5-methoxy-tryptamine). Contrariwise, darker skin is due to more dispersed melanin-containing granules in the cells, and this dispersion control in the organism is performed by the aforementioned α-MSH, which is a peptide found in the pituitary gland of several animal species, including the human, and its amino acid sequence is already known, as represented below:
(Acetyl-Ser-Tyr-Ser-Met-Glu-His-Phe-Arg-Trp-Gly-Lys-Pro-Val-CONH 2 )
Therefore, besides the importance of this hormone to the physiological effects already mentioned, a better understanding of the α-MSH effect can be useful, for example, for possible elucidation of the causes or mechanisms of several diseases regarding irregular pigmentation of the skin. And in some lower animals, this peptide hormone is also very important because it allows alterations of the color of the skin as a function of the ambient luminosity, thus facilitating the survival of some species.
The first chemical synthesis of this peptide was made some decades ago (J. Am. Chem. Soc. 83, 2289 [1961]) and recent researches on this important hormone have aimed at clarifying its action mechanism at the cellular membrane level, because its specific receptor was already characterized and found in different tissues and organs (Science 257, 1248 [1992]), including tumor cells (Proc. Natl. Acad. Sci. USA 93, 13715 [1996]). For this, several approaches are applied, among which many are spectroscopic, so that, besides furnishing conformational information of the hormone in solution, they can also supply details on interaction and positioning in synthetic or natural membranes.
Within this context, a more potent α-MSH analogue has for instance already been labeled with fluorescent probes in specific positions of its sequence for further conformational and structural studies and for detection of its cellular receptor (J. Pharm. Sci. 74, 237 [1985]).
Prior to this application, there has not been published an α-MSH analogue containing a paramagnetic compound (spin probe or spin label) that maintains entirely its original biological activity. The usefulness of hormone labeling with this special type of marker molecule has the advantage of, for the first time, facilitating the application of the RPE method already mentioned [Spin Labeling—Theory and Applications, Berliner, L.J., New York, 1989] for the investigation of this important tridecapeptide hormone.
In contrast with other spectroscopic methods, ESR permits the detection of conformational alterations of the hormone either in solution or associated with macrostructures such as membranes, based on spectral data that monitor the degree of motion of the molecule or of the system where the spin probe is bound. In addition, owing to the fluorescent quenching property of the nitroxide function of the spin label (Biochemistry, 20, 1932 [1981]) the ESR method allows a unique alternative approach for conjugation as compared with the conventional fluorescence method.
However, the most important pre-requisite in any strategy of introducing a spin marker in the α-MSH molecule or in any other biological molecule of interest is the need for maintenance of original biological potency. It is not so probable that it is as different from the radioactive labeling of hormone which does not modify its chemical structure, a non-natural compound and with significant size is being inserted in the structure of the native hormone under study. Besides this pre-requisite, it was also necessary that the introduction of the spin probe in the hormone structure should be in such a way as to reflect closely the peptide conformational features. For this reason, spin labels that bind to the hormone through a great amount of chemical bonds (long spin probes) and therefore, with high rotation freedom were not considered to be very appropriate. This is the case in some examples referred to in the literature where a long and flexible marker was used for ESR study of peptides, e.g. Nature 359, 653 (1992). The ideal case would be, therefore, a paramagnetic probe that binds as rigidly as possible to the peptide structure and directly in its skeleton through a peptide bond as usually happens with amino acid residues.
The inventors initiated the use, some decades ago, of an amino acid-type spin probe abbreviated as Toac (2,2,6,6-tetramethylpiperidine-1-oxyl-4-amino-4-carboxylic acid)—e.g. Bull. Soc. Chim. Fr. 815 (1967) in the peptide chemistry field, and it seemed to fulfill partially these requirements for binding more rigidly to the structure of the hormone. By containing the amine and carboxylic groups in a same carbon of the heterocyclic Toac structure, this spin label can be introduced as an amino acid directly to the peptide backbone.
To make it possible to couple in a peptide sequence through the classic solid phase peptide synthesis methodology, [e.g. Peptides: Analysis, Synthesis and Biology (Barany, G. and Merrifield, R. B. 1980)], the tert-butyloxycarbonyl group was introduced (Boc) in the Toac amino group function, according to Braz. J. Med. Biol. Res. 14, 173 (1981). Due to the lability of the free radical nitroxide group in a strong acid medium present during the peptide synthesis method (trifluoroacetic acid), its introduction was only possible in the N-terminal position of the peptide structure e.g. Biochim. Biophys. Acta, 742, 63 (1983). Later on, this limitation of the use of ESR in peptides was also overcome by the inventors, when using another Toac-amino group protection, the base labile 9-fluorenylmethyloxycarbonyl (Fmoc), in J. Am. Chem. Soc. 115, 11042 (1993). With this protecting group we demonstrated for the first time in the literature a way of introducing the spin probe Toac at any internal positions of the peptide hormone structure, making possible therefore the substitution of any residue of amino acid of its original sequence for this paramagnetic compound. A great variety of examples of application of this strategy were later published, but none of them had reported the synthesis of a spin labeled biologically active peptide that maintained entirely its natural potency.
SUMMARY OF THE INVENTION
The invention here described includes the synthesis by chemical methods of an α-melanocyte stimulating hormone analogue labeled with Toac which maintains 100% of its natural biological activity.
The chemical structure of the α-MSH synthesized in accordance with this invention is the following:
(Acetyl-Toac-Ser-Tyr-Ser-Met-Glu-His-Phe-Arg-Trp-Gly-Lys-Pro-Val-CONH 2 ) (SEQ ID NO:1)
This structure will be referred in this application as Ac-Toac 0 -α-MSH or EPM-2.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of an HPLC (high performance liquid chromatography) profile of the purified EPM-2 peptide.
FIGS. 2A and 2B are a depiction of the mass spectra of the α-MSH and EPM-2 peptides, respectively.
FIGS. 3A and 3B are depictions of the EPR spectra of 10 −4 M Toac and EPM-2, respectively, in aqueous solution.
FIG. 4 is a graph of dose-response curves to EPM-2 as compared to native α-MSH, in a frog ( Rana catesbeiana ) skin bioassay.
FIG. 5 is a graph showing the reversal of the maximal responses to the native hormone and to EPM-2 (10 −8 M) after removal of the peptides and rinsing of the preparation.
DETAILED DESCRIPTION OF THE INVENTION
We have discovered that the strategy of coupling the spin probe Toac in the N-terminal portion is due to the fact that previous studies have shown that this position is less essential for the maintenance of the α-MSH activity. As we have found the presence of the acetyl group in the amino terminal group of the sequence is also necessary for this activity, we carry out this acetylation step after the Toac incorporation. The general solid phase chemical methodology for peptide synthesis was applied for this sequence where the temporary protecting group Boc is used for peptide chain elongation bound to the starting polymer. The resin used was methylbenzidrylamino-resin, a toluoylmethylamine-containing a copolymer of styrene and 1% divinylbenzene for linking of the C-terminal residue of the sequence, vide, Peptides 2, 45 (1981). The reactive side chains were protected temporarily with appropriate chemical groups.
In each synthetic cycle, the Boc protecting group is removed with 30% TFA (v/v) in dichloromethane (DCM) treatment for 30 min and the following deprotonation of the amine group of the sequence for coupling step is carried out in diisopropylethylamine, 10% v/v, in DCM for 10 minutes.
The coupling reaction of amino acids is usually done with the acylating agent diisopropylcarbodiimide in DCM/DMF (1:1) for about 2 hours. The monitoring of this important synthesis reaction is carried out with the ninhydrin test, and if recoupling is needed, the acylating agent is changed to tetrafluoroborate-2-(1H-benzotriazolyl-1,1,3,3-tetramethyluronium), i.e., TBTU. The choice of the solvent system for each synthesis cycle followed the method introduced recently by the inventors, based on a new solvent polarity parameter that considers the sum of the acceptor (AN) and donor (DN) electron properties of the solvents, see, J. Org. Chem. 61, 8992 (1996). The selected solvent for the α-MSH synthesis based on this study was N-methylpyrrolidinone (NMP).
The introduction of the Toac probe was performed using its Fmoc derivative and followed the already mentioned synthesis strategy which allows the introduction of this spin label internally to the peptide sequence. The acetylation step was done using a large excess of acetic anhydride in DMF for 1 h and in general, we did not observe relevant difficulties in the assembly of this acetylated tetradecapeptide.
The cleavage of peptide from the resin was carried out in anhydrous HF for 90 min at 0° C. In this reaction, ethanedithiol was added for the Trp formyl-group removal and cresol and dimethylsulfide to minimize side reactions during this acid treatment. The proportion of these components was: HF:o-cresol:dimethylsulfide:ethanedithiol (8.5:0.5:0.5:0.5). After the cleavage the resin is rinsed with ethyl acetate for removal of by-products and the desired peptide was extracted from the resin with 5% acetic acid and lyophilized. A white powder material was obtained with a final yield of 83%.
Comparative Alkaline Treatment for the Reversion of Nitroxide Protonation After HF Cleavage
The insertion of the Toac molecule in a peptide sequence needs an additional alkaline treatment for reversion of the nitroxide protonation that occurs during HF cleavage. As there is no systematic study showing the most effective and quickest method of this reversion known up to now, we decided to test comparatively different basic conditions for this reversion. We observed that the more efficient reversion protocol was aqueous ammonium hydroxide solution at pH 10 for 2 hours at 50° C. The monitoring of the reversion rate was based on the analytical HPLC retention time of both Toac protonated and unprotonated forms. Due to its higher polarity the protonated form eluted faster than the parent component.
Purification of the Peptide
The crude peptide subjected to the alkaline reversion was purified in preparative HPLC with a C18 column (25 for 300 mm) in an acetonitrile/water gradient containing 1% of TFA. The main fraction isolated in this chromatogram yielded after lyophilyzation, 37 mg of a white powder, whose purity is represented in the analytical HPLC shown in FIG. 1 . The results shown in FIG. 1 were derived using an ODS (octadecyl silane) (4.6×150 mm) column and elution with linear gradient 5% to 95% B in 30 min, a flow rate of 1.5 mL/min and detection at 220 nm. Solvent A was 0.1% TFA in H 2 O; and solvent B was 0.1% TFA in 60% acetonitrile/H 2 O.
The purity of this material was also proven by mass spectroscopy with a MALDI-type apparatus (matrix assisted desorption ionization) from Micromass. FIG. 2 shows the expected 1862 molecular weight peak of the EPM-2 against the 1664 molecular weight peak of native α-MSH. The correct composition of this sample was also checked by amino acid analysis in a Beckman model 6300 analyzer. The following relative proportions of amino acids were found: (the theoretical values are in parentheses): 1.95 Ser (2), 1.03 Met (1); 1.01 Glu (1); 0.96 His (1); 0.98 Phe (1); 0.97 Arg (1); 1.04 Trp (1); 0.97 Gly (1); 1.05 Lys (1); 0.95 For (1) and 1.01 Val (1). The acid hydrolysis carried out includes dissolution of the peptide in HCl (6 N) degassed (with N 2 ) solution containing 0.5% phenol and left for 72 h at 110° C. in a Pyrex capped vial. As the Trp residue is decomposed by this acid treatment, the peptide was hydrolyzed by the p-toluenosulfonic acid method. The peptide was subjected to this treatment for 72 h and further diluted with a pH 2.2 buffer before being injected in the amino acid analyzer column.
Besides all these analytic characterizations applied for the spin labeled peptide, RPE spectroscopy was also used to confirm the paramagnetic signal of the sample. FIG. 3 displays the ESR spectrum of the labeled hormone after purification and diluted in ammonium acetate solution (0.05 M, pH 5.0), as compared to the free Toac in the same conditions.
Biological Activity Assay
The biological activity assay of the EPM-2 was carried out comparatively to the native α-MSH. The classical method of measuring by reflectance the alteration in the frog skin pigmentation was assayed, see, Gen. Comp. Endocrinol. 55, 104 (1984). The potency of the synthesized hormone was determined through a dose-effect curve and long lasting activities were measured until a maximum of 3 h after the peptide removal from the incubation system carried out with successive washes.
Briefly, the skin of the thigh and the dorsal portion of a frog were removed and cut in pieces of 2×2 cm which were placed among two rings of PVC and maintained for 1 h in Ringer's solution. After this period, the melanin granules aggregate in the melanocytes, and the skin becomes clearer. When α-MSH or its spin labeled analogue is added to the medium, there is a dispersion of the pigments in the cell, resulting in skin darkening. The change in the coloration is therefore monitored (decrease in the skin reflectance) in a photovolt reflectometer. The result is expressed as percentage in relation to the initial value.
The labeled analogue is clearly a full α-MSH agonist with equivalent potency as can be seen in FIG. 4 .
In addition, after the removal of the agonist and followed by several Ringer's solution washings, the reversal of the maximum response for the labeled analogue was obtained after 90 min, with the same speed of the native hormone (FIG. 5 ).
By containing the spin probe Toac in its structure and for fully maintaining the biological potency of the native α-MSH, the novel chemical product herein described and denoted EPM-2 may be of practical application in the following situations:
As a Comparative Model Compound for Investigation of Active α-MSH Conformation
The knowledge of the correct α-MSH action mechanism in vertebrates can be better investigated by using the EPM-2 derivative. This is due to the fact that by containing a paramagnetic group in its structure, its conformational features may be evaluated with the ESR spectroscopic method. Initially, variations of pH, temperature, ionic strength and the amount of organic solvents in the medium can be performed in solution and analyzed with reference to the ESR spectra of this paramagnetic peptide hormone.
The influence of the organic solvents trifluoroethanol (TFE) and hexafluoroisopropanol (HFPI), known to induce secondary structures such as the α-helix, might be also investigated. Complementarily to the ESR method, this conformational approach can be also carried out with other spectroscopies such as circular dichroism, nuclear magnetic resonance and fluorescence. In these last two methods, for possessing the property of suppressing resonance or absorption/emission effects respectively, the paramagnetic peptide of this invention may be employed in a great variety of comparative spectroscopic studies.
The above detailed conformational studies can be extended to internal regions of macrostructures such as lipid bilayers and artificial membranes. This approach mimics the native hormone conformation when inserted in a common biological membrane. By taking into account an other property of the ESR method, the molecular association of paramagnetic compounds can be studied based on the spin-spin interaction phenomenon that occurs between spin probes but strongly dependent on the average distance among these molecules, e.g. Spin Labeling—Theory and Applications, (Berliner, L.J., New York, 1989). Thus, in addition to the sensitivity to detect the molecular interactions inside these macrostructures, it is also possible to further estimate inter-molecular distances, regardless of the system.
EPM-2 is also useful as a molecular probe for detection, quantification and characterization studies of the α-MSH receptor. The utility of Toac will be dependent on the fluorescence quenching effect induced by the nitroxide function. The use of radioactive or fluorescent agonists has been the most common strategy to localize, quantify and characterize membrane receptors. One may therefore detect and quantify receptor-containing cells and how they are positioned throughout cell membranes. The more appropriate methods so far used for localization, quantification and characterization of membrane receptors use fluorescent agonists, as this strategy is less dangerous and the agonist which will bind to the receptor presents higher chemical stability than the parent radioactive analogue.
Thus, by taking into account the fluorescence quenching property, Toac-labeled α-MSH will, in brief, be useful for:
α-MSH Receptor Visualization, Localization and Characterization
As fluorescent α-MSH analogue has been already synthesized for receptor binding studies, the use of the EPM-2 fluorescent quenching property may be of value, for instance, for checking receptor localization and quantification. As there are modern methods to visualize receptors in cell cultures, frozen cell slices and cell fragments in vitro or in vivo, one may predict a relevant EPM-2 utility for help elucidate the action mechanism of this hormone when bound to the receptor.
Quantification of Cell Lines Containing α-MSH Receptors
This important information at the receptor level may be obtained by modern biochemical methods such as flow cytometry, in which one can identify and characterize common cells lineages as containing or not containing the α-MSH receptor.
Investigation of Receptor-Fluorescent Hormone Binding
The mechanism and the kinetics of interaction investigation of the fluorescent α-MSH derivative with its receptors can be improved with the use of EPM-2. This peptide will be also valuable for monitoring bindings of other analogues or chemical products that possess the common property in binding to α-MSH receptor.
As a Proteolytic Enzyme Substrate or Inhibitor
In the case where an evaluation the peptide hormone towards enzyme degradation is desired, the presence of Toac radical will be of value as it will supply details of molecular mobility related to enzymatic peptide degradation, either in solution or internally to several types of macrostructures (natural membranes, lipid bilayers, polymer beads, cells, etc).
As a Chemical Product with Therapeutic Potentiality
Due to the participation of α-MSH in different physiological processes, this fully active paramagnetic analogue may be useful as a drug, alone or conjugated with others having therapeutic properties. The fact that its both extremities are blocked and also contains internally a non-natural Toac probe may impart to this peptide higher stability against degradation inside the organism, thus increasing its potential as a drug for some specific cases.
1
1
13
PRT
Artificial Sequence
Description of Artificial Sequence Synthetic
peptide
1
Ser Tyr Ser Met Glu His Phe Arg Trp Gly Lys Pro Val
1 5 10 | The present invention relates to an α-melanocyte stimulating hormone (α-MSH) analogue, labeled with an amino acid-type paramagnetic spin probe, for example, Toac, or 2,2,6,6-tetramethylpiperidine-1-oxyl-4-amino-4-carboxylic acid, and methods for the synthesis thereof. The preferred analogue of the invention, acetyl-Toac 0 -α-MSH (abbreviated as EPM-2) is the first such analogue that maintains entirely the natural α-MSH activity. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to thermal cracking of a gas oil. It particularly relates to a mild thermal cracking of gas oil to minimize the production of naphtha and increase the amount of middle distillate components.
2. Description of the Prior Art
Mild thermal cracking processes are well known in the art. Heavy hydrocarbonaceous oils are subjected to mild thermal cracking processes to convert at least a portion of the high boiling components to lower boiling components. The naphtha component which is obtained from thermal cracking processes is usually of poor quality, that is, it has a high content of olefins and sulfur which makes it undesirable for many end uses. Improvements in thermal cracking have been proposed to minimize the amount of naphtha product, that is, to increase the amount of middle distillate components relative to the amount of naphtha component obtained from the process. For example, Netherland patent application No. 282,794 discloses a mild thermal cracking process (visbreaking) of heavy hydrocarbon oils containing residual fractions in which the process is conducted in the presence of added naphtha, such as a recycle naphtha stream from the visbreaking process, to decrease the net naphtha yield and to increase the middle distillate component. The term "net yield" relative to naphtha refers to the total naphtha yield less the quantity of added naphtha.
It is also known to recycle countercurrently the overhead products including and up to light gas oil to a visbreaking stage of heavy hydrocarbon oils, such as reduced crude. The recycled overhead products provide the endothermic heat of conversion of the heavy oil and the heat of vaporization of the distillate material (see, for example, British Pat. No. 722,369).
A vapor phase type cracking of heavy oil, which may be a gas oil, is known in which an aromatic product is recycled. The final product includes an increased amount of butadiene and ethylene (see U.S. Pat. No. 2,378,067).
A one or two-step process is known for the thermal treatment of heavy hydrocarbons boiling mostly above 1000° F. The process includes a recycle step wherein a portion of low boiling material, which may have a boiling range below 650° F., and all of the heavy material including unconverted feed, is recycled to the thermal cracking step (see U.S. Pat. No. 3,707,459).
A catalytic cracking process is known in which a gas oil is cracked in the presence of the catalyst and added naphtha to obtain an increased yield of middle distillate (see U.S. Pat. No. 3,954,600).
It has now been found that thermal cracking of a feedstock consisting essentially of gas oil in the absence of a catalyst and in the presence of added naphtha only will minimize the net yield of naphtha in the thermally cracked product.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided, a process for the thermal cracking of a hydrocarbonaceous oil feed which comprises: (a) treating a hydrocarbonaceous oil feed consisting essentially of gas oil in a thermal cracking zone at thermal cracking conditions in the absence of a catalyst and in the presence of an added olefin-containing naphtha and (b) recovering a thermally cracked product.
In one embodiment of the invention, the gas oil thermal cracking stage is the second thermal cracking stage of an integrated process in which a heavier hydrocarbonaceous oil is first thermally cracked and the gas oil product resulting from the first thermal cracking stage is used as at least a portion of the feed of the second thermal cracking stage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flow plan of one embodiment of the invention.
FIG. 2 is a schematic flow plan of another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the invention will be described with reference to the accompanying drawings.
Referring to FIG. 1, a hydrocarbonaceous oil feed consisting essentially of gas oil is introduced into a thermal cracking zone 1. By the term "gas oil" is intended herein a mixture of hydrocarbons boiling, at atmospheric pressure, in the range of about 430° to 1100° F. It may be preferred to utilize a gas oil boiling in the range of 600° to 1050° F. A stream of olefin-containing naphtha is introduced via line 12 into line 10 which carries the gas oil feed into the thermal cracking zone. Typically, the thermal cracking zone will comprise coils disposed in a furnace. Alternatively, the olefin-containing naphtha could be introduced separately into the thermal cracking zone. Suitable olefin-containing naphthas are mixtures of hydrocarbons boiling at atmospheric pressure in the range of about C5 to 430° F., which contain at least about 10 volume percent olefins boiling within the naphtha range. Preferably, the olefin-containing naphtha is a fraction that contains less than 30 volume percent aromatics, more preferably less than 20 volume percent aromatics.
Suitable olefin-containing naphthas include, for example, naphtha produced by mild thermal cracking processes; naphtha produced by a catalytic cracking process (cracked naphtha); naphtha produced by a coking process (coker naphtha); naphtha produced by a steam cracking process (steamed cracked naphtha). Preferably, a recycled stream of naphtha produced from the mild thermal cracking process is utilized. If desired, the aromatics may be extracted by conventional means from the olefin-containing naphtha stream prior to adding the naphtha to the thermal cracking process since the presence of aromatics is not essential to the process and that aromatics may find more valuable uses in other processes.
The volumetric ratio of naphtha to gas oil in the mixture introduced into the thermal cracking zone may range broadly from about 0.01:1 to 0.5:1, preferably from about 0.05:1 to 0.25:1.
The gas oil and added olefin-containing naphtha are subjected to thermal cracking conditions in thermal cracking zone 1. Suitable thermal cracking conditions include a temperature ranging from about 700° to 1100° F., preferably a temperature ranging from about 800° to about 950° F. and a pressure ranging from about 50 to about 1500 psig, preferably a pressure ranging from about 200 to 1200 psig. The thermal cracking zone may be a coil disposed in a heated furnace.
Under the above conditions, the gas oil is partially converted to lower boiling hydrocarbon products. The thermally cracked products are removed from the thermal cracking zone 1 by line 14 and passed to a separation zone 2. Separation of the thermally cracked products is carried out in a conventional manner such as by fractional distillation. An olefin-containing naphtha fraction is recovered via line 16 and gas is recovered by line 17. Middle distillates are recovered by line 18. A heavy fraction is removed by line 19.
In the preferred embodiments shown in FIG. 1, at least a portion of the olefin-containing naphtha produced from the thermal cracking stage is recycled via line 12 for introduction into thermal cracking zone 1 as the added olefin-containing naphtha.
Referring to FIG. 2, which shows a two-stage thermal cracking process, a heavy hydrocarbonaceous oil comprising residual components, such as a heavy crude petroleum oil is passed by line 20 into a first thermal cracking stage 22. Suitable conditions for the first thermal cracking stage include a temperature ranging from about 700° to about 1100° F., preferably from about 750° to about 950° F., and a pressure ranging from about 50 to about 1500 psig, preferably from about 200 to about 1200 psig. When the desired degree of conversion has been obtained, the thermally cracked product resulting from the first thermal cracking zone is passed by line 24 to a separation zone 26, which may be an atmospheric pipestill, wherein the cracked products are separated into a C4 - gas recovered by line 28, a C5 to 350° F. naphtha fraction removed by line 30, a 350° to 700° F. fraction removed by line 32 and a 700° F.+ fraction removed by line 34. The 700° F.+ fraction is passed to separation zone 36 such as a vacuum pipestill. The vacuum residuum boiling above 1050° F. is removed via line 38. The gas oil fraction boiling in the range of 700° to 1050° F. (at atmospheric pressure) is removed via line 40 and passed to a second thermal cracking zone, that is, to zone 44 by line 40. A portion of the olefin-containing naphtha, internally generated by the process, is introduced into line 40 by line 42. The thermal cracking zone 44 into which only gas oil and added olefin-containing naphtha are subjected to thermal cracking may be operated at relatively more severe thermal cracking conditions than the actual thermal cracking conditions used in a first thermal cracking zone (22). Suitable thermal cracking conditions for zone 44 include a temperature ranging from about 700° to about 1100° F., preferably from about 800° to about 950° F. and a pressure ranging from about 50 to about 1500 psig, preferably from about 200 to about 1200 psig. The thermally cracked effluent of zone 44 is removed via line 46 and passed to a separation zone 48 such as an atmospheric pipestill. A gas stream is removed via line 50. An olefin-containing naphtha stream is removed via line 52 and passed to a mixing zone 54 wherein it is mixed with a naphtha of line 30 for use as recycle to the thermal cracking zones. If desired, a portion of the olefin-containing naphtha produced in the process may also be recycled to the first thermal cracking zone 22 via line 56. A 350° to 700° F. fraction is recovered from zone 48 via line 58 and a 700° to 1050° F. fraction is recovered via line 60. The cut points of the various fractions given in the description of the FIG. 2 embodiment are merely exemplary and given for simplicity of description. The given cut points are not critical for the operation of the process and may be varied as would be evident to one skilled in the art. All boiling points referred to herein are atmospheric pressure boiling points unless otherwise specified.
The following example is presented to illustrate the invention.
EXAMPLE
Thermal cracking experiments were conducted with and without the addition of naphtha. The conversion level was held constant at about 29 weight percent conversion to 700 minus products based on feed. The gas oil utilized as feed in these experiments was a 700° to 1050° F. gas oil. In the run in which naphtha was used, the naphtha employed comprised 36.2 volume percent olefins and 9.5 volume percent aromatics. The operating conditions and results of these experiments are summarized in the following table.
TABLE______________________________________Run 1 2______________________________________Gas Oil, wt. % on mixture 100 84.7Naphtha, wt. % on mixture -- 15.3Operating ConditionsTemperature, °F. 848 852Pressure, psig 895 928Space velocity of gas oil, 4.69 1.48V/Hr/V at 60° F.Product Yields on Mixture, wt. %C.sub.4.sup.- 2.5 3.9C.sub.5 -350° F. 6.5 13.5350-700° F. 20.0 21.9700° F..sup.+ 71.0 60.7Net Yield on Gas Oil Only, wt. %.sup.(1)C.sub.4.sup.- 2.5 4.6C.sub.5 -350° F. 6.5 -2.2350-700° F. 20.0 25.9700° F..sup.+ 71.0 71.7Conversion of Gas Oil to 700° F..sup.-, wt. % 29.0 28.3______________________________________ .sup.(1) Calculated by substracting the amount of naphtha added from tota naphtha product and then normalizing the yields to 100 percent.
As can be seen from the table, run 2, which is a run in accordance with the present invention, gave essentially no net naphtha yield, whereas run 1, which is a run in which no naphtha was added to the gas oil feed, gave a significant amount of net naphtha product. | A mild thermal cracking of gas oil in the presence of added olefinic naphtha increases the yield of middle distillate. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/494,325, filed Aug. 11, 2003, which is hereby incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of communications systems, and, more particularly, to client-server communications and related methods.
BACKGROUND OF THE INVENTION
[0003] One way in which applications communicate with one another is to use a client-server relationship. In such a relationship, one application functions as a client and provides an interface to the user. The other application is the server application, which resides on an application server and is responsible for the majority of computation and/or data processing.
[0004] This client-server relationship can be extended to World Wide Web applications where the client application (typically a Web browser) and the server component (a Web or application server on the Internet) will interact. One approach for Web-based client-server applications to communicate with one another is to use hypertext transfer protocol (HTTP) as a request-response protocol. Traditionally, HTTP is used on the World Wide Web for browser clients to access and download content from Internet Web sites to users' computing environments (e.g., home, corporate network, etc.).
[0005] Many computing environments provide rich or sophisticated functionality to their users when the user is acting within the confines of his protected computing environment. For example, a corporate user may have access to proprietary corporate databases while using his desktop computer in his office. However, when a user is outside this environment (e.g., the user is on the road), he may still require access to such functionality.
[0006] Most computing environments allow connections originating within the environment to outside locations, but connections originating outside the environment are restricted from accessing the environment. This is typically accomplished through the use of a firewall, for example. Furthermore, some computing environments further restrict outbound network connections to access only HTTP services. This makes it difficult, if not impossible, for a roaming user to access important functionality or services from his protected computing environment.
[0007] The problem is perhaps most prevalent for home-based users. For example, it is difficult for users to connect from their personal computer at their home to their corporate servers at work. A dial-up or high-speed Web-based connection often requires client software on the home machine and/or a secure token for authentication. Furthermore, most corporations may not support corporate access using personal computers.
[0008] Various prior art approaches have been developed for allowing users to access information from outside a protected computing environment. By way of example, Symmetry Pro from Infowave Software, Inc., is a software service that provides corporate users with wireless access to their corporate e-mail using a wireless handheld device. In particular, e-mail messages that arrive in a user's corporate inbox are encrypted and then delivered via the Symmetry Pro software service to the user's wireless handheld device.
[0009] Two other prior art approaches include Fire Extinguisher and Gnu HTTPTunnel. Both of these products attempt to encapsulate TCP traffic over an HTTP connection, acting as a generic bi-directional proxy. Yet, one significant drawback of such approaches is that they may not provide a desired level of authentication to protect secure communications in certain applications.
SUMMARY OF THE INVENTION
[0010] In view of the foregoing background, it is therefore an object of the present invention to provide a communications system which provides enhanced client-server communication features and related methods.
[0011] This and other objects, features, and advantages in accordance with the present invention are provided by a communications system which may include an application server and at least one communications device for processing requests from one another. The at least one communications device may process requests using a hypertext transfer protocol (HTTP) client application, for example. Furthermore, the system may also include an HTTP server for interfacing the HTTP client application with the application server. The HTTP server and the HTTP client application may format requests to be communicated therebetween via the Internet in an HTTP format, and each may provide additional state information with the HTTP formatted requests recognizable by the other for authenticating the application server and the HTTP client application to one another. Furthermore, the HTTP client application may request a first universal resource locator (URL) from the HTTP server for accepting work requests from the application server, and request a second URL different from the first URL from the HTTP server for responding to work requests from the application server.
[0012] Accordingly, the communications system advantageously allows data or applications within a protected computing environment (e.g., a corporate network) to be securely accessed by users when outside of the environment. That is, the at least one communications device may be located within the protected environment (e.g., a user's desktop computer). Since the HTTP client application and HTTP server communicate using HTTP requests, the HTTP client application and HTTP server may advantageously communicate through a network port reserved for Internet traffic (i.e., HTTP formatted requests and responses). Thus, a user may access the communications device and various applications or information (e.g., e-mail, calendars, contacts, etc.) which may otherwise be blocked by a network firewall. Moreover, use of the first and second URLs allows the HTTP server to more readily distinguish and manage requests coming from or going to the HTTP client application.
[0013] More particularly, the additional state information may be a global unique identifier (GUID) associated with the HTTP client application. Additionally, the HTTP client application and the HTTP server further provide sequencing information with the HTTP formatted requests. The sequencing information advantageously allows a given response to be matched with a respective request. Furthermore, the HTTP client application and the HTTP server may format the additional state information as HTTP headers for respective HTTP formatted requests.
[0014] A method aspect of the invention is for interfacing an application server and at least one communications device using an HTTP server. The application server and the at least one client communications device may be for processing requests from one another, and the at least one communications device may process requests using an HTTP client application. The method may include formatting requests to be communicated between the HTTP server and the HTTP client application via the Internet in an HTTP format, and providing additional state information with the HTTP formatted requests communicated between the HTTP server and the HTTP client application for authenticating the application server and the HTTP client application to one another. The respective additional state information of the HTTP server and the HTTP client application may be recognizable by the other. Moreover, at the HTTP client application, a first universal resource locator (URL) may be requested from the HTTP server for accepting work requests from the application server, and a second URL different from the first URL may be requested from the HTTP server for responding to work requests from the application server.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic block diagram of a communications system in accordance with the present invention.
[0016] FIG. 2 is a flow diagram illustrating a client-server communications method in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0018] Generally speaking, the present invention allows an HTTP client to act in a server capacity while still following accepted HTTP client behavior. The invention thus advantageously allows a client application in a user's protected computing environment (e.g., a corporate network) to establish a secure connection with an Internet service and then respond to requests from an authenticated user (e.g., the user's home computer or wireless communications device).
[0019] Referring initially to FIG. 1 , a Web-based client-server communications system 100 is first described. The system 100 illustratively includes an HTTP client or client application 104 , located in a protected computing environment 106 . By way of example, the protected computing environment may be a corporate network 107 having a plurality of communications devices 108 a - 108 n (e.g., personal computers (PCs)) connected thereto, and a firewall 112 for limiting external access to the network, as will be appreciated by those skilled in the art. It should be noted that while the firewall 112 and network 107 are shown as separate elements for clarity of illustration, the various firewall and network routing functions performed thereby may be implemented in one or more network servers or other devices, as will be appreciated by those skilled in the art.
[0020] The HTTP client application 104 communicates bi-directionally with an HTTP server 102 , which in the present example is outside the protected computing environment 106 , via the Internet 109 , for example. The HTTP server 102 illustratively communicates with an application server 101 to retrieve or process any application-related data. In one exemplary embodiment, the HTTP server 102 may belong to a service provider that interfaces users with their respective communications devices 108 a - 108 n within the protected computing environment 106 . Accordingly, the application server 101 may be for performing e-mail delivery or aggregation services using the HTTP server 102 to provide an interface to a user's communications device 108 within the protected computing environment 106 , as will be described further below. Of course, other types of data may be accessed as well, as will be appreciated by those skilled in the art. A user could then access the e-mail (or other) data collected by the application server 101 via a home computer, wireless communications device (e.g., a personal data assistant (PDA)), etc., as will also be appreciated by those skilled in the art.
[0021] In accordance with the invention, the HTTP server 102 and the HTTP client application 104 preferably follow accepted HTTP server-client behaviors and/or relationships. This allows the two to communicate using a dedicated network port reserved for Internet (i.e., HTTP) traffic (typically port 80 ), without being blocked by the firewall 112 . Yet, the HTTP server 102 and the HTTP client application 104 are also both able to insert additional state information into requests and responses, and recognize state information inserted by the other.
[0022] In the illustrated embodiment, the client application 104 is an “intelligent” application that is running on a computer in the user's protected computing environment 106 . The HTTP client application 104 establishes an outbound network connection to the designated HTTP server 102 , and requests a specific uniform resource locator (URL) therefrom. In addition, the HTTP client application 104 provides additional HTTP headers, such as data specifying a globally unique identifier (GUID) to the HTTP server 102 , for example. This establishes a semi-permanent connection that is available for the HTTP server 102 to use for accessing the HTTP client application 104 without being blocked by the firewall 112 .
[0023] More specifically, the application(s) running on the application server 101 is now able to access the HTTP client 104 from outside the protected computing environment 106 by making a request to the HTTP server 102 . When an the application server 100 makes an indirect request of the HTTP client application 104 via the HTTP server 102 , the HTTP server 102 in turn formats that request into a valid HTTP request. This request is then encapsulated into an HTTP response to the HTTP client application 104 . The response includes a header section, which includes both data required by the HTTP specification as well as additional state and sequencing information injected by the HTTP server 102 , and a body section, which includes a full HTTP request.
[0024] When the HTTP client application 104 receives the response, it is then able to access the response body, which includes an HTTP request, which further includes both a header and body section. The HTTP client application 104 is then able to act on the request and gather the appropriate results based thereon. The results of the requests are then communicated back through the HTTP server 102 to the application server 101 by contacting the HTTP server and making a request of another URL different than the first URL noted above. This HTTP request encapsulates an HTTP response, where the request headers include required data as well as enough state information to allow the HTTP server 102 to associate the encapsulated response with a previous request. The request body includes a full HTTP response.
[0025] In accordance with one particularly advantageous aspect of the invention, the communications device 108 a may function as a shared interface allowing the application server 101 to also access user accounts associated with the communications devices 108 b - 108 n . That is, since the communications devices 108 a - 108 n are connected in a network configuration (such as a local area network (LAN) or wide area network (WAN), for example), these devices may potentially access user account information stored on the network 107 (e.g., on a network server), and/or on one another, as well as other network data, as will be appreciated by those skilled in the art. By way of example, the user accounts may be e-mail accounts, but numerous other types of information such as address/contact data, calendar data, etc., may also be accessed in this manner. As such, even though the HTTP client application 104 is only installed on the communications device 108 a , it may advantageously provide a “gateway” for the application server 101 to access user accounts associated with other communications devices 108 b - 108 n , as will be appreciated by those skilled in the art. Of course, it will also be appreciated that a separate HTTP client application 104 could be installed on one or more of the other communications devices 108 b - 108 n , if desired.
[0026] Turning additionally to FIG. 2 , a flow diagram illustrating the decision path to connect the HTTP client application 104 to the HTTP server 102 is now described. Before the illustrated process flow begins (Block 200 ), the HTTP client application 104 is installed on the communications device 108 a in the protected computing environment 106 . It should be noted that in some embodiments the HTTP client application 104 may instead be installed on a network server, for example, and provided the shared or common access functionality for multiple communications devices as described above. The software could advantageously be downloaded from the service provider hosting the HTTP server 102 and application server 101 , for example. For purposes of the present example, it will be assumed that the HTTP client application 104 is installed on a user's desktop PC in the protected computing environment 106 (i.e., on his desktop PC at work).
[0027] Upon installation, the HTTP client application 104 is assigned a GUID, which is saved in a knowledge base (not shown) accessible by the HTTP server 102 and/or application server 101 . The HTTP client application 104 supplies this GUID in all communications with the HTTP server 102 . The decision flow begins with the user running a session of the HTTP client application 104 on the computing device 108 a in the protected computing environment 106 , at Block 201 . For example, the user may run the HTTP client application 104 upon leaving the office for the evening or for an extended period. The HTTP client application 104 opens a connection to the HTTP server 102 , at Block 202 , and identifies itself uniquely by supplying the GUID, at Block 206 . The HTTP client application 104 then requests a first dedicated URL to indicate that it is ready to accept work requests coming from the HTTP server 102 .
[0028] The HTTP server 102 then performs authentication to ensure a successful connection, at Block 208 . If the authentication succeeds, the HTTP server 102 then waits for a response, at Block 212 . If the authentication fails, a failure message is provided (Block 210 ), and the HTTP server 102 loops back to the original starting point (Block 200 ). The HTTP server 102 does not proceed until a successful authentication is registered.
[0029] As noted above, once a successful authentication is accepted, the HTTP server 102 waits for a response, at Block 212 , and then determines whether there is a timeout, at Block 214 . If there is a timeout, the HTTP server 102 then determines whether the HTTP reply is received, at Block 218 . If there is no timeout, the connection is closed (Block 216 ), and the system loops back to the step illustrated at Block 202 .
[0030] If the HTTP reply is not received, the process also loops back to the step illustrated at Block 202 . If a reply is received, the HTTP server 102 unpacks the embedded HTTP request, at Block 220 , and processes the request, at Block 222 . The application server 100 ensures that the request is coming from a valid client application by retrieving the appropriate GUID from the knowledge base. The application server 101 then makes a request to HTTP server 102 , including the GUID. The HTTP server 102 turns the application request into a valid HTTP request, and forwards that request to the HTTP client application which has the identical GUID.
[0031] The HTTP client application 104 then performs the requested work, gathers the results, and creates an HTTP response, at Block 224 . The HTTP client application 104 contacts the HTTP server 102 , requests a second URL different from the first to indicate that it wishes to send back results rather than seeking work, and encapsulates the results as a valid HTTP response within the body of an HTTP request.
[0032] The HTTP client application 104 then determines whether an HTTP connection is open, at Block 226 . If it is open, the HTTP client application 104 sends a request for the second URL, at Block 232 . However, if the HTTP connection is not opened, the HTTP client application 104 opens another HTTP connection (Block 228 ), authenticates the information (Block 230 ), and then requests the revised URL (Block 232 ).
[0033] After the HTTP client application 104 requests the revised URL, the HTTP client application sends the HTTP response as part of the HTTP request body, at Block 234 . The HTTP client application 104 then determines whether the HTTP connection is still open, at Block 236 . If it is opened, the HTTP client application 104 loops back to the step illustrated at Block 204 to request the URL. If the connection is not open, the HTTP client application 104 loops back to the step illustrated at Block 202 to open the HTTP connection, and the process repeats itself.
[0034] Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. | A communications system may include an application server and at least one communications device for processing requests from one another. The communications device may process requests using an HTTP client application, for example. Furthermore, the system may also include an HTTP server for interfacing the HTTP client application with the application server. The HTTP server and the HTTP client application may format requests to be communicated therebetween via the Internet in an HTTP format, and each may provide additional state information with the HTTP formatted requests recognizable by the other for authenticating the application server and the HTTP client application to one another. Furthermore, the HTTP client application may request a first universal resource locator (URL) from the HTTP server for accepting work requests from the application server, and a second URL different from the first URL for responding to work requests from the application server. | 7 |
This application is a continuation of application Ser. No. 08/698,608 filed Aug. 16, 1996 now U.S. Pat. No. 5,823,266 issued Oct. 20, 1998.
TECHNICAL FIELD
This invention relates to new assemblies and methods for connecting and releasing tubing sections and other tool sections for downhole use in oil and gas fields. More particularly, this invention relates to new assemblies and methods for connecting and releasing tubing sections and other tool sections that do not require rotating the tool to latch and release the connector.
BACKGROUND OF THE INVENTION
For the purposes of this description, the term "tool section" refers to any tubular member or section intended for downhole use, including, for example, standard pipe joint sections, well packers, and other downhole tools for use in oil and gas wells.
In the past, conventional threaded pin-and-bell connectors have been used to connect tool sections for various downhole applications. For example, after a tool section is positioned and set in a slip assembly at the rig floor of a well (usually with a threaded pin connector at the upper end thereof), a second tool section is picked up and brought into position over the first tool section. As the second tool section (usually with a threaded bell connector at the lower end thereof) is swinging in the blocks of the rig, it must be carefully axially aligned with the first tool section so that it can be set on the pin connector of the first tool section. The second tool section is then rotated to make up the threaded connection.
There are several problems of using threaded pin-and-bell connections. For example, the process of carefully aligning and threading one elongated tool section to the next is time consuming. Skilled oil-field hands need about one to two minutes to make up or break apart typical tool sections using threaded pin-and-bell connectors, which are often about thirty feet long. The step of aligning the second tool section can be particularly difficult in windy conditions, which cause the thirty-foot section to swing in the blocks. If the second tool section is not properly aligned, the threads of the pin-and bell connectors are likely to gall and bind.
As an alternative to conventional threaded pin-and-bell connectors, some tool connectors are activated or released by certain types of rotational movements other than threading. However, it is becoming increasingly common to use tool sections with coil tubing. Coil tubing may be hundreds or thousands of feet long, such that it is extremely difficult or completely impractical to attempt to rotate the coil tubing to operate a latch or release connection. Thus, it would be desirable to provide a latch and release connector for use with tool sections that does not have to be rotated.
In some applications, tool sections and connector assemblies must be able to pass through reduced diameter tubing or other downhole restrictions to reach the location in the casing where the perforation is to be performed. In these applications, the axial cross-section profile of the tool string is particularly important. For example, in the perforation of a five-inch casing, passing through a small bore may be necessary for the tool assemblies, such as two-and-one-half inch or one-and-eleven-sixteenth inch tubing or other passageway. These through-tubing tool assemblies can be characterized as low-profile assemblies because of the restricted passageways through which they must pass to reach the desired downhole perforation location. These low-profile tool assemblies do not have the luxury of design spacing which is present in tool assemblies whose maximum outside dimensions approximate that of the casing that is to be perforated. These small profile or through-tubing tool assemblies present particular problems that are not present in their larger profiled cousins.
Additional problems are encountered in using downhole tool sections through a blowout preventer. The typical drilling well is provided with a blowout preventer ("BOP") at the well head, which is intended to maintain any pressure within the well head and prevent a blowout of the well. A blowout preventer is also used for safety to recomplete an existing well. A blowout can be an extremely hazardous situation if the oil or gas explodes or catches fire. Furthermore, even if the oil or gas does not ignite, allowing such uncontrolled escape is extremely wasteful of a valuable resource and harmful to the environment. In some countries such as the United States, an uncontrolled escape can subject the producer to substantial government fines for the environmental pollution and the costs of environmental clean up. Blowout preventers are well known in the art, and represented, for example, by U.S. Pat. No. 4,416,441 entitled "Blowout Preventer" issued to Denzal W. Van Winkle on Nov. 22, 1983 and by U.S. Pat. No. 4,943,031 entitled "Blowout Preventer" issued to Denzal W. Van Winkle on Jul. 24, 1990, both of which patents are incorporated herein by reference in their entirety.
According to the art, two or more blowout preventers are typically used in a stack at the well head. For example, the rams of a lower blowout preventer are employed as slip rams, which have serrated metal teeth for gripping and holding a section of downhole tubing or other tool. The slip rams are useful as a type of slip assembly for holding a section of downhole tubing or tool section, which can have many additional sections connected to and suspended from the lower end thereof. The rams of a second blowout preventer above the first are employed as sealing rams, having rubber seals adapted to be compressed against the downhole tubing or other tool to form a pressure-tight seal around the tubing or tool.
Having additional blowout preventers in the stack is common. For example, the rams of a third blowout preventer above the sealing BOP can be equipped with shearing blades for cutting a piece of tubing for which the threads have seized onto the next tubing and cannot be normally unthreaded. The rams of a fourth blowout preventer above the rest can be employed as a blind seal, such that the well head can be completely sealed. Thus, a production well usually has at least two blowout preventers at the well head used for controlling the well.
Unfortunately, the use of conventional threaded pin-and-bell connectors through a lubricator above a blowout preventer stack is particularly time consuming. For example, it typically requires about five minutes for skilled oil-field hands to make up tool sections together through a lubricator above a blowout preventer stack. There has been a particular long-felt need for an apparatus and method that would permit much faster connection and release of tool sections through a lubricator and blowout preventer stack. The cost of oil field hands and recovered production time involved in stringing several tool sections together has driven the search for faster apparatuses and methods. Nevertheless, to the knowledge of the inventors there is still a great need for additional improvements and methods.
Of all the downhole tool sections employed in a well, perforating gun sections present some of the most serious difficulties and challenges. Conventional perforating gun sections used in perforating well casings typically include charge carriers designed to support several separate perforating charges within the desired longitudinal spacing and sometimes a desired radial orientation. Examples of various convention perforating gun sections are illustrated in U.S. Pat. No. 5,095,999 issued to Daniel C. Markel on Mar. 17, 1992, the specification of which is incorporated herein in its entirety. In particular, the Markel patent illustrates a conventional enclosed perforating gun section having a plurality of perforating charges mounted on a carrier strip and enclosed and protected within a carrier tube. (See U.S. Pat. No. 5,095,999, Column 5, lines 20-39 and FIG. 5.)
As is well known in the industry, perforating gun sections use perforating shaped explosive charges designed to shape and direct the explosion with great precision along the focal axis. Typically, a perforating shaped charge will shape and direct a liner material to create a uniform circular jet that is highly focused and directed along the focal axis. The focused jet penetrates the casing that lines the well bore and the surrounding geological formation. The detonation of the perforating charges is intended to increase production of the well, which is hoped will result in a substantial increase in production pressure at the well head.
Usually, maximizing the perforations achievable in a single-shot downhole procedure is desirable. For example, it is sometimes desirable to perforate hundreds, even thousands, of linear feet of downhole casing to enhance well production. However, the length of the typical perforating gun section is about thirty feet. Of course, it is possible to achieve increased perforation of the downhole well casing by repeating the procedure of lowering a perforating gun section to perforate the downhole well casing and retrieving the spent perforating gun section until the desired longitudinal portion of the downhole well casing has been perforated. However, the time and expense involved in repeating each such downhole procedure mitigate in favor of perforating the desired portion of the well bore in a single downhole procedure. Thus, if it is desirable to perforate such lengths of the downhole casing, as is frequently desirable, two or more perforating gun sections must be connected together. The assembled string of perforating gun sections is then lowered downhole to perforate the well in a single shot.
Furthermore, connecting perforating gun sections with such conventional threaded pin-and-bell connectors presents special problems and risks. For example, manually rotating the second perforating gun section with a hand wrench is more time consuming than the with the use of power tongs. With a hand wrench, however, the oil-field hands can feel the process of threading the connector and be more sensitive to whether the threads are properly aligned to prevent galling. But while the use of power tongs to rotate a perforating gun section to make up the threaded connection is faster, if it works, the threads of the connection are much more likely to gall because of the speed of rotation and the oil-field hands' inability to feel the threading and make any necessary adjustments in the alignment of the threads.
A galled threaded connector for perforating gun sections presents particular problems and dangers because of the explosives used in the sections. For example, if the threads gall and bind in a threaded pin-and-bell connector between two perforating gun sections, the transmission of the detonating signal between the two sections may not be reliable. Thus, it is usually desirable or necessary to separate the galled connection, and replace the connector and possibly both the perforating gun sections. However, unthreading the galled threads of the connector is sometimes difficult or impossible. Furthermore, cutting or shearing galled perforating gun sections, which contain high explosives, is counter indicated for obvious safety concerns. Thus, a galled threaded connection between perforating gun sections presents a serious problem. In the past, one of the only solutions to the problem of a seriously galled threaded connection has been to raise the two galled perforating gun sections and unthread the lower connection from the remainder of the perforating gun string, to then safely remove and handle the two improperly joined sections. However, this is wasteful of expensive perforating gun section equipment and extremely time consuming.
For these reasons, it can take several minutes to align, set, and manually makeup each threaded connection between the perforating gun sections, and a galled connection can seriously impede the process of perforating a well. Thus, there has been a long-felt need for a better, more reliable, and faster connector for perforating gun sections.
Furthermore, working with perforating gun sections through a stack of blowout preventers presents several additional problems and challenges. This is true even though the pressure at the well head is initially substantially balanced such that the well head can be opened for the insertion of a tool section. For example, after using the perforating gun section to perforate the downhole well bore, it hopefully increases the well production and the production pressure at the well head. Thus, a problem is then presented of how to withdraw the spent perforating gun section through the blowout preventer. The problem is particularly problematic because a spent perforating gun section has itself been thoroughly perforated by the detonation of the perforating shaped charges. For example, the sealing rams of the sealing blowout preventer may have difficulty fully sealing against the warped, twisted, and punctured metal of the perforating gun section. Furthermore, the open holes created in the spent perforating gun section provide multiple conduits for the pressurized fluid in the well beneath the blowout preventers to enter the spent perforating gun section. Thus, the spent perforating gun section provides an undesired conduit through the blowout preventer stack, leaking or spewing the pressurized production.
A prior art method of addressing this problem of how to remove a spent perforating gun section has been to balance the pressure in the well. Balancing the pressure is normally accomplished by pumping the appropriate density of drilling mud into the well head to equalize the pressure below and above the well head. However, this balancing procedure is sometimes called "killing" the well because it inhibits the production and can create other pressure management and technical difficulties. There has been a long-felt need for an apparatus and method for withdrawing the spent perforating gun section through the stack of blowout preventers at the well head without having to even temporarily kill the enhanced well production.
Furthermore, enhancing the well production of a well that has some positive well pressure at the well head is often desirable. In such a case, perforating the downhole casing is still desirable. Of course, working through a blowout preventer stack with an intact perforating gun section before it has been detonated can be accomplished by employing a lubricator above the blowout preventer stack. The perforating gun sections can be made up with the lubricator according to techniques well known to those of skill in the art. However, the use of a lubricator above the blowout preventer further limits the length of the perforating gun sections that can be used to the practical length of the lubricator. A typical lubricator for such applications can accommodate perforating gun sections of up to about 35 feet (11 meters).
Thus, there has been a long-felt need for assemblies and methods capable of more quickly stringing two tools together for firing in a single downhole procedure, thereby reducing the time and expense involved in perforating a well There has been a long-felt need for apparatuses and methods of withdrawing and more quickly separating spent tool sections from a well. In addition, there has been a particular need for apparatuses and methods for connecting and separating tool sections through a blowout preventer stack while maintaining the pressure below the blowout preventer stack.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, assemblies and methods are provided for connecting tool sections for downhole use. According to this first aspect of the invention, a tool connector includes a stinger and a stinger receptacle. The stinger is adapted to be stabbed into the stinger receptacle. A loaded engaging member movable between a running position before the stinger is stabbed into the stinger receptacle and a latched position when the stinger is stabbed into the stinger receptacle to latch the stinger and the stinger receptacle together. A release member retains the loaded engaging member in the running position. When the stinger is stabbed into the stinger receptacle and a set force is applied to the stinger and stinger receptacle, the release member releases the loaded engaging member to move to the latched position and latch the stinger and the stinger receptacle together. Neither the stinger nor the stinger receptacle have to be rotated to make up the connection between the perforating gun sections.
According to a second aspect of the invention, the tool connector is releasable. The tool connector further includes a releasable stop member to stop the engaging member in the latched position. When the stop member is released, the engaging member moves to a released position such that the stinger and stinger receptacle are separable. Thus, the tool sections can also be released without rotating.
According to a third aspect of the invention, a tool connector having particular application to perforating gun sections is provided. According to this aspect, the tool connector is provided with an internal explosive transfer system for transferring the detonation signal from one perforating gun, through the perforating gun connector, and to the next perforating gun. The internal explosive transfer system protects the booster charges to provide additional safety.
These and other aspects, features, and advantages of the present invention will be apparent to those skilled in the art upon reading the following detailed description of preferred embodiments according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are incorporated into and form a part of the specification to provide illustrative examples of the present invention. These drawings with the description serve to explain the principles of the invention. The drawings are only for purposes of illustrating preferred and alternate embodiments of how the invention can be made and used. The drawings are not to be construed as limiting the invention to only the illustrated and described examples. Various; advantages and features of the present invention will be apparent from a consideration of the accompanying drawings in which:
FIG. 1 is an axial cross-section view of the stinger subassembly for a latch and release tool connector according to the presently most preferred embodiment of the invention;
FIG. 2 is an detail cross-section view of part of the internal explosive transfer system of the stinger subassembly according to FIG. 1;
FIG. 3 is a detail cross-section view of an alternative embodiment of the probe portion of the stinger subassembly shown in FIG. 1, wherein the tip is disposable;
FIG. 4 is an axial cross-section view of the latch and release subassembly for a latch and release tool connector according to the presently most preferred embodiment of the invention;
FIG. 5 is a horizontal cross-section view through the line 5--5 of FIG. 4 showing the spring-loaded stop/release pads in more detail;
FIG. 6 is a horizontal cross-section view through the line 6--6 of FIG. 4 showing the collet fingers in more detail;
FIG. 7 is an axial cross-section view showing the latch and release subassembly according to FIG. 4 in a running position for engaging the stinger subassembly according to FIG. 1;
FIG. 8 is an axial cross-section view showing the latch and release subassembly according to FIG. 4 in a latched position on the stinger subassembly according to FIG. 1; and
FIG. 9 is an axial cross-section view showing the latch and release subassembly according to FIG. 4 in a released position on the stinger subassembly according to FIG. 1.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will be described by referring to drawings of examples of how the invention can be made and used. Like reference characters are used throughout the several figures of the drawing to indicate like or corresponding parts.
The presently most preferred embodiment of the invention is a latch and release connector for use with perforating gun sections, which is one of the most challenging applications for the invention. It is to be understood, however, that the present invention can be employed to connect other types of downhole tools and simple tubing sections.
The structures of the stinger subassembly 10 shown in FIG. 1 will first be described in detail, and then the structures of the latch subassembly 100 shown in FIG. 2. Thereafter, how the structures cooperate and are used to latch perforating gun sections with an ordinary slip assembly and a clamp or through a blowout preventer stack will be described in detail. Regarding the use with a blowout preventer stack, the stack is assumed to have lower seal/slip rams and upper operating rams.
STINGER SUBASSEMBLY
Referring now to FIG. 1, a stinger subassembly 10 according to the presently most preferred embodiment of the invention is shown in an axial cross-section view. In general, the stinger subassembly 10 has a probe portion 12, a slip landing portion 14, a bell connector portion 16, and a stinger internal explosive transfer system 18. According to the presently most preferred embodiment of the invention, the stinger subassembly is generally symmetrical about a stinger central axis A 1 .
In FIG. 1, the stinger subassembly 10 is shown with its central axis A 1 in a vertical orientation and such that the probe portion 12 is oriented upward. This illustrated orientation is how the stinger subassembly 10 would normally be oriented for use at the well head of a well. References to "upward," "downward," "above," "below," and other relative terms are understood to be with reference to the orientation of the stinger subassembly 10 shown in FIG. 1 of the drawing.
The stinger subassembly 10 is adapted to mate with the latch subassembly 100 shown in FIG. 2 of the drawing and as hereinafter described in detail.
Probe Portion of Stinger Subassembly
Referring to FIG. 1, the probe portion 12 of the stinger subassembly 10 preferably has tip 20, a probe first ramp surface 22, a shank surface 24, a probe second ramp surface 26, a probe recess 28, a probe first shoulder surface 30, a probe landing surface 32, a probe second shoulder surface 34, and a centralizer surface 36. Of the stinger overall axial length L 1 of the stinger subassembly 10, the probe portion 12 has an axial probe length L 2 .
According to the presently most preferred embodiment of the invention, the tip 20 presents a flat, circular surface that has a tip diameter D 1 . From the tip 20, the probe first ramped surface 22 is frusto-conical and expands in diameter downward along the axis A 1 from the tip 20 to the shank surface 24. This probe first ramp surface 22 faces upward and helps deflect and guide the probe portion 12 of the stinger subassembly 10 into the latch subassembly 100 as hereinafter described in detail. The shank surface 24 provides a structure for mating with the latch subassembly 100 and has a shank diameter D 2 .
Below the shank surface 24 is the probe second ramp surface 26, the probe recess 28, and probe first shoulder surface 30. According to the presently most preferred embodiment of the stinger subassembly 10 illustrated in FIG. 1, the probe second ramp surface 26 is preferably frusto-conical and reduces in diameter downward along the axis A 1 from the shank surface 24. Thus, this probe second ramp surface 26 faces downward and helps deflect collet fingers of the latch subassembly 100 out of the recess 28 when the collet fingers are moved upward relative to the stinger subassembly 10 as will hereinafter be described in detail. According to the presently most preferred embodiment of the invention, the probe recess 28 is preferably a circumferential recess. Thus, the collet fingers can engage the probe recess 28 regardless of the relative rotational positions of the stinger subassembly 10 and the latch subassembly 100 as hereinafter described in detail. The circumferential probe recess 28 has a recess diameter D 3 . The probe first shoulder surface 30 faces upwards and defines the lower end of the recess 28.
Below the probe first shoulder surface 30 is the probe landing surface 32 and the probe second shoulder surface 34. According to the presently most preferred embodiment of the stinger subassembly 10 illustrated in FIG. 1, the probe landing surface 32 is cylindrical and adapted to fit within the lower portion of the housing of the latch subassembly 100 as hereinafter described in detail. The cylindrical probe landing surface 32 has a landing diameter D 4 . The probe second shoulder surface 34 faces upward and serves as a mechanical stop to the further insertion of the probe portion 12 of the stinger subassembly 10 into the housing of the latch subassembly 100 as hereinafter described in detail.
Below the probe second shoulder surface 34 is the centralizer surface 36. According to the presently most preferred embodiment of the stinger subassembly 10 illustrated in FIG. 1, the centralizer surface 36 is cylindrical having a centralizer diameter D 5 and is adapted to help centralize the stinger subassembly 10 within the tubulars of a well bore.
Slip Landing Portion of Stinger Subassembly
Continuing to refer to FIG. 1 of the drawing, the slip landing portion 14 of the stinger subassembly 10 is below the centralizer surface 36 of the probe portion 12. The slip landing portion 14 has a slip landing first shoulder surface 38, a slip landing surface 40, and a slip landing second shoulder surface 42. The slip landing portion 14 is preferably integrally formed with the probe portion 12 of the stinger subassembly. Of the overall length L 1 of the stinger subassembly, the slip landing portion 14 of the stinger subassembly 10 has an axial landing length L 3 .
The slip landing first shoulder surface 38 faces downwards and defines the upper end of the slip landing surface 40. The slip landing surface 40 is cylindrical having a slip landing diameter D 6 and is structurally adapted to be engaged and held by a slip assembly at the rig floor or the seal/slip rams of a blowout preventer as hereinafter described in detail. The slip second shoulder surface 42 faces upwards and defines the lower end of the slip landing surface 40. The recessed slip landing surface 40 helps indicate a positive engagement of the seal/slip rams of a blowout preventer. However, it is to be understood that the slip landing surface 40 need not be recessed compared with the largest overall diameter of the stinger subassembly 10.
Bell Connector Portion of Stinger Subassembly
Continuing to refer to FIG. 1, the bell connector portion 113 of the stinger subassembly 10 is below the slip second shoulder surface 42 defining the lower end of the slip landing portion 14. The structure of the bell connector portion 16 can be of a standard form to adapt with correspondingly standard pin connectors on perforating gun sections. The bell connector portion 16 is preferably integrally formed with the slip landing portion 14 of the stinger subassembly. Of the overall length L 1 of the stinger subassembly, the bell connector portion 16 of the stinger subassembly 10 has an axial bell length L 4 .
According to the presently most preferred embodiment of the invention, the bell connector portion 16 is a generally tubular body symmetrical about stinger central axis A 1 and defining a cylindrical connector surface 44 having a bell diameter D 7 . The interior of the bell connector portion 16 has a bell sealing area 46, a female threaded bore section 48, and an end seat section 50 formed therein. The interior of the bell connector portion 16 is adapted for receiving and engaging a correspondingly threaded and structured male pin connector. For example, the bell sealing area 46 is adapted to provide a surface for compressing one or more O-ring seals on a correspondingly structured pin connector. The cooperation of the bell sealing area 46 with the corresponding structure and O-ring seals of a corresponding pin connector forms a pressure-tight seal. Thus, the bell connector portion 16 is structurally adapted to be made-up with the correspondingly structured and threaded male pin connector of a perforating gun connector (not shown). The bell diameter D 7 is normally also adapted to help centralize the stinger subassembly 10 within the tubulars of a well bore.
Stinger Internal Explosive Transfer System of Stinger Subassembly
Continuing to refer to FIG. 1 of the drawing, the stinger internal explosive transfer system 18 is preferably located centrally within the stinger subassembly 10. According to the presently most preferred embodiment of the invention, the stinger internal explosive transfer system 18 includes a stinger internal chamber 52 that extends from a first end 54 adjacent the tip 20 of the probe portion 12 through the probe portion, through the slip/seal ram landing portion 14, and into the bell connector portion 16 to a second end 56 adjacent the end seat section 50 of the bell connector portion. The first end 54 of the stinger internal chamber 52 is sealed by the web material 58 defining the tip 20 of the probe portion 12. Positioned within the stinger internal tubular chamber 52 adjacent the first end 54 is a stinger booster charge 60. The booster charge is adapted to ignite a stinger detonating cord 62 positioned throughout substantially the entire length of the chamber 52. A stinger initiator section 64 is located at the second end 56 of the stinger internal chamber 52.
Referring now to FIG. 2 of the drawing, the stinger initiator section 64 of the stinger internal explosive transfer system 18 is shown in more detail. The section 64 is shown adjacent the threads 48 of the bell connector portion 16 of the stinger subassembly. According to the presently most preferred embodiment of the invention, the stinger initiator section 64 includes a firing pin housing 66 with initiator retainer 68 that are threaded into the second end 56 of the stinger internal chamber 52 and sealed with initiator O-ring seals 70 and 72. The end of the detonating cord 62 is provided with an end seal 74 adjacent the firing pin housing 66. A firing pin 76 is mounted within the firing pin housing 66 with shear pins 78. The firing pin 76 is adapted to be fired by the detonating cord 62 toward the stinger initiator 80. According to the invention, the initiator 80 is deformed, but not breached by the firing pin 76, thus, a seal between the interior of the bell connector portion 16 is maintained.
As will hereinafter be described in detail, the stinger internal explosive transfer system 18 is adapted to continue and transfer the detonation of the perforating charges from one perforating gun section, through the stinger subassembly 10, and to the next perforating gun section made-up with the bell connector portion 16 of the stinger subassembly 10. To help with the transfer of the detonation from the stinger subassembly 10 through the bell connector portion 16 to the next perforating gun section made up with the bell connector portion, the interior of the bell connector portion 16 is sealed against well fluids as previously described.
Alternative End Portion and Disposable End Cap for Stinger Subassembly
Referring to FIG. 3 of the drawing, according to an alternative embodiment of the present invention, an alternative structure is provided for a probe portion 12a of a stinger subassembly. The probe portion 12a includes an upper end portion 82, which is adapted to receive a disposable end cap 84.
The upper end portion 82 of the probe portion 12 of the stinger subassembly 10 has the first end 54 of the stinger internal chamber 52 formed therein. The stinger receiving initiator charge 60 is positioned within the first end 54 of the stinger internal chamber 52. The upper end portion 82 has male threads 86 formed thereon. Beneath the male threads 86 is formed an O-ring groove 88 adapted to receive and trap a sealing O-ring 90.
The disposable end cap 82 has outer surfaces 20a, 22a, and 24a that substantially conform to the surfaces 20, 22, and 24 previously described for the probe portion 12. The disposable end cap 82 also has an end web portion 58a that corresponds to the web portion 58 previously described for the probe portion 12. The body of the end cap 82 has a generally bell-shaped interior with a female threaded portion 92. The female threaded portion 92 of the end cap 82 is adapted to be threaded onto correspondingly male threaded portion 86 formed on the body of the probe portion 12a. Below the female threaded portion 92 is an end cap sealing surface 94, which is adapted to seal against the O-ring 90 positioned in the O-ring groove 88 when the end cap is threaded onto the probe portion 12a. Thus, the stinger subassembly 10 can be provided with a disposable end cap 82, thereby making the stinger subassembly reusable.
LATCH SUBASSEMBLY
Referring now to FIG. 4 of the drawing, a latch subassembly 100 according to the presently most preferred embodiment of the invention is shown in an axial cross-section view. In general, the latch subassembly 100 has a pin connector portion 102, a body portion 104, spring-loaded stop/release pads 106, a spring-loaded housing 108, collet fingers 110, and a latch internal explosive transfer system 112. According to the presently most preferred embodiment of the invention, the latch subassembly 100 is generally symmetrical about its central axis A 2 except as otherwise noted.
In FIG. 4, the latch subassembly 100 is shown with its central axis A 2 in a vertical orientation and such that the housing portion 106 is downward. This orientation is how the latch subassembly 100 would normally be oriented for use at the well head of a well. Again, references to "upward," "downward," "above," "below," and other relative terms are understood to be with reference to the orientation of the latch subassembly 100 shown in FIG. 4 of the drawing.
Pin Connector Portion of Latch Subassembly
Referring now to FIG. 4 of the drawing, the latch subassembly 100 is described and shown in detail. In particular, the pin connector portion 102 is at the upper end of the latch subassembly 100. The structure of the pin connector portion 102 can be of a standard form to adapt with correspondingly standard bell connectors on perforating gun sections. Of the overall length L 5 of the latch subassembly 100, the pin connector portion 102 of the latch subassembly has an axial pin length L 6 .
For the purposes of this description, it will be assumed that a corresponding bell connector portion of a perforating gun assembly (not shown) to be made up with the latch subassembly will have the same structure as the bell connector portion 16 previously described for the stinger subassembly 10. Thus, the pin connector portion 102 is a generally tubular body symmetrical about latch axis A 2 and defining an end surface 114, a male threaded pin section 116, a pin ramped surface 118, pin sealing surfaces 120, pin O-ring grooves 122, a pin shoulder surface 124, and a connector centralizer surface 126. The pin connector portion 102 is adapted to be made up with a correspondingly structured and threaded bell connector portion of a perforating gun section. When the pin connector portion 102 and a corresponding bell connector portion of a perforating gun section are moved toward each other, the pin connector portion 102 is guided into the open end section of the bell connector portion. The male threaded pin section 116 is made up with the female threaded section of the corresponding bell connector portion. The pin ramped surface 118 helps guide the pin connector portion 102 into the open end section of the corresponding bell connector portion. The pin O-ring grooves 122 formed in the pin sealing surface 120 are adapted to receive O-rings for helping to seal the pin sealing surface 120 with the bell sealing area of a corresponding bell connector portion of a perforating gun section. The pin sealing surface 120 also helps in aligning the latch central axis A 2 of the latch subassembly and its pin connector portion 102 with the corresponding bell connector portion of a perforating gun section. The pin end surface 114 and pin shoulder surface 124 provide mechanical stops against over-tightening the threaded connection between the pin connector portion 102 and a corresponding bell connector portion of a perforating gun section. The connector centralizer surface 126 having a pin diameter D 8 is adapted to help centralize the latch subassembly 100 within the tubulars of a well bore.
According to the presently most preferred embodiment of the invention, the lower end of the bell connector portion 102 further has an inwardly facing shelf 128. As will hereinafter be described in detail, this shelf 128 helps in retaining the spring-loaded stop/release pads on the body portion 104.
Body Portion of Latch Subassembly
Continuing to refer to FIG. 4 of the drawing, the body portion 104 of the latch subassembly 100 is a structural member attached to the pin connector portion 102. The body portion 104 has an upper body portion 130 extending into the pin connector portion 102, a central body portion 132, and a lower body portion 134. The upper body portion 130 is for securely mounting the body portion 104 to the pin connector portion 102. As will hereinafter be described in detail, the spring-loaded stop/release pads 106 are connected to the central body portion 132, and the spring-loaded housing 108 and the collet fingers 110 are mounted to the lower body portion 134.
According to the presently most preferred embodiment of the invention, the upper body portion 130 is a structural member in the general form of a cylindrical mandrel or other solid structural member adapted for connecting to the pin connector portion 102 of the latch subassembly 100. The upper body portion has a male threaded section adapted to be threaded into corresponding female threads formed in the pin connector portion 102.
According to the presently most preferred embodiment of the invention, the central body portion 132 is a structural member having a generally cylindrical structure with an overall central body diameter D 9 . The central body portion 132 is preferably integrally formed with the upper body portion 130. The overall central body diameter D 9 is less than the connector centralizer diameter D 8 of the pin connector portion 102 to allow the spring-loaded stop/release pads 106 to be mounted to the outside of the central body portion 132. Nevertheless, the spring-loaded stop/release pads 106 still present an overall profile for the latch subassembly 100 that is not greater than the connector centralizer diameter D 8 . Thus, the latch subassembly 100 can pass through downhole tubing of a desired size.
A plurality of alignment bores are formed in the central body portion 132, such as the illustrated two alignment bores 136a and 136b. Each of the alignment bores is preferably a cylindrical bore formed in the central body portion 132 and oriented radially about the latch central axis A 2 . As will hereinafter be described in detail, the alignment bores 136a-b are adapted to help maintain the stop/release pads 106 on the central body portion 132. Two additional alignment bores (not shown) are preferably radially oriented 180 degrees from each other and 90 degrees from the alignment bores 136a and 136b, respectively. Thus, a total of four alignment bores are radially spaced apart 90 degrees about the latch central axis A 2 . A plurality of spring bores are formed in the central body portion 132, such as the illustrated two upper spring bores 138a-b and the two lower spring bores 140a-b illustrated in FIG. 4. Each of the spring bores 138a-b and 140a-b is preferably a cylindrical bore formed in the central body portion 132 and oriented radially about the latch central axis A 2 . The upper spring bores 138a-b are each adapted to receive an upper spiral spring 142 therein, and the lower spring bores 14a-b are similarly each adapted to receive a similar spiral spring 144 therein.
The two upper spring bores 138a and 138b are preferably radially opposed 180 degrees about the latch central axis A 2 as shown in FIG. 4. Thus, the upper spiral springs 142 positioned in these two upper spring bores can be loaded to exert opposed radial forces. Two additional upper spring bores (not shown) are preferably radially oriented 180 degrees from each other and 90 degrees from the upper spring bores 138a and 138b, respectively. Thus, a total of four upper spring bores are radially spaced apart 90 degrees about the latch central axis A 2 . As will hereinafter be described in detail, each of the four upper spiral springs 142 (only two shown in FIG. 4) mounted in the upper spring bores can be loaded to exert a force opposed to another upper spiral spring 142 mounted in a radially opposed upper spring bore.
Similarly, the two lower spring bores 140a and 140b are preferably radially opposed 180 degrees about the latch central axis A 2 as shown in FIG. 4. Two additional lower spring bores (not shown) are preferably radially oriented 180 degrees from each other and 90 degrees from the lower spring bores 140a and 140b, respectively. Thus, a total of four lower spring bores are radially spaced apart 90 degrees about the latch central axis A 2 . As will hereinafter be described in detail, each of the four lower spiral springs 144 (only two shown in the FIG. 4) mounted in the lower spring bores are loaded to exert a force opposed to another lower spiral spring 144 mounted in a radially opposed lower spring bore.
According to the presently most preferred embodiment of the invention, the lower body portion 134 is a structural member having a generally cylindrical structure with a lower body diameter D 10 . The lower body portion 134 is secured to the central body portion 132.
The lower body portion 134 has a collar portion 146, which is preferably integrally formed thereon. The collar portion 146 defines an upwardly facing collar shoulder surface 148. As will hereinafter be described in detail, the collar shoulder surface 148 helps in mounting the spring-loaded housing 108 to the lower body portion 134. Furthermore, the collar portion 146 provides added structural material for helping in connecting the spring-loaded housing 108 thereto.
The bottom end of the lower body portion 134 defines a generally bell-shaped opening 150. As will hereinafter be described in detail, the bell-shaped opening 150 is adapted to receive the probe tip 20 and the probe first ramped surface 22 of the probe portion 12 of the stinger subassembly 10.
Further according to the presently most preferred embodiment of the invention, the bottom end of the lower body portion 134 adjacent the bell-shaped opening 150 has the collet fingers 110 connected thereto.
The lower body diameter D 10 is preferably substantially the same as the overall central body diameter D 9 for central body portion 132. The lower body diameter D 10 of the lower body portion 134 is less than the connector centralizer diameter D 8 of the pin connector portion 102 to allow the spring-loaded housing 108 to be mounted to the outside of the lower body portion 134. Nevertheless, the spring-loaded housing still presents an overall profile for the latch subassembly 100 that is not greater than the connector centralizer diameter D 8 . Thus, the latch subassembly 100 can pass through downhole tubing of a desired size. Similarly, the diameter of the collar portion 146, although greater than the lower body diameter D 10 , is still less than the connector centralizer diameter D 8 of the pin connector portion 102. This smaller diameter allows the spring-loaded housing 108 to be mounted to the outside of the lower body portion 134 yet still present an overall profile for the latch subassembly 100 that is not greater than the connector centralizer D 8 . Thus, the latch subassembly 100 can pass through downhole tubing of a desired size.
Spring-Loaded Stop/Release Pads of Latch Subassembly
Referring now to FIGS. 4 and 5 of the drawing, the spring-loaded stop/release pads 106 are mounted to the central body portion 132. Of the overall length L 5 of the latch subassembly 100, the spring-loaded stop/release pads 106 have an axial pads length L 7 .
According to the presently most preferred embodiment of the invention, the structure of the spring-loaded stop/release pads 106 is based on a tubular structure divided into four identical portions, as represented in the drawing by the two pads 152a and 152b shown in FIG. 4. All four of the pads 152a-d are shown in FIG. 5. Together, the four pads of the spring-loaded stop/release pads 106 present an overall pads diameter D 11 . The overall pads diameter D 11 of the spring-loaded stop/release pads 106 is not greater than the connector centralizer diameter D 8 of the pin connector portion 102. Thus, the latch subassembly 100 can pass through downhole tubing of a desired size. As best shown in FIG. 5, the four pads 152a-d are positioned on the central body portion 132 over the radially oriented springs, such as upper springs 142. Thus, the springs 142 exert radially outward forces on the pads 152a-d.
The upper end of each of the pads, as shown in FIG. 4 for the two pads 152a and 152b, also includes a peg 154a and 154b, respectively, adapted to fit within any of the four alignment bores, such as illustrated in FIG. 4 for the alignment bores 136a and 136b. Thus, the pegs help in retaining the vertical position of the pads on the central body portion 132.
Further according to the presently most preferred embodiment of the invention, the upper end of each of the pads, as shown in FIG. 4 for the two pads 152a and 152b, extend into the shelf 128 of the pin connector portion 102. This helps in retaining the pads against the springs 142 and 144. As shown in FIG. 4, in the lower end of each of the pads, as shown for the pads 152a and 152b, is formed a shallow recess 156a and 156b, respectively. The shallow recesses are identically positioned on each of the pads such that when the four pads are positioned about the central body portion 132, the recesses define an at least partially circumferential recess. Thus, the recesses are adapted to position a tubular collar 158 over the lower end of the pads 152a-d. The cooperation of the shallow recesses with the tubular collar 158 retains the four pads, represented by pads 152a and 152b, against the upper springs 142 and lower springs 144. Thereby, the four pads are spring-loaded to the central body portion 132.
To assemble the spring-loaded stop/release pads onto the central body portion 132, the body portion 104 is separated from the bell connector portion 102. The plurality of upper springs 142 are positioned in the upper spring bores 138a-d of the central body portion 132 as shown in FIGS. 4 and 5, and the plurality of lower springs 144 are positioned in the lower spring bores of central body portion, as shown in FIG. 4 for lower spring bores 140a-b. The pads 152a-d are then positioned over the central body portion 132, such that the peg 154 of each pad is positioned in one of the alignment bores, as shown in FIG. 4 for alignment bores 136a-b. The tubular collar 158 is positioned over the pads as shown in FIG. 4 to restrain them against the upper springs 142 and lower springs 144. The upper body portion 130 of the body portion 104 is then secured to the bell connector portion 102 such that the upper ends of the pads are restrained against the upper springs 142 and lower springs 144 as shown in FIG. 4.
Spring-Loaded Housing of Latch Subassembly
Continuing to refer to FIG. 4 of the drawing, the spring-loaded housing 108 is mounted on the lower body portion 134. The overall housing diameter D 12 of the spring-loaded housing 108 is not greater than the pin centralizer diameter D 8 , whereby the latch subassembly 100 can pass through downhole tubing of a desired size. When the spring-loaded housing 108 is set and ready for use as illustrated in FIG. 4 of the drawing, the housing 108 is spaced apart from the lower end of the spring-loaded stop/release pads 106 by an axial spacing length L 8 . As will hereinafter be described in detail, however, the spring-loaded housing 108 is adapted to be axially moved upward on the lower body portion 134, first to close the axial spacing length L 8 , and then to overlap with the lower end of the spring-loaded stop/release pads 106. Of the overall length L 5 of the latch subassembly 100 when it is in the set position shown of FIG. 4, the spring-loaded housing 108 has an axial length L 9 .
According to the presently most preferred embodiment of the invention, the spring-loaded housing 108 includes a substantially tubular housing member 160 adapted to slide over the lower body portion 134. As will hereinafter be described in more detail, the tubular housing member 160 is preferably formed in two sections, an upper housing portion 160a and a lower housing portion 160b. The tubular housing member 160 has an inner diameter that is larger than the lower body diameter D 10 of the lower body portion 134, but adapted to slide over the collar portion 146 of the lower body portion 134. Thus, there is a first annular space 162 defined between the lower body diameter D 10 of the lower body portion 134 and the inner diameter of the tubular housing member 160 of the spring-loaded housing 108. The upper end of the first annular space 162 is open. The tubular member 160 has an inwardly facing flange 164 that can slide with the tubular member 160 along the lower body portion 134 and defines the lower end of the first annular space 162. As will hereinafter be described in detail, the first annular space 162 is adapted to move over the lower ends of the four pads 152a-d when the pads are radially compressed against the springs 142 and 144 such that the pads 152a-d present a smaller diameter profile.
The flange 164 defines the upper end of a second annular space 166. The lower end of the second annular space 166 is defined by the upwardly facing collar shoulder surface 148 on the collar portion 146 of the lower body portion 134. The housing spring 168, which is trapped at its lower end by the upwardly facing collar shoulder surface 148 of the collar portion 146, exerts an upward force against the flange 164 of the tubular housing member 160. This upward force exerted by the spring 168 is parallel to the latch central axis A 2 .
One or more retaining pins, such as screws 170 are tapped or threaded through the tubular housing member 160 and into the collar portion 146 of the lower body portion 134. Thus, the retaining screws 170 retain the tubular housing member over the lower body portion 134 against the force of the housing spring 168 positioned within the second annular space 166.
The lower end of the tubular housing member 160 has an inwardly facing deflecting structure 172, which is for engaging the collet fingers 110 with the stinger subassembly 10 as will hereinafter be described in detail. According to the presently most preferred embodiment of the invention, the deflecting structure 172 has a deflecting first ramped surface 174, an engaging surface 176, and a deflecting second ramped surface 178. The deflecting first ramped surface 174 is frusto-conical and reduces in diameter downward along the axis A 2 of the latch subassembly 100. The engaging surface 176 defines an inner cylindrical wall below the deflecting first ramped surface 174. The deflecting second ramped surface 178 is frusto-conical and expands in diameter downward along the axis A 2 of the latch subassembly 100.
As previously mentioned, according to the presently most preferred embodiment of the invention, the tubular housing member 160 is preferably formed into two portions, upper housing portion 160a and lower housing portion 160b. The upper housing portion 160a and the lower housing portion 160b are threaded together and retained with one or more set screws 180. This separable housing structure permits the latch assembly 100 to be more easily assembled. For example, the lower body portion 134 is removed from the central body portion 132, so that the upper housing portion 160a can be placed over the lower body portion 134 from its upper end. Otherwise, if the lower housing portion 160b were integrally formed with the upper housing portion 160a, the deflecting structure 172 would not slide over the diameter of the collar portion 146 on the lower body portion 134.
Finally, according to the presently most preferred embodiment of the invention, a housing snap-ring seal 181 is provided between the lower body portion 134 and the tubular housing member 160 to prevent the housing from moving downward and accidentally releasing while running into and out of the well. The snap-ring 181 expands beyond the inside diameter of the pin threads on housing 160a.
To assemble the spring-loaded housing 108 onto the lower body portion 134, the lower body portion 134 is separated from the central body portion 132. The housing spring 168 is positioned over the lower body portion 132 and slid downward until it is stopped by the upwardly facing collar shoulder surface 148 on the collar portion 146 of the lower body portion 134. The upper housing portion 160a is then positioned over the lower body portion 132 and slid downward such that the inwardly facing flange 164 compresses the spring 168 as shown in FIG. 4. The one or more retaining screws 170 are tapped or threaded through the tubular housing member 160 and into the collar portion 146 of the lower body portion 134. Thus, the retaining screws 170 retain the tubular housing member over the lower body portion 134 against the force of the housing spring 168 positioned within the second annular space 166. The lower housing portion 160b is slid upward from the lowermost end of the lower body portion 134. Then the lower housing portion 160b is threaded to the upper housing portion 160a and retained with one or more set screws 180.
Collet Fingers of Latch Subassembly
Continuing to refer to FIG. 4 of the drawing, the collet fingers 110 of the latch subassembly 100 are attached to the lower body portion 134. At least two collet fingers 110, such as the first and second collet fingers 182a and 182b are employed. However, it is to be understood that additional collet fingers can be used, which may be particularly desirable for a larger latch subassembly for use in larger downhole tubing applications. The arcuate extension of each of the collet fingers 182a and 182b is a matter of design choice, and is expected to range up to nearly 90 degrees of radial arc about the latch axis A 2 . Thus, if desired, four or more collet fingers 110 can be employed in the latch subassembly 100. According to the presently most preferred embodiment, as shown in FIG. 6 of the drawing of the invention, six collet fingers 182a-f are employed. Referring back to FIG. 4 of the drawing, each of the individual collet fingers, as represented by collet fingers 182a and 182b, has a dog portion 184 and a finger tip portion 186.
The upper end of the dog portion 184 of each collet finger 182a-b is an extension of the lower body portion 134. The dog portion 184 is adapted to be sufficiently deformable to be deflected inward or outward relative to the relaxed position shown in FIG. 4 of the drawing. Alternatively, the dog portion 184 of each collet finger 182a-b can be pivotally mounted to the lower body portion 134 adjacent the bottom of the bell-shaped opening 150.
According to the presently most preferred embodiment of the invention, the finger tip portion 186 of each of the collet fingers 182a-b has a plurality of surfaces adapted to be deflected by and engage with other surfaces of the stinger subassembly 10 and the latch subassembly 100. In particular, the finger tip portion of each of the collet fingers 182a-b has a first outwardly facing ramped surface 188, an outwardly facing vertical surface 190, a second outwardly facing ramped surface 192, a first inwardly facing ramped surface 194, an inwardly facing vertical surface 196, and a second inwardly facing ramped surface 198. The cooperation of these surfaces 188-198 with other surfaces and structures will hereinafter be described in more detail.
Latch Internal Explosive Transfer System
Continuing to refer to FIG. 4 of the drawing, the latch internal explosive transfer system 112 is preferably located centrally within the latch subassembly 100. According to the presently most preferred embodiment of the invention, the latch internal explosive transfer system 112 includes a latch internal chamber 200. The chamber 200 extends from a first end 202 adjacent the end surface 114 of the pin connector portion 102 and through the entire body portion 104 to a second end 204 adjacent the bell-shaped opening 150 of the lower body portion 134. Positioned within the latch internal chamber 200 adjacent the first end 202 is a latch receiving booster charge 206. A latch detonating cord 208 is positioned through substantially the entire length of the chamber 200. A latch booster charge 210 and a downward focused shaped charge 212 are positioned in the chamber 200 adjacent the second end 204 of the chamber 200. As will hereinafter be described in detail, the latch internal explosive transfer system 112 is adapted to continue and transfer the detonation of the perforating charges from one perforating gun section made-up with the pin connector portion 102 of the latch subassembly 100, through the latch subassembly 100, and to a stinger subassembly 10 latched to the latch subassembly 100. As previously mentioned, the stinger subassembly 10 in turn continues and transfers the detonation to the next perforating gun section made-up with the bell connector portion 16 of the stinger subassembly 10.
Method of Using Latch and Release Perforating Gun Connector
Referring now to FIG. 7 of the drawing, the stinger subassembly 10 is shown as it is positioned when the slip landing surface 40 of the slip landing portion 14 are held by the seal/slip rams of a blowout preventer (not shown). For the purposes of this description, the stinger subassembly 10 has already been made up with a lower perforating gun section (not shown), which has been inserted through the blowout preventer seal/slip rams. The latch subassembly 100 has been made up with an upper perforating gun section (not shown), which has been moved into a lubricator above the blowout preventer. The upper perforating gun section with the latch subassembly 100 at the lower end thereof is then lowered through the blowout preventer onto the probe portion 12 of the stinger subassembly 10. The latch subassembly 100 is lowered until the deflecting structure 172 of the spring-loaded housing 108 is stopped by the second shoulder surface 34 above the centralizer surface 36 of the stinger subassembly 10, as shown in FIG. 7.
In this running position illustrated in FIG. 7, the tip 20 of the probe portion 12 of the stinger subassembly 10 is slightly spaced apart from the upper end of the bell-shaped opening 150 formed in the lower body portion 134. In this running position, the finger tip portion 186 of each of the individual collet fingers 182a and 182b can at least partially begin to be deflected into the recess 28 of the probe portion 12 on the stinger subassembly 10. As can be seen in FIG. 7, the housing spring 168 is trapped in the second annular space 166 defined by the lower body portion 134, the tubular housing member 160, and the flange 164. As previously described, the potential energy of the housing spring 168 is retained by the retaining screws 170 threaded through the tubular housing portion 160 into the collar portion 146 of the lower body portion 134.
At this point, a downward force is applied to the latch subassembly 100. This force is transmitted axially through the latch subassembly 100 to the lower body portion, through the retaining screws 170, through the spring-loaded housing 108 at the deflecting structure 172 to the second shoulder surface 34 above the centralizer surface 36 of the stinger subassembly 10. A sufficiently strong downward force is applied to the latch subassembly that the retaining screws 170 are sheared between tubular housing member 160 and the lower body portion 134. Once the retaining screws 170 have been sheared, the tubular housing member 160 is released from the lower body portion 134. Thus, the housing spring 168, which is trapped between the surface 148 of the collar portion 146 of the lower body portion 134 and the flange 164 of the tubular housing member 160, is now free to drive the slidably mounted tubular housing body 160 upward on the lower body portion 134.
Referring now to FIG. 8 of the drawing, the latch subassembly 100 is shown in a latched position on the stinger subassembly 10. Each of the retaining screws 170 are shown as having been sheared into two portions. An outer portion 170a of the sheared retaining screw travels with the upwardly moving tubular housing member 160. An inner portion 170b of the sheared retaining screw remains with the collar portion 146 of the lower body portion 134. The upward movement of the tubular housing member 160 on the lower body portion 134 permits the latch subassembly 100 to settle onto the tip 20 of the probe portion 12 of the stinger subassembly 10. Driven by the released housing spring 168, the tubular housing member 160 moves upward on the lower body portion 134 until it is stopped by the pads, such as pads 152a-b, of the spring-loaded stop/release pads 106. At this point, the potential energy of the housing spring 168 is only partially released in driving the tubular housing member 160 upward. The upward movement of the tubular housing member 160 also causes the deflecting structure 172 to force and deflect the collet fingers inward. More particularly, the deflecting first ramped surface 174 of the deflecting structure 172 engages the second outwardly facing ramped surface 192 of the finger tip portion 186 inward. Thus, the finger tip portion 186 of each of the collet fingers 182a and 182b are deflected into the probe recess 28 of the probe portion 12 of the stinger subassembly 10. The various surfaces on the probe portion 12 of the stinger subassembly and the deflecting structure 172 of the tubular housing member cooperate to trap the finger tip portions 186 of the collet fingers 182a-b in the probe recess 28. Thus, the latch subassembly 100 is securely latched onto the probe portion 12 of the stinger subassembly. This process of latching the latch subassembly 100 to the stinger subassembly 10 can be accomplished in a matter of seconds.
The stinger subassembly 10 and the latch subassembly 100 form a completed connection between the lower and upper perforating gun sections (not shown). The perforating gun sections can then be lowered downhole to perforate the well.
It is to be understood, of course, that additional perforating gun sections can be successively added to the string using successive additional pairs of stinger subassemblies 10 and latch subassemblies 100.
Furthermore, according to the presently most preferred embodiment of the invention, a detonating signal can be transmitted from the latch subassembly 100 to the stinger subassembly 10. Referring back to FIG. 4 of the drawing, a detonating signal is transmitted from an upper perforating gun to the latch internal explosive transfer system 112 of the latch subassembly 100. The detonating signal from the upper perforating gun detonates the latch receiving booster charge 206. The booster charge 206 in turn ignites the latch detonating cord 208 positioned within the latch internal chamber 200. The latch detonating cord 208 transfers the detonating signal to the latch booster charge 210, which detonates the latch downward focused shaped charge 212. The shaped charge 212 pierces the web material of the lower body portion 134 below the second end 204 of the chamber 200 and fires through the stinger tip web 58 of the stinger subassembly 10 that is latched to the latch subassembly 100.
Referring again to FIG. 8 of the drawing, which shows the latch subassembly 100 in a latched position on the stinger subassembly 10, the tip 20 of the probe 12 of the stinger subassembly 10 is preferably flush with the inner surface of the bell-shaped opening 150 of the lower body portion 134 of the latch subassembly 100. The latch shaped charge 212 pierces through the thickness of the web material 58 defining the tip 20 of the probe portion 12. The latch downward focused shaped charge 212 is adapted to pierce the tip 20 of the subassembly 10. According to the previously described alternative embodiment of the stinger subassembly with respect to FIG. 3 of the drawing, the latch downward focused shape charge 212 pierces the disposable end cap 84.
Referring back to FIG. 1 of the drawing, which shows the stinger subassembly 10 in detail, piercing the web material 58 defining the tip 20 of the probe portion 12 initiates the stinger internal explosive transfer system 18. More particularly, the latch shaped charge 212 pierces the material to initiate the stinger booster charge 60. The stinger booster charge 60 in turn ignites the stinger detonating cord 62 within the stinger internal chamber 52. The stinger detonating cord 62 transfers the detonating signal to the stinger initiator section 64, best shown in FIG. 2. The firing pin 76 mounted within the firing pin housing 66 is fired by the detonating cord 62 toward the stinger initiator 80. According to the invention, the initiator 80 is deformed, but not breached by the firing pin 76, thus, a seal between the interior of the stinger internal chamber 52 and the bell connector portion 16 is maintained. The deforming material of the initiator drives downward to detonate the initiator. This detonation of the initiator initiates a booster charge in a perforating gun section connected to the bell connector portion 16 of stinger subassembly 10. Thus, the detonating signal is transferred from the stinger subassembly 10 to a booster charge and detonating cord in the lower perforating gun section (not shown). The detonating cord in the lower perforating gun section serially detonates the perforating charges in that perforating gun section.
If a plurality of perforating gun sections are connected using the stinger subassembly 10 and latch subassembly 100, the detonating signal is carried through the successive connections as described herein.
After the perforating gun sections have been detonated downhole to perforate the well, they are raised back toward the well head. The second (upper) perforating gun section is raised through the blowout preventer stack until the slip landing portion 14 of the stinger subassembly 10 aligns with the seal/slip rams of the blowout preventer stack. The seal/slip rams of the blowout preventer stack are engaged to seal and hold the perforating gun section string at the stinger subassembly 10. Since the integrity of the stinger subassembly 10 has been maintained, the latch subassembly 100 can be removed from the stinger subassembly 10 without allowing any fluid to escape through the seal/slip rams of the blowout preventer stack.
According to the presently most preferred embodiment of the invention, a clamp or the operating rams of another blowout preventer above the seal/slip rams in the blowout preventer stack are employed to release the latch subassembly 100 from the stinger subassembly 10. As used herein, the term "operating" rams refers to any of a number of different types of rams that are usually employed above the seal/slip rams, except shearing or other type rams that would undesirably damage the latch subassembly. Referring to FIG. 8, the operating rams engage the spring-loaded stop/release pads 106 and radially compress the pads 152a-b toward the latch central axis A 2 . This compressing force opposes the radially outward force of springs 142 and 144 and deflects the pads 152a-d inward toward the central body portion 132. Thus, the effective diameter of the spring-loaded stop release pads 106 is reduced. Meanwhile, the tubular housing member 160 is still being acted upon by the housing spring 168 trapped within the second annular space 166. Thus, once the spring-loaded stop release pads 106 are sufficiently compressed, the open end of the tubular housing member 160 can slide upward over the pads 152a-d.
Referring now to FIG. 9 of the drawing, the latch subassembly is shown in a released position. The housing spring 168 maintains the tubular housing member 160 over the pads 152a-d, which retains them in the reduced diameter form against the opposing forces of the springs 142 and 144 of the spring-loaded latch pads 106. The further upward movement of the tubular housing member 160 also causes the deflecting structure 172 to move upward. This releases the finger pads 186 of the collet fingers 182a-b, such that the latch subassembly 100 can be lifted off the probe portion 12 of the stinger subassembly 10. More particularly, as the latch subassembly 100 is lifted upward, the probe second ramp surface 26 deflects the second inwardly facing ramped surface 188 of the finger tip portion 186 of each of the collet fingers 182a-b. Thus, the finger tip portion 186 of each of the collet fingers 182a-b is deflected out of the probe recess 28 of the probe portion 12 of the stinger subassembly 10. This process of releasing the latch subassembly 100 from the stinger subassembly 10 can be accomplished within a few seconds. Throughout the process, the integrity of the blowout preventer stack pressure seal at the well head can be maintained.
An Example of Latch and Release Gun Connector for Use Through 5-Inch Tubing
Of course, the particular dimensions of the stinger subassembly 10 and latch subassembly 100 according to this invention are a matter of engineering design choice depending on many parameters. Such parameters, include, for example, the particular size of the well tubing and casing in which the stinger subassembly is to be used. The stinger subassembly 10 and latch subassembly 100 can be designed, for example, for use in 5-inch tubing. However, this illustrative example is for the purposes of more fully describing the presently most preferred embodiment of the invention, but not to limit the invention to the particular dimensions of such a disclosed preferred embodiment.
Accordingly, referring back to FIG. 1 of the drawing, the stinger subassembly 10 can have, for example, the following basic dimensions: an overall axial stinger length L 1 of about 24 inches (61 cm), an axial probe length L 2 of about 10 inches (26 cm); an axial landing length L 3 of about 10 inches (26 cm); an axial bell length L 4 of about 5 inches (13 cm); a tip diameter D 1 of about 1 inches (2.5 cm); a shank diameter D 2 of about 2 inches (5 cm); a recess diameter D 3 of about 1.5 inches (4 cm); a probe landing diameter D 4 of about 2.5 inches (6.5 cm); a centralizer diameter D 5 of about 3.5 inches (9 cm); a slip landing diameter D 6 of about 3 inches (8 cm); and a bell diameter D 7 of about 3.5 inches (9 cm).
Referring again to FIG. 4 of the drawing, the latch subassembly 100 can have, for example, the following basic dimensions: an overall axial latch length L 5 of about 30 inches (76 cm); an axial pin length L 6 of about 8 inches (20 cm); an axial pads length L 7 of about 9 inches (22 cm); an axial spacing length L 8 of about 1.2 inches (3 cm); an axial housing length L 9 of about 12 inches (30 cm); a pin diameter D 8 of about 3.5 inches (9 cm); an overall central body diameter D 9 of about 3.2 inches (8 cm); a lower body diameter D 10 of about 2.2 inches (5.5 cm); an overall pads diameter D 11 of about 3.2 inches (8 cm); and an overall housing diameter D 12 of about 3.5 inches (9 cm).
The embodiments shown and described above are only exemplary. For example, the preferred embodiment for the spring-loaded housing is representative of a structure for storing potential energy for moving the housing. Even though numerous characteristics and advantages of the present inventions have been set forth in the foregoing description, together with the details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in the detail, especially in the matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad and general meaning of the terms used in the attached claims.
The restrictive description and drawings of the specific examples above do not point out what an infringement of this patent would be, but are to provide at least one explanation of how to make and use the inventions. The limit of the inventions and the bounds of the patent protection are measured by and defined in the following claims. | A tool connector is provided for downhole use in oil and gas fields. The tool connector includes a stinger and a stinger receptacle. The stinger is adapted to be stabbed into the stinger receptacle. A loaded engaging member movable between a running position before the stinger is stabbed into the stinger receptacle and a latched position when the stinger is stabbed into the stinger receptacle to latch the stinger and the stinger receptacle together. A release member retains the loaded engaging member in the running position. When the stinger is stabbed into the stinger receptacle and a set force is applied to the stinger and stinger receptacle, the release member releases the loaded engaging member to move to the latched position and latch the stinger and the stinger receptacle together. According to a second aspect of the invention, the tool connector is releasable, further including a releasable stop member to stop the engaging member in the latched position. When the stop member is released, the engaging member moves to a released position such that the stinger and stinger receptacle are separable. According to a third aspect of the invention having particular application to perforating gun sections, a tool connector is provided with an internal explosive transfer system for transferring the detonation signal from one perforating gun, through the perforating gun connector, and to the next perforating gun. In addition, a method of connecting a first tool section to a second tool section is provided. | 4 |
RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 11/080,658, filed Mar. 16, 2005, which claims priority under 35 U.S.C. 119(e) from U.S. Provisional Application Ser. No. 60/553,238, filed Mar. 16, 2004, which applications are each incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to new ionic photoacid generator (PAG) compounds and photoresist composition that include such compounds. In particular, the invention relates to a novel class of ionic PAGs that contain organic onium cations and new sulfonate compounds with no perfluorooctyl sulfonates (no-PFOS) anions. The new PAG anions address the combination of environmental and performance concerns raised by PFOS based PAGs.
[0004] 2. Description of Related Art
[0005] Several acid catalyzed chemically amplified resist compositions have been developed. Chemically amplified resist compositions generally comprise a photosensitive acid (“photoacid”) generator (PAG) and an acid sensitive polymer (resist). Upon exposure to radiation (e.g., x-ray radiation, ultraviolet radiation), the photoacid generator, by producing a proton, creates a photogenerated catalyst (usually a strong acid) during the exposure to radiation. During a post-exposure bake (PEB), the acid may act as a catalyst for further reactions. For example, the acid generated may facilitate the deprotection or cross-linking in the photoresist. The generation of acid from the PAG does not necessarily require heat. However, many known chemically amplified resists require a post-exposure bake (PEB) of one to two minutes in length to complete the reaction between the acid moiety and the acid labile component. The chemical amplification type resist materials include positive working materials that leave the unexposed material with the exposed areas removed and negative working materials that leave the exposed areas with the unexposed areas removed.
[0006] On use of the chemical amplification type, positive working, resist compositions, a resist film is formed by dissolving a resin having acid labile groups as a binder and a compound capable of generating an acid upon exposure to radiation (to be referred to as photoacid generator) in a solvent, applying the resist solution onto a substrate by a variety of methods, and evaporating off the solvent optionally by heating. The resist film is then exposed to radiation, for example, deep UV through a mask of a predetermined pattern. This is optionally followed by post-exposure baking (PEB) for promoting acid-catalyzed reaction. The exposed resist film is developed with an aqueous alkaline developer for removing the exposed area of the resist film, obtaining a positive pattern profile. The substrate is then etched by any desired technique. Finally the remaining resist film is removed by dissolution in a remover solution or ashing, leaving the substrate having the desired pattern profile.
[0007] The chemical amplification type, positive working, resist compositions adapted for KrF excimer lasers generally use a phenolic resin, for example, polyhydroxystyrene in which some or all of the hydrogen atoms of phenolic hydroxyl groups are protected with acid labile protective groups. Onium salts, such as iodonium salts and sulfonium salts having perfluorinated anion, are typically used as the photoacid generator. If necessary, there are added additives, for example, a dissolution inhibiting or promoting compound in the form of a carboxylic acid and/or phenol derivative having a molecular weight of up to 3,000 in which some or all of the hydrogen atoms of carboxylic acid and/or phenolic hydroxyl groups are protected with acid labile groups, a carboxylic acid compound for improving dissolution characteristics, a basic compound for improving contrast, and a surfactant for improving coating characteristics.
[0008] Ionic photoacid generators, preferably onium salts, are advantageously used as the photoacid generator in chemical amplification type resist compositions, especially chemical amplification type, positive working, resist compositions adapted for KrF excimer lasers because they provide a high sensitivity and resolution and are free from storage instability.
[0009] As stated above, photoacid generators (PAGs), play a critical role in a chemical amplified resist systems. Among the various classes of ionic and nonionic PAGs that have been developed, one of the most widely used classes is the perfluorinated onium salts. Recently, government action has made the use of the most effective PAGs based on perfluorooctyl sulfonates (PFOS), no longer viable. In addition to environmental concerns, the PFOS-based PAGs are a concern due to their fluorous self-assembly and their diffusion characteristics at smaller dimension. Previous efforts to develop new PAGs have focused mainly on improvement of the photosensitive onium cation side to increase the quantum yield or to improve the absorbance. The nature of the photoacid produced upon irradiation of the PAG is directly related to the anion of the ionic PAG. Difference in acid strength, boiling point, size, miscibility, and stability of the photoacid produced can affect the parameters related to photoresist performance, such as deprotection (or cross-linking) efficiency, photospeed, post exposure bake (PEB) sensitivity, post-exposure delay (PED) stability, resolution, standing waves, image profiles, and acid volatility. Thus, novel PAG anions that can tackle these environmental and performance issue are needed.
SUMMARY
[0010] The present invention focuses on the anionic part of ionic photoacid generators (PAGs). By considered design of new sulfonate anion molecule, the homogeneous distribution of the PAG in the resist is improved and appropriate mobility of the photogenerated acid is provided while at the same time addressing environmental issues. To address the environmental issues of PFOS PAGs, sulfonic acids are developed that contain far fewer than the 8 fluorinated carbons found in PFOS. A number of perfluoro segments is replaced with different functional groups that maintains the strong polarization of the acid (i.e., pKa), control the size, aid film formation and compatibility with the matrix resin. In contrast to PFOS, these new PAGs with a novel fluoro-organic sulfonate anion contain many functional groups which in turn make them degrade to produce relatively short fluorine containing molecule by chemical or physical attack and are expected to be non-bioaccumalitive and environmentally friendly so that there is less impact on the environment and living organisms.
[0011] The present invention is directed to a new approach to produce environmentally friendly-photoacid generators (PAGs) having anions that comprise either short or no perfluoroalkyl chain (no-PFOS) attached to a variety of functional groups. The photoacid generators of the present invention can be formed from the onium salts, and derivative compounds, shown below:
[0000]
[0000] wherein, R 1 =CH 2 CH 2 CH 2 OH, OCH 2 CH 3 , OC(CH 3 ) 3 , CH 2 CH 2 OCH 3 ,Cl, CH 2 CH 2 Cl, CH═CH 2 , —(CH 2 ) m CH 3 , OCF 2 CF 2 I, —CH 2 CH(Br)CH 3 ,
[0000]
[0012] R 10 =H, Br, CN, OCH 3 , COO − , NO 2 , OCOCH 3
[0013] R 12 =H, Br, CN, OCH 3 , COO − , NO 2 , OCOCH 3
[0014] n=1 to 4 and m=1 to 15;
[0000]
[0015] wherein R 3 =H, F, Cl, CH 3 ;
[0000]
[0016] wherein, R 4 =H, F, Br, OCH 3 , COO − , CN, OCOCH 3 ;
[0000]
[0017] wherein, Z=F or CF 3 ; R 5 =H, F, CF 3 ; and/or
[0000]
[0018] wherein R 6 =H, F, Br, OCH 3 , COO − , CN, OCOCH 3 .
[0019] In each of the onium salt compositions provided above R 0 may be the same or different substituted or unsubstituted, straight, branched or cyclic alkyl group of 1 to 10 carbon atoms or substituted or unsubstituted aryl group of 6 to 14 carbon atoms, M + is any compound or atom capable of providing an onium cation, preferably a sulfur or an iodine atom, and “a” is 2 or 3, preferably “a” is equal to 3 when M is sulfur and equal to 2 when M is iodine.
[0020] The onium salts of the present invention provide a photoacid generator for chemical amplification type resist compositions comprising the onium salts defined above.
[0021] The invention further provides
[0022] a) a chemical amplification type resist composition comprising (A) a resin which changes its solubility in an alkaline developer under the action of an acid, and (B) the aforementioned photoacid generator (PAG) which generates an acid upon exposure to radiation; or
[0023] b) a chemical amplification type resist composition comprising (A) a resin which changes its solubility in an alkaline developer under the action of an acid, (B) the aforementioned photoacid generator (PAG) which generates an acid upon exposure to radiation, and (C) a compound capable of generating an acid upon exposure to radiation, other than component (B). The resist composition may further include (D) a basic compound and/or (E) a carboxyl group-containing compound.
[0024] Additionally, the present invention provides a process for forming a pattern, comprising the steps of applying the aforementioned resist composition onto a substrate to form a coating; heat treating the coating and exposing the coating to high energy or electron beam through a photo-mask; optionally heat treating the exposed coating, and developing the coating with a developer.
DETAILED DESCRIPTION
[0025] The present invention is directed to novel photoacid generators (PAGs) with no perfluorooctyl sulfonates (PFOS). The photoacid generators of the present invention are formed from onium salts, and derivative compounds, shown in Formula (I), (II), (III), (IV), and (V) below:
[0000]
[0000] wherein R 1 =CH 2 CH 2 CH 2 OH, OCH 2 CH 3 , OC(CH 3 ) 3 , CH 2 CH 2 OCH 3 ,Cl, CH 2 CH 2 Cl, CH═CH 2 , —(CH 2 ) m CH 3 , OCF 2 CF 2 I, —CH 2 CH(Br)CH 3 ,
[0000]
[0026] R 10 and R 12 are each independently H, Br, CN, OCH 3 , COO—, NO 2 , or OCOCH 3 ; n=1 to 4; and m=1 to 15;
[0000]
[0027] wherein R 3 =H, F, Cl, CH 3 ;
[0000]
[0028] wherein, R 4 =H, F, Br, OCH 3 , COO − , CN, OCOCH 3 ;
[0000]
[0029] wherein, Z=F or CF 3 ; R 5 =H, F, CF 3 ; and/or
[0000]
[0030] wherein R 6 =H, F, Br, OCH 3 , COO − , CN, OCOCH 3 .
[0000] In each of the onium salt compositions provided above Ro may be the same or different substituted or unsubstituted, straight, branched or cyclic alkyl group of 1 to 10 carbon atoms or substituted or unsubstituted aryl group of 6 to 14 carbon atoms, M + is any compound or atom capable of providing an onium cation, preferably a sulfur or iodine atom, and “a” is 2 or 3, preferably “a” is equal to 3 when M is sulfur and equal to 2 when M is iodine.
[0031] In formulas (I), (II), (III), (IV), and (V), M+provides an organic onium cation, most preferably M is sulfur or iodine. PAGs of the present invention contain preferably sulfonium and iodonium salt. However, other suitable organic onium salts may also be used including for example, halonium, sulfoxonium, selenonium, pyridinium, carbonium and phosphonium and certain oragnometallic complex cations (eg., Ferrocenium cations).
[0032] In formulas (I), (II), (III), (IV), and (V), Ro, which may be the same or different, stands for substituted or unsubstituted, straight, branched or cyclic alkyl groups of 1 to 10 carbon atoms or substituted or unsubstituted aryl groups of 6 to 14 carbon atoms. Illustrative, non-limiting, examples include straight, branched or cyclic alkyl groups such as methyl, ethyl, n-propyl, sec-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, n-pentyl, sec-pentyl, cyclopentyl, n-hexyl, and cyclohexyl; substituted alkyl groups such as 2-oxopropyl, 2-oxocyclopentyl, 2-oxocyclohexyl, 2-hydroxycyclopentyl and 2-hydroxycyclohexyl; and aryl groups such as phenyl, 4-methylphenyl, 4-ethylphenyl, 4-methoxyphenyl, 4-tert-butylphenyl, 4-tert-butoxyphenyl, 4-cyclohexylphenyl, 4-cyclohexyloxyphenyl, 2,4-dimethylphenyl, 2,4,6-trimethylphenyl, 2,4,6-triisopropylphenyl, 3,4-bis(tert-butoxy)phenyl, 4-dimethylaminophenyl, 1-naphthyl and 2-naphthyl.
[0033] The onium salts of formula (I), (II), (III), (IV) or (V) find best use as the photoacid generator in resist materials, especially chemical amplification type resist materials although the application of the onium salts is not limited thereto. The invention provides resist compositions comprising onium salts of formula (I), (II), (III), (IV) or (V) as the photoacid generator (B). The resist compositions may be either positive or negative working. The resist compositions of the invention include a variety of embodiments, optionally including:
[0034] 1) a chemically amplified positive working resist composition comprising (A) a resin which changes its solubility in an alkaline developer under the action of an acid, (B) a photoacid generator comprising an onium salt of formula (I), (II), (III), (IV) or (V) capable of generating an acid upon exposure to radiation, and (G) an organic solvent;
[0035] 2) a chemically amplified positive working resist composition of 1) further comprising (C) a photoacid generator capable of generating an acid upon exposure to radiation other than component (B);
[0036] 3) a chemically amplified positive working resist composition of 1) or 2) further comprising (D) a basic compound;
[0037] 4) a chemically amplified positive working resist composition of 1) to 3) further comprising (E) an organic acid derivative;
[0038] 5) a chemically amplified positive working resist composition of 1) to 4) further comprising (F) a compound with a molecular weight of up to 3,000 which changes its solubility in an alkaline developer under the action of an acid;
[0039] 6) a chemically amplified negative working resist composition comprising (B) a photoacid generator comprising an onium salt of formula (I), (II), (III), (IV) or (V) capable of generating an acid upon exposure to radiation, (H) an alkali-soluble resin, an acid crosslinking agent capable of forming a crosslinked structure under the action of an acid, and (G) an organic solvent;
[0040] 7) a chemically amplified negative working resist composition of 6) further comprising (C) another photoacid generator;
[0041] 8) a chemically amplified negative working resist composition of 6) or 7) further comprising (D) a basic compound; and
[0042] 9) a chemically amplified negative working resist composition of 6), 7) or 8) further comprising (J) an alkali-soluble compound with a molecular weight of up to 2,500; but are not limited thereto.
[0043] Additionally, the invention provides a process for forming a pattern, comprising the steps of applying the resist composition defined above onto a substrate to form a coating; heat treating the coating and exposing the coating to high energy radiation preferably with a wavelength of up to 300 nm or electron beam through a photo-mask; optionally heat treating the exposed coating, and developing the coating with a developer.
[0044] The respective components of the resist composition are described in detail.
Component (G)
[0045] Component (G) is preferably an organic solvent. Illustrative, non-limiting, examples include butyl acetate, amyl acetate, cyclohexyl acetate, 3-methoxybutyl acetate, methyl ethyl ketone, methyl amyl ketone, cyclohexanone, cyclopentanone, 3-ethoxyethyl propionate, 3-ethoxymethyl propionate, 3-methoxymethyl propionate, methyl acetoacetate, ethyl acetoacetate, diacetone alcohol, methyl pyruvate, ethyl pyruvate, propylene glycol monomethyl ether, propylene glycol monoethyl ether, propylene glycol monomethyl ether propionate, propylene glycol monoethyl ether propionate, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, 3-methyl-3-methoxybutanol, N-methyl-pyrrolidone, dimethylsulfoxide, γ-butyrolactone, propylene glycol methyl ether acetate, propylene glycol ethyl ether acetate, propylene glycol propyl ether acetate, methyl lactate, ethyl lactate, propyl lactate, and tetramethylene sulfone. Of these, the propylene glycol alkyl ether acetates and alkyl lactates are especially preferred.
[0046] It is noted that the alkyl groups of the propylene glycol alkyl ether acetates are preferably those of 1 to 4 carbon atoms, for example, methyl, ethyl and propyl, with methyl and ethyl being especially preferred. Since the propylene glycol alkyl ether acetates include 1,2- and 1,3-substituted ones, each includes three isomers depending on the combination of substituted positions, which may be used alone or in admixture. It is also noted that the alkyl groups of the alkyl lactates are preferably those of 1 to 4 carbon atoms, for example, methyl, ethyl and propyl, with methyl and ethyl being especially preferred. These solvents may be used alone or in admixture. An exemplary useful solvent mixture is a mixture of a propylene glycol alkyl ether acetate and an alkyl lactate. The mixing ratio of the propylene glycol alkyl ether acetate and the alkyl lactate is not critical although it is preferred to mix 50 to 99 parts by weight of the propylene glycol alkyl ether acetate with 50 to 1 parts by weight of the alkyl lactate. The solvent mixture of the propylene glycol alkyl ether acetate and the alkyl lactate may further contain one or more other solvents.
Component (A)
[0047] Component (A) is a resin which changes its solubility in an alkaline developer solution under the action of an acid. It is preferably, though not limited thereto, an alkali-soluble resin having phenolic hydroxyl and/or carboxyl groups in which some or all of the phenolic hydroxyl and/or carboxyl groups are protected with acid-labile protective groups.
[0048] The preferred alkali-soluble resins having phenolic hydroxyl and/or carboxyl groups include homopolymers and copolymers of p-hydroxystyrene, m-hydroxystyrene, α-methyl-p-hydroxystyrene, 4-hydroxy-2-methylstyrene, 4-hydroxy-3-methylstyrene, methacrylic acid and acrylic acid. Also included are copolymers in which units free of alkali-soluble sites such as styrene, α-methylstyrene, acrylate, methacrylate, hydrogenated hydroxystyrene, maleic anhydride and maleimide are introduced in addition to the above-described units in such a proportion that the solubility in an alkaline developer may not be extremely reduced. Substituents on the acrylates and methacrylates may be any of the substituents which do not undergo acidolysis. Exemplary substituents are straight, branched or cyclic C 1-8 alkyl groups and aromatic groups such as aryl groups, but not limited thereto.
[0049] Examples of the alkali-soluble resins are given below. These polymers may also be used as the material from which the resin (A) which changes its solubility in an alkaline developer under the action of an acid is prepared and as the alkali-soluble resin which serves as component (H) to be described later. Examples include poly(p-hydroxystyrene), poly(m-hydroxystyrene), poly(4-hydroxy-2-methylstyrene), poly(4-hydroxy-3-methylstyrene), poly(α methyl-p-hydroxystyrene), partially hydrogenated p-hydroxystyrene copolymers, p-hydroxystyrene-α-methyl-p-hydroxystyrene copolymers, p-hydroxystyrene-.alpha.-methylstyrene copolymers, p-hydroxystyrene-styrene copolymers, p-hydroxystyrene-m-hydroxystyrene copolymers, p-hydroxystyrene-styrene copolymers, p-hydroxystyrene-acrylic acid copolymers, p-hydroxystyrene-methacrylic acid copolymers, p-hydroxystyrene-methyl methacrylate copolymers, p-hydroxystyrene-acrylic acid-methyl methacrylate copolymers, p-hydroxystyrene-methyl acrylate copolymers, p-hydroxy-styrene-methacrylic acid-methyl methacrylate copolymers, poly(methacrylic acid), poly(acrylic acid), acrylic acid-methyl acrylate copolymers, methacrylic acid-methyl methacrylate copolymers, acrylic acid-maleimide copolymers, methacrylic acid-maleimide copolymers, p-hydroxystyrene-acrylic acid-maleimide copolymers, and p-hydroxystyrene-methacrylic acid-maleimide copolymers as well as dendritic and hyperbranched polymers thereof, but are not limited to these combinations.
[0050] The alkali-soluble resins or polymers should preferably have a weight average molecular weight (Mw) of 3,000 to 100,000. Many polymers with Mw of less than 3,000 do not perform well and are poor in heat resistance and film formation. Many polymers with Mw of more than 100,000 give rise to a problem with respect to dissolution in the resist solvent and developer. The polymer should also preferably have a dispersity (Mw/Mn) of up to 3.5, and more preferably up to 1.5. With a dispersity of more than 3.5, resolution is low in many cases. Although the preparation method is not critical, a poly(p-hydroxystyrene) or similar polymer with a low dispersity or narrow dispersion can be synthesized by controlled free radical or living anionic polymerization.
[0051] The resin (A) is preferably an alkali-soluble resin (as mentioned above) having hydroxyl or carboxyl groups, some of which are replaced by acid labile groups such that the solubility in an alkaline developer changes as a result of severing of the acid labile groups under the action of an acid generated by the photoacid generator upon exposure to radiation.
[0052] In the chemical amplification type resist composition, an appropriate amount of (B) the photoacid generator comprising an onium salt of formula (I), (II), (III), (IV) or (V) added is from 0.5 part to 20 parts by weight, and preferably from 1 to 10 parts by weight, per 100 parts by weight of the solids in the composition. The photoacid generators may be used alone or in admixture of two or more. The transmittance of the resist film can be controlled by using a photoacid generator having a low transmittance at the exposure wavelength and adjusting the amount of the photoacid generator added.
Component (C)
[0053] In one preferred embodiment, the resist composition further contains (C) a compound capable of generating an acid upon exposure to high energy radiation, that is, a second photoacid generator other than the photoacid generator (B). The second photoacid generators include sulfonium salts and iodonium salts as well as sulfonyldiazomethane, N-sulfonyloxyimide, benzoinsulfonate, nitrobenzylsulfonate, sulfone, and glyoxime derivatives. They may be used alone or in admixture of two or more. Preferred photoacid generators used herein are sulfonium salts and iodonium salts.
[0054] In the resist composition comprising (B) the photoacid generator comprising the onium salt of formula (I), (II), (III), (IV) or (V) as the first photoacid generator according to the invention, an appropriate amount of the second photoacid generator (C) is 0 to 20 parts, and especially 1 to 10 parts by weight per 100 parts by weight of the solids in the composition. The second photoacid generators may be used alone or in admixture of two or more. The transmittance of the resist film can be controlled by using a (second) photoacid generator having a low transmittance at the exposure wavelength and adjusting the amount of the photoacid generator added.
Component (D)
[0055] The basic compound used as component (D) is preferably a compound capable of suppressing the rate of diffusion when the acid generated by the photoacid generator diffuses within the resist film. The inclusion of this type of basic compound holds down the rate of acid diffusion within the resist film, resulting in better resolution. In addition, it suppresses changes in sensitivity following exposure and reduces substrate and environment dependence, as well as improving the exposure latitude and the pattern profile.
[0056] Examples of basic compounds include primary, secondary, and tertiary aliphatic amines, mixed amines, aromatic amines, heterocyclic amines, carboxyl group-bearing nitrogenous compounds, sulfonyl group-bearing nitrogenous compounds, hydroxyl group-bearing nitrogenous compounds, hydroxyphenyl group-bearing nitrogenous compounds, alcoholic nitrogenous compounds, amide derivatives, and imide derivatives.
[0057] The basic compounds may be used alone or in admixture of two or more. The basic compound is preferably formulated in an amount of 0 to 2 parts, and especially 0.01 to 1 part by weight, per 100 parts by weight of the solids in the resist composition. The use of more than 2 parts of the basis compound would result in too low a sensitivity.
Component (E)
[0058] Illustrative examples of the organic acid derivatives (E) include, but are not limited to, organic acid derivatives including 4-hydroxyphenylacetic acid, 2,5-dihydroxyphenylacetic acid, 3,4-dihydroxyphenylacetic acid, 1,2-phenylenediacetic acid, 1,3-phenylenediacetic acid, 1,4-phenylenediacetic acid, 1,2-phenylenedioxydiacetic acid, 1,4-phenylenedipropanoic acid, benzoic acid, salicylic acid, 4,4-bis(4′-hydroxy-phenyl)valeric acid, 4-tert-butoxyphenylacetic acid, 4-(4′-hydroxyphenyl)butyric acid, 3,4-dihydroxymandelic acid, and 4-hydroxymandelic acid. Of these, salicylic acid and 4,4-bis(4′-hydroxyphenyl)valeric acid are preferred. They may be used alone or in admixture of two or more.
[0059] In the resist composition comprising the onium salt according to the invention, the organic acid derivative is preferably formulated in an amount of up to 5 parts, and especially up to 1 part by weight, per 100 parts by weight of the solids in the resist composition. The use of more than 5 parts of the organic acid derivative would result in too low a resolution. Depending on the combination of the other components in the resist composition, the organic acid derivative may be omitted.
Component (F)
[0060] In one preferred embodiment, the resist composition further contains (F) a compound with a molecular weight of up to 3,000 which changes its solubility in an alkaline developer under the action of an acid, that is, a dissolution inhibitor. Typically, a compound obtained by partially or entirely substituting acid labile substituents on a phenol or carboxylic acid derivative having a molecular weight of up to 2,500 is added as the dissolution inhibitor
[0061] In the resist composition comprising the onium salt according to the invention, an appropriate amount of the dissolution inhibitor (F) is up to 20 parts, and especially up to 15 parts by weight per 100 parts by weight of the solids in the composition. With more than 20 parts of the dissolution inhibitor, the resist composition becomes less heat resistant because of an increased content of monomer components.
[0062] In a chemical amplification, negative working, resist composition, (B) the photoacid generator comprising onium salts of formula (I), (II), (III), (IV) or (V) may be used as well. This composition further contains an alkali-soluble resin as component (H), examples of which are intermediates of the above-described component (A) though not limited thereto.
[0063] Examples of the alkali-soluble resin include poly(p-hydroxystyrene), poly(m-hydroxystyrene), poly(4-hydroxy-2-methylstyrene), poly(4-hydroxy-3-methylstyrene), poly(α-methyl-p-hydroxystyrene), partially hydrogenated p-hydroxystyrene copolymers, p-hydroxystyrene-α-methyl-p-hydroxystyrene copolymers, p-hydroxystyrene-.alpha.-methylstyrene copolymers, p-hydroxystyrene-styrene copolymers, p-hydroxy-styrene-m-hydroxystyrene copolymers, p-hydroxystyrene-styrene copolymers, p-hydroxystyrene-acrylic acid copolymers, p-hydroxystyrene-methacrylic acid copolymers, p-hydroxystyrene-methyl methacrylate copolymers, p-hydroxystyrene-acrylic acid-methyl methacrylate copolymers, p-hydroxystyrene-methyl acrylate copolymers, p-hydroxystyrene-methacrylic acid-methyl methacrylate copolymers, poly(methacrylic acid), poly(acrylic acid), acrylic acid-methyl acrylate copolymers, methacrylic acid-methyl methacrylate copolymers, acrylic acid-maleimide copolymers, methacrylic acid-maleimide copolymers, p-hydroxystyrene-acrylic acid-maleimide copolymers, and p-hydroxystyrene-methacrylic acid-maleimide copolymers as well as dendritic and hyperbranched polymers thereof, but are not limited to these combinations.
[0064] Preferred are poly(p-hydroxystyrene), partially hydrogenated p-hydroxystyrene copolymers, p-hydroxystyrene-styrene copolymers, p-hydroxystyrene-acrylic acid copolymers, and p-hydroxystyrene-methacrylic acid copolymers, as well as dendritic and hyperbranched polymers of the foregoing polymers.
[0065] The polymer should preferably have a weight average molecular weight (Mw) of 3,000 to 100,000. Many polymers with Mw of less than 3,000 do not perform well and are poor in heat resistance and film formation. Many polymers with Mw of more than 100,000 give rise to a problem with respect to dissolution in the resist solvent and developer. The polymer should also preferably have a dispersity (Mw/Mn) of up to 3.5, and more preferably up to 1.5. With a dispersity of more than 3.5, resolution is low in many cases. Although the preparation method is not critical, a poly(p-hydroxystyrene) or similar polymer with a low dispersity or narrow dispersion can be synthesized by controlled free radical or living anionic polymerization.
[0066] To impart a certain function, suitable substituent groups may be introduced into some of the phenolic hydroxyl and carboxyl groups on the acid labile group-protected polymer. Exemplary and preferred are substituent groups for improving adhesion to the substrate, substituent groups for improving etching resistance, and especially substituent groups which are relatively stable against acid and alkali and effective for controlling such that the dissolution rate in an alkali developer of unexposed and low exposed areas of a resist film may not become too high. Illustrative, non-limiting, substituent groups include 2-hydroxyethyl, 2-hydroxypropyl, methoxymethyl, methoxycarbonyl, ethoxycarbonyl, methoxycarbonylmethyl, ethoxycarbonylmethyl, 4-methyl-2-oxo-4-oxolanyl, 4-methyl-2-oxo-4-oxanyl, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, acetyl, pivaloyl, adamantyl, isobornyl, and cyclohexyl. It is also possible to introduce acid-decomposable substituent groups such as t-butoxycarbonyl and relatively acid-undecomposable substituent groups such as t-butyl and t-butoxycarbonylmethyl.
[0067] Also contained in the negative resist composition is an acid crosslinking agent capable of forming a crosslinked structure under the action of an acid. Typical acid crosslinking agents are compounds having at least two hydroxymethyl, alkoxymethyl, epoxy or vinyl ether groups in a molecule. Substituted glycoluril derivatives, urea derivatives, and hexa(methoxymethyl) melamine compounds are suitable as the acid crosslinking agent in the chemically amplified, negative resist composition comprising the onium salt according to the invention. Examples include N,N,N′,N′-tetramethoxymethylurea, hexamethoxymethylmelamine, tetraalkoxymethyl-substituted glycoluril compounds such as tetrahydroxymethyl-substituted glycoluril and tetramethoxy-methylglycoluril, and condensates of phenolic compounds such as substituted or unsubstituted bis(hydroxymethylphenol) compounds and bisphenol A with epichlorohydrin. Especially preferred acid crosslinking agents are 1,3,5,7-tetraalkoxy-methylglycolurils such as 1,3,5,7-tetramethoxymethylglycoluril, 1,3,5,7-tetrahydroxymethylglycoluril, 2,6-dihydroxymethyl-p-cresol, 2,6-dihydroxymethylphenol, 2,2′,6,6′-tetrahydroxymethyl-bisphenol A, 1,4-bis[2-(2-hydroxypropyl)]benzene, N,N,N′,N′-tetramethoxymethylurea, and hexamethoxymethylmelamine. In the resist composition, an appropriate amount of the acid crosslinking agent is about 1 to 25 parts, and especially about 5 to 15 parts by weight per 100 parts by weight of the solids in the composition. The acid crosslinking agents may be used alone or in admixture of two or more.
[0068] In the chemical amplification type, negative working, resist composition, (J) an alkali-soluble compound having a molecular weight of up to 2,500 may be blended. The compound should preferably have at least two phenol and/or carboxyl groups. Illustrative, non-limiting, examples include cresol, catechol, resorcinol, pyrogallol, fluoroglycin, bis(4-hydroxyphenyl)methane, 2,2-bis(4′-hydroxyphenyl)propane, bis(4-hydroxyphenyl)sulfone, 1,1,1-tris(4′-hydroxyphenyl)ethane, 1,1,2-tris(4′-hydroxyphenyl)ethane, hydroxybenzophenone, 4-hydroxyphenylacetic acid, 3-hydroxyphenylacetic acid, 2-hydroxyphenylacetic acid, 3-(4-hydroxyphenyl)propionic acid, 3-(2-hydroxyphenyl)propionic acid, 2,5-dihydroxyphenylacetic acid, 3,4-dihydroxyphenylacetic acid, 1,2-phenylenediacetic acid, 1,3-phenylenediacetic acid, 1,4-phenylenediacetic acid, 1,2-phenylenedioxydiacetic acid, 1,4-phenylenedipropanoic acid, benzoic acid, salicylic acid, 4,4-bis(4′-hydroxyphenyl)valeric acid, 4-tert-butoxyphenylacetic acid, 4-(4-hydroxyphenyl)butyric acid, 3,4-dihydroxymandelic acid, and 4-hydroxymandelic acid. Of these, salicylic acid and 4,4-bis(4′-hydroxyphenyl) valeric acid are preferred. They may be used alone or in admixture of two or more. The addition amount is 0 to 20 parts, preferably 2 to 10 parts by weight per 100 parts by weight of the solids in the composition although it is not critical.
[0069] In the resist composition according to the invention, there may be added such additives as a surfactant for improving coating, and a light absorbing agent for reducing diffuse reflection from the substrate.
[0070] Illustrative, non-limiting, examples of the surfactant include nonionic surfactants, for example, polyoxyethylene alkyl ethers such as polyoxyethylene lauryl ether, polyoxyethylene stearyl ether, polyoxyethylene cetyl ether, and polyoxyethylene oleyl ether, polyoxyethylene alkylaryl ethers such as polyoxyethylene octylphenol ether and polyoxyethylene nonylphenol ether, polyoxyethylene polyoxypropylene block copolymers, sorbitan fatty acid esters such as sorbitan monolaurate, sorbitan monopalmitate, and sorbitan monostearate, and polyoxyethylene sorbitan fatty acid esters such as polyoxyethylene sorbitan monolaurate, polyoxyethylene sorbitan monopalmitate, polyoxyethylene sorbitan monostearate, polyoxyethylene sorbitan trioleate, and polyoxyethylene sorbitan tristearate; fluorochemical surfactants such as EFTOP EF301, EF303 and EF352 (Tohkem Products K. K.), Megaface F171, F172 and F173 (Dai-Nippon Ink & Chemicals K. K.), Florade FC430 and FC431 (Sumitomo 3M K. K.), Asahiguard AG710, Surflon S-381, S-382, SC101, SC102, SC103, SC104, SC105, SC106, Surfynol E1004, KH-10, KH-20, KH-30 and KH-40 (Asahi Glass K. K.); organosiloxane polymers KP341, X-70-092 and X-70-093 (Shin-Etsu Chemical Co., Ltd.), acrylic acid or methacrylic acid Polyflow No. 75 and No. 95 (Kyoeisha Ushi Kagaku Kogyo K. K.). Inter alia, FC430, Surflon S-381 and Surfynol E1004 are preferred. These surfactants may be used alone or in admixture.
[0071] In the resist composition according to the invention, the surfactant is preferably formulated in an amount of up to 2 parts, and especially up to 1 part by weight, per 100 parts by weight of the solids in the resist composition.
[0072] In the resist composition according to the invention, a UV absorber may be added. An appropriate amount of UV absorber blended is 0 to 10 parts, more preferably 0.5 to 10 parts, most preferably 1 to 5 parts by weight per 100 parts by weight of the base resin.
[0073] For the microfabrication of integrated circuits, any well-known lithography may be used to form a resist pattern from the chemical amplification, positive or negative working, resist composition according to the invention.
[0074] The composition is applied onto a substrate (e.g., Si, SiO.sub.2, SiN, SiON, TiN, WSi, BPSG, SOG, organic anti-reflecting film, etc.) by a suitable coating technique such as spin coating, roll coating, flow coating, dip coating, spray coating or doctor coating. The coating is prebaked on a hot plate at a temperature of 60 to 150° C. for about 1 to 10 minutes, preferably 80 to 120° C. for 1 to 5 minutes. The resulting resist film is generally 0.1 to 2.0 μm thick. With a mask having a desired pattern placed above the resist film, the resist film is then exposed to actinic radiation, preferably having an exposure wavelength of up to 300 nm, such as UV, deep-UV, electron beams, x-rays, excimer laser light, γ-rays and synchrotron radiation in an exposure dose of about 1 to 200 mJ/cm 2 , preferably about 10 to 100 mJ/cm 2 . The film is further baked on a hot plate at 60 to 150° C. for 1 to 5 minutes, preferably 80 to 120° C. for 1 to 3 minutes (post-exposure baking=PEB).
[0075] Thereafter the resist film is developed with a developer in the form of an aqueous base solution, for example, 0.1 to 5%, preferably 2 to 3% aqueous solution of tetramethylammonium hydroxide (TMAH) for 0.1 to 3 minutes, preferably 0.5 to 2 minutes by conventional techniques such as dipping, puddling or spraying. In this way, a desired resist pattern is formed on the substrate. It is appreciated that the resist composition of the invention is best suited for micro-patterning using such actinic radiation as deep UV with a wavelength of 254 to 193 nm, 13.4 nm (EUV), electron beams, x-rays, excimer laser light, γ-rays and synchrotron radiation. With any of the above-described parameters outside the above-described range, the process may sometimes fail to produce the desired pattern.
EXAMPLES
[0076] The onium salts may be synthesized using known methods and techniques. The following are several examples of preferred embodiments of the onium salts in accordance with the present invention. However, the synthesis methods and techniques are not limited by the following examples.
[0077] A typical synthetic procedure to obtain an onium salt as depicted in Formula (VI) carrying short perfluoroalkyl chain as counter ion is described below.
[0000]
[0078] wherein M is I or S, a=2 when M is I and a=3 when M is S,
n=1 to 4, R 0 is C 6 H 5 , and
[0080] R 1 =(CH 2 ) 6 CH 3 , (CH 2 ) 7 CH 3 , OCH 2 CH 3 ,
OC(CH 3 ) 3 , CH 2 CH 2 OCH 3 ,
[0000]
[0000] Iodochlorotetrafluoroalkane was transformed to sodium chlorotetrafluoroalkane sulfinate on reaction with sodium dithionite and sodium bicarbonate in aqueous acetonitrile. The sulfinate reacted smoothly with elemental chlorine in water at 0° C. and gave sulfonyl chloride, which in turn was converted to its sulfonate using sodium hydroxide as the oxidizing agent. Alkylated perfluoroalkane sulfonate was obtained either by addition of sulfonate to an olefin in the presence of ammonium persulfate [(NH 4 ) 2 S 2 O 9 ] or by reacting metal alkoxide with sulfonate. The alkylated perfluoralkane sulfonate underwent an exchange reaction with photosensitive cation in methanol or CH 2 Cl 2 /H 2 O or ketonic solvents and produces a new ionic photoacid generator.
[0082] Synthetic procedure to attain the onium salts of Formula (VII), Formula (X), and Formula (VIII), carrying short perfluoroalkyl chain as counter ion is summarized below.
[0000]
[0083] wherein M is I or S, a=2 when M is I and a=3 when M is S,
n=2, m=2 or 4, R 0 is C 6 H 5 ,
[0085] R 2 =Cl, CH 2 CH 2 OH, CH 2 CH 2 CH 2 OH, CH 2 CH 2 Cl, CH═CH 2 , and
R 3 =CH 2 CH(Br)CH 3
Bromo(or iodo) tetrafluoralkane was transformed to sodium perfluoroalkane sulfinate on reaction with sodium dithionite and sodium bicarbonate in aqueous acetonitrile. The sulfinate reacted smoothly with elemental chlorine in water at 0° C. and gave sulfonyl chloride, which in turn was converted to its sulfonate using ammonium hydroxide as the oxidizing agent. The perfluoralkane sulfonate underwent an exchange reaction with photosensitive cation in methanol or CH 2 Cl 2 /H 2 O or ketonic solvents and produces a new ionic photoacid generator.
[0087] Synthetic route to obtain the onium salt of Formula (IX) carrying short perfluoroether chain as counter ion discussed below.
[0000]
[0088] wherein M is I or S, a=2 when M is I and a=3 when M is S, and
R 0 is C 6 H 5
5-Iodooctafluoro-3-oxapentanesulphonyl fluoride was transformed to its lithium sulfonate using lithium carbonate as the oxidizing agent. The perfluorether sulfonate underwent an exchange reaction with photosensitive cation in methanol or CH 2 Cl 2 /H 2 O or ketonic solvents and produces a new ionic photoacid generator.
[0090] The synthetic procedure to arrive at an anionic part of the onium salt of Formula (XI) and Formula (XII) with perfluoroalkyl group or perfluoroether which in turn attached to phenyl/substituted phenyl group via an ether linkage is summarized below.
[0000]
[0091] wherein M is I or S, a=2 when M is I and a=3when M is S, n=1 to 4,
R 0 is C 6 H 5 , and R 1 =H, Br, CN, OCH 3 , COO − , NO 2 , OCOCH 3 ; and/or
[0000]
[0093] wherein M is I or S, a=2 when M is I and a=3 when M is S
[0094] R 0 is C 6 H 5 , and R 2 =H, Br, CN, OCH 3 , COO − , NO 2 , OCOCH 3
[0000] Reaction of potassium salt of phenol with dihalotetrafluoroalkane or with, 1,6-dibromoperfluoro-2,5-dioxahexane results in phenyl ether which is transformed to sulfinate on reaction with sodium dithionite and sodium bicarbonate in aqueous acetonitrile. The sulfinate can be converted to sulfonate by two methods either by reacting the sulfinate with elemental chlorine in water to sulfonyl chloride then oxidation with lithium hydroxide in aqueous THF or direct oxidation with hydrogen peroxide in aqueous acetonitrile. Finally an exchange reaction of sulfonate with photoactive cation in aqueous acetonitrile or ketonic solvents such as acetone, 2-butanone or 4-methyl-2-pentanone affords a new ionic photoacid generator.
[0095] A typical synthetic procedure to obtain an anionic part of the onium salt of Formula (XIII) with branched perfluoroalkyl group which in turn attached to phenyl/substituted phenyl group is described below.
[0000]
[0096] wherein M is I or S, a=2 when M is I and a=3 when M is S,
R 0 is C 6 H 5 , and R 3 =H, F, Cl, CH 3
Reaction of hexafluoro-2-phenylisopropanol or the substituted phenyl version with phosphorus tribromide results in hexafluoro-2-phenylisopropyl bromide which can be transformed to sulfinate on reaction with sodium dithionite and sodium bicarbonate in aqueous acetonitrile. The sulfinate can be converted to sulfonate by two methods either by reacting the sulfinate with elemental chlorine in water to sulfonyl chloride then oxidation with lithium hydroxide in aqueous THF or direct oxidation with hydrogen peroxide in aqueous acetonitrile. Finally an exchange reaction of sulfonate with photoactive cation in aqueous acetonitrile or ketonic solvents such as acetone, 2-butanone or 4-methyl-2-pentanone affords a new ionic photoacid generator.
[0098] A simplified synthetic procedure to arrive an anionic part of the onium salt of Formula (XIV), Formula (XV), and Formula (XVI) with phenyl ring directly attached to the sulfonium ions is described below.
[0000]
[0099] wherein M is I or S, a=2 when M is I and a=3 when M is S,
[0100] R 0 is C 6 H 5 , and R4=H, F, Br, OCH 3 , COO—, CN, OCOCH 3 ;
[0000]
[0101] wherein M is I or S, a=2 when M is I and a=3 when M is S,
R 0 is C 6 H 5 , Z=F or CF 3 , and R 5 =H, F, CF 3
[0000]
[0103] wherein M is I or S, a2 when M is I and a=3 when M is S
[0104] R 0 is C 6 H 5 , and R 6 =H, F, Br, OCH 3 , COO − , CN, OCOCH 3
[0105] The sulfonate can be synthesized either by direct sulfodehalogenation reaction or from the sulfonic acid by treating with silver or lithium or sodium compounds. Reaction of aromatic halogen with sodium hydrogen sulfite or sodium sulfate or potassium metabisulfite can result corresponding sulfonate. Finally an exchange reaction of sulfonate with photoactive cation in aqueous acetonitrile or ketonic solvents such as acetone, 2-butanone or 4-methyl-2-pentanone affords a new ionic photoacid generator.
[0106] Although the present invention has been disclosed in terms of a preferred embodiment, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention as defined by the following claims. | Novel classes of ionic photoacid generator (PAGs) compounds having relatively environmentally friendly anions with no perfluorooctyl sulfonate (no-PFOS) are provided and photoresist composition that comprise such compounds. The new PAGs produce a photoacid having a short or no perfluoro alkyl chain (i.e., no-PFOS) attached to a variety of functional groups. The PAGs of the invention are useful as photoactive component in the chemically amplified resist compositions used for microfabrication. | 2 |
BACKGROUND OF THE INVENTION
In the drafting art certain symbols and geometric figures of various sizes are repetitively required on a drawing. To avoid the time consuming procedure of drawing such figures, employing conventional instruments, such as triangles, compass, protractor, etc., it has long been the practice to provide templates with apertures therein, the edges of which are so shaped to form the desired figure by moving a pencil or pen around opening guide edges. Thus, templates having various size circles, ellipses, squares, hexagons, etc. are familiar. Due to the non-adjustability of such templates, however, they are limited somewhat in utility in that only one predetermined figure may be drawn with each aperture, or, if only a portion of the aperture is employed, then conventional drafting instruments must also be employed. Thus, if a slot with semi-circular ends is desired, one half of a circular aperture may be employed for each end and the figure completed by connecting such ends, employing a straight edge of any suitable form. This saves little time over the use of compass and T-square, or the like, and suffers the further disadvantage that skill is always required to join lines in exact alignment in contradistinction to a template wherein the line is continuous, the only points of alignment being at its starting and finishing point, which with a template, are usually overlapped.
Adjustable templates have also been proposed so that a predetermined size and shape of figure may be selected. The U.S. Patent to Lane No. 2,720,706 is exemplary of such type of template in which figures of several shapes having straight sides may be drawn. Until such time that an adjustable template is devised with which any shape and any size figure may be drawn, templates of this type will have their limitations in utility. Such limitations are not objectionable, however, if a specific template serves the major purposes of a draftman for a particular type of drawing. Moreover, in view of the relatively low cost of simple limited utility templates, as compared to a yet undevised and necessarily complicated adjustable all purpose template, the use of several limited utility templates will probably always be more economically practical.
SUMMARY OF THE INVENTION
The present invention relates to the class of adjustable drafting templates, just referred to, which has particular utility in electronic circuit drawings and others employing often repeated conventional figures or symbols of different sizes. The conventional shapes are squares, rectangles, circles and elongated slots with semi-circular ends, employed in many types of mechanical drawings. The electronic symbols include elongated figures with parallel sides and a flat base at one end and a pointed or semi-circular shape at the other end. Isosceles triangles and semi-circles may also be drawn as special forms of these shapes.
Several modifications are contemplated within the purview of the invention. In its most comprehensive form all of the shapes referred to may be drawn with one template. In its more limited form only a selected portion of such shapes may be drawn.
The generic form of the invention comprises a pair of rectilinearly slideable members which define slots of variable width and length having parallel sides and selected shaped ends.
In its more refined form, the members may be positively locked together and in all forms disclosed interchangeable parts may be employed to extend the field of utility.
In accordance with the foregoing, the general object of the invention is to provide improvements in adjustable limited utility templates.
Another object is to optionally extend such utility by the use of interchangeable components.
Another object is to provide a template having a plurality of adjustable apertures therein for drawing a certain set of figures.
A further object is to provide a portion of the foregoing template for drawing a portion of the set of predetermined figures.
Still further objects, advantages, and salient features will become more apparent from the detailed description to follow, the appended claims, and the accompanying drawing, to now be briefly described.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top plan of one form of the invention;
FIG. 2 is an enlarged section taken on line 2--2, FIG. 1;
FIG. 3 is a broken-away isometric view taken substantially on line 3--3, FIG. 1;
FIG. 4 is a top plan of an alternative form of the invention, portions being broken away;
FIG. 5 is an enlarged section taken on line 5--5, FIG. 4; and
FIG. 6 is a top plan of a portion of FIG. 4, illustrating a modification thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawing in detail, and first to FIG. 1, template 10 is a flat plate of plastic, celluloid or other material, preferably transparent, as commonly employed for drafting instruments such as triangles, French curves, fixed shapes, aperture templates, or the like, of the order of about 1/8" thickness.
The left half of the plate is provided with a plurality of parallel elongated apertures or slots 12a, 12b, 12c, etc., which increase in width, their widths being identified by suitable indicia 14. The right ends 16a, 16b, 16c, etc. of the slots are semi-circular and the left ends 18a, 18b, etc. are straight and perpendicular to the parallel edges. Preferably, the slots are of about the same length and their ends substantially aligned in the stacked arrangement illustrated to most effectively utilize the area of the plate.
A cursor or slideable member 20 extends across the slots and is suitably guided to move rectilinearly parallel thereto. The left edge of the cursor is provided with a plurality of isosceles triangle shaped cut-outs 22a, 22b, 22c, etc. disposed symetrically with respect to the slots. The right edge 24 of the cursor is straight and perpendicular to the edges of the slots. In the position shown, a plurality of isosceles triangles of different sizes may be drawn by moving an implement, such as a pencil or pen around the edges of the triangular openings. When the cursor 20 is moved to the right from that shown, the openings will be formed by parallel sides, a base or end perpendicular thereto and another end formed by two corresponding sides of an isosceles triangle, that is, as an arrow head with a flat base.
The slots at the right side of straight edge 24 are similar to those just described except that the ends are semicircular rather than triangular. These could thus be characterized as bullet-head symbols with flat bases. When cursor 20 is moved to the right such symbols or figures are shortened until they become semicircles.
Referring now to right cursor 20A, this differs from cursor 20 in that cut-outs 26a,26b,26c, etc., are semicircular, rather than triangular. The slots are the same as in the left half except that their ends are reversed. In the position shown, the openings at the left of cursor 20A are elongated slots with parallel sides and semicircular ends. When it is moved to its extreme left position the openings become circles. The openings at the right of the straight edge are rectangles in the position shown. When the cursor is moved to near its extreme right position (at indicia 27) they become squares. Further movement chops the squares into small rectangles.
Other suitable indicia 28 is preferably employed to identify the length of the openings. Also, small holes 29 are preferably provided for locating the center line of its associated slot.
CURSOR CONSTRUCTION
Each of the cursors so far described is preferably provided with means for locking it in desired position and a description of one will serve for both. Referring to FIG. 3, a stud-like member 30 comprises a generally octagonal base 32 having a slot 34 therein, a round shank 36 and square terminal end 38 with a slot 40. Base 32 forms a resilient cam, by reason of its slot, and is proportioned to fit between a pair of adjacent legs 44 (FIG. 1) defining edges of a slot. When rotated, it cams against such legs forming a lock. Knob 42 fits the square shank and is resiliently retained thereon by end 38 which is provided with opposed detents 46.
The cursor is also provided with portions 48 which fit and slide between the various legs and maintain its direction of movement perpendicular to the axes of the slots. As best shown in FIG. 2, its outer edges are provided with resilient V-shaped guides 50 which slide in corresponding grooves in the opposite edges of plate 10. A bevel 52 is also provided for inserting a knife edge for removing the cursor when desired.
As best shown in FIG. 3, the straight and cut-out edges of the cursor are provided with bevels 54 so that the pencil guiding edges on the cursor lie in the same plane as the top surface of plate 10 to obviate slight errors in forming the end shapes which might otherwise occur.
Referring now to FIG. 4, this construction provides the same template shapes as FIG. 1 but in a somewhat less expensive form of construction. The central portion 110 may be considered analogous to plate 10 with its various slots and portions 120, 120A, may be considered analogous to cursors 20, 20A. In this construction, the three members lie in the same plane with the fingers on members 120, 120A slideably disposed in the slots of central member 110. Tie bars 56, extending across the width of member 110, may be provided to maintain the fingers of central member 110 in precise spaced parallel arrangement by welds 58 (FIG. 5). The outermost fingers are also preferably provided with v-shaped slides 60 to maintain the various portions in the same plane.
MODIFICATIONS
Fig. 1
the slots on the left side vary in width from 1/8" to 3/4" by increments of 1/8". The slots on the right side vary in width from 3/16" to 13/16", also by increments of 1/8". Thus, slots are provided from 1/8" to 13/16" by increments of 1/16". If it is desired to employ 1/16" increments with a limited shape of figures, then a cursor like 20A (not shown) may be substituted for cursor 20. As will be understood, it will differ from cursor 20 in that its semi-circular edges will point toward the like edges of cursor 20A. With this construction, circles from 1/8" to 13/16" diameter may be drawn in increments of 1/16". As will be apparent, slots of like width with semi-circular ends may also be drawn. As will be further apparent, a cursor like cursor 20 (not shown) may be substituted for cursor 20A with its triangular edges pointing to the right. Similarly, arrow-headed slots may be drawn, differing in width by increments of 1/16".
Fig. 4
fig. 6 illustrates the upper right portion of FIG. 4. With this construction only the right half of plate 110 is employed, together with the right slide member 120A shown in FIG. 4 and an auxiliary member 220A is provided of the shape shown in the left side of FIG. 4, these being interchangeable. With this construction all of the figures which may be drawn with the FIG. 4 construction may be drawn by the FIG. 6 construction. Otherwise stated, FIG. 4 duplicates the same width slots at each side of its center which are provided with sliders having different shaped ends. In FIG. 6 the duplication of the slots is eliminated and two interchangeable sliders 120A, 220A are provided having different shaped ends.
Further Modifications and Choices
If the user's needs are principally for circles, slots with semi-circular ends, squares and rectangles, then the right halves only, of FIGS. 1 or 4 may be provided. If a greater number of figure widths are desired then the entire structure of FIGS. 1 or 4 may be provided with slots of intermediate width and the appropriate cursor. If the user's principal needs are for arrow or bullet head figures then the left halves of FIGS. 1 or 4 may be provided, and similarly, if a greater number of figure widths are desired then the entire structure of FIGS. 1 or 4 may be provided with slots of intermediate width. If the user's needs are for both types of the groups of figures referred to, then the FIGS. 1 or 4 construction should be preferred if the user is to be limited to only one template.
In view of the exemplary combinations and variations, it will be apparent that further modifications are possible which are contemplated within the purview of the invention as set forth by the appended claims. | Adjustable drafting template characterized by relatively slideable members which may be positioned to form openings for drawing figures with two parallel sides of different widths and lengths having ends of various shapes; also, circles, chordal portions thereof, squares, portions thereof, and equilateral triangles. | 1 |
RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/049,140, filed Feb. 1, 2005 now U.S. Pat. No. 7,331,309 and entitled “CLUMPING ANIMAL LITTER COMPOSITION AND METHOD OF PRODUCING THE SAME”, the contents of which are incorporated in their entirety herein by reference.
FIELD OF THE INVENTION
This invention relates to a clumping animal litter comprising a homogenous mixture of a polymer, a gum and cellulosic components and methods of preparation thereof; particularly, an animal litter which comprises a homogenous mixture of anionic polyacylamide, guar gum, a grist and optionally cellulosic fines in combination, thereby providing a litter with enhanced absorption, clumping size and hardness.
BACKGROUND OF THE INVENTION
Methods and compositions are known that utilize absorbent materials in litter boxes and animal cages in an effort to efficiently and effectively collect animal urine and/or feces. Currently, there are generally two types of litter; clumping and non-clumping. The non-clumping type consists of an absorbent particulate material, which acts to absorb animal dross until the material reaches a saturation point, at which time the litter must be replaced. Unfortunately, without chemical additives, until the saturation point is reached the soiled absorbent material can grow mold and/or emit an objectionable odor requiring frequent replacement with fresh litter.
Clumping types of litter are currently the most popular litter on the market. In this type, the portion of the wetted granular litter forms a solid agglomerate, or clump, usually within a short period of time. This clump can then be easily removed while the rest of the granular litter remains.
Clay is currently the most commonly used absorbent material in both clumping and non-clumping types of animal litter, as it is able to absorb a substantial amount of liquid. However, due to the costs associated with mining and shipping of clays, litters made from this material tend to be more expensive and environmentally destructive than that produced from organic wood-based sources such as sawdust, waste paper, pulp, husks, wood pellets and the like. Furthermore, clays contain silica, a known carcinogen. Thus, the use of silica containing compounds raises health concerns for both the animal involved and the person changing the litter. Moreover, clumps of clay do not readily break down in water and may clog household plumping.
U.S. Pat. No. 5,927,049 to the present inventors (herein incorporated by reference in its entirety) has effectively solved these problems utilizing a simple and elegant procedure for the creation of a non-clumping, all-natural litter that is biodegradable, odor controlling, dustless, smooth throughout continued handling and capable of absorbing 5 times more fluid than clay. In particular, this invention exploits the odor neutralizing properties inherent in southern yellow pine, which eliminate volatile odors (e.g. mercaptan, amines, skatole gases) emitted from animal waste without the need for additional artificial additives.
While much of the prior art discloses the use of organic wood-based sources as a preferred or alternative embodiment, until the advent of the aforementioned method to the instant inventors few manufactures have been able to create a wood-based particulate litter that is economical to produce. These wood-based animal litters are expensive to fabricate, as they are often difficult to manufacture. Wood-based litters typically require multiple applications of aqueous additives (e.g. biocides, deodorizers, pesticides and the like), followed by a drying step in order to create litters with the desired properties.
Thus, what is lacking in the prior art is a clumping animal litter with superior absorbance and enhanced clumping properties that remains intact under mechanical stress, yet economical to produce and inhibits mold growth. Ideality the animal litter composition would use industrial or agricultural byproducts, thereby providing an economical and environmental friendly litter that is able to readily disperse when disposed into the household plumbing system.
DESCRIPTION OF THE PRIOR ART
Recently a variety of methods and procedures have been described in the prior art for preparing animal litters utilizing superabsorbent polymers in combination with both inorganic and organic substrates and mixtures of both. Many patents have been directed toward a clumping litter that forms agglomerates quickly and with sufficient mechanical integrity and size so as to permit easy removal of animal waste in a solid mass.
For example, U.S. Pat. No. 5,609,123 to Luke et al describes a pet litter composition comprising a particulate substrate with a low absorptive capacity, preferably a non-swelling clay, having bonded onto its surface fine particulate particles coated with a superabsorbent polymeric material and another particulate “clumping particle” to promote clumping. The superabsorbent polymer is an anionic polymer, preferably formed from a blend of carboxylic acid monomers, e.g. (meth)acrylic acid from 10 to 100% weight and (meth) acrylamide monomers from 0 to 90% weight. Unlike the high molecular weight, water soluble, anionic polymer utilized in the present invention, the superabsorbent polymer of Luke et al is a water insoluble, cross-linked polymeric material. Additionally, the manufacturing process of Luke et al requires that the surface of the substrate particle be sprayed first with a specific amount of liquid and allowed to absorb into the substrate particles, before application of the superabsorbent polymer and clumping particle blend. Too much liquid can cause undesirable swelling that can interfere with the beneficial performance of the superabsorbent polymer and clumping particles.
U.S. Pat. No. 6,148,768 to Ochi et al describes a pet litter for disposal of animal wastes, which comprise granular bodies containing fiber and a superabsorbent polymer skin layer. The granular body is composed of a core containing the fiber and a skin layer, which covers the core. The skin layer preferably contains an anti-powdering agent and superabsorbent polymer, such as a cross-linked polyacrylic acid. The patent fails to teach or suggest the use of a gum or gum derivatives on the granular body.
U.S. Pat. No. 4,157,696 to Carlberg describes an animal waste absorbent and deodorizing composition for use as an animal litter. The composition comprises pellets made from fly ash and cellulose fibers that form channels from the surface of the pellet to the interior of the pellet to permit capillary action to draw the dross into the interior of the pellet to deodorize and dehydrate the waste. Various pelletizing aids may be used, such as the synthetic polymer formed from sodium acrylate and acrylamide.
U.S. Pat. No. 6,662,749 to Wiedenhaft et al discloses an animal litter comprising a cellulosic substrate coated with an inner coating composed of an absorbent polyacrylate or acrylate copolymers and a second outer coating of guar gum, the binding agent used to form the aggregate. The particularly preferred polyacrylate is sold under the name Spinks 211 (H.C. Spinks Clay Company, Inc. located in Paris, Tenn.). However, unlike the instant invention, this animal litter requires the stepwise addition of an inner coating of an absorbent polymer onto the substrate with an outer coating of guar. Thus, the inner coating of polymer can only exhibit its absorbent properties when the liquid penetrates the outer coating of guar gum, which can disrupt the formation of the aggregate.
None of abovementioned prior art teach or suggest the use of a homogenous mixture of an absorbent polymer, a gum, grist and optionally cellulosic fines, to provide a clumping litter with improved clumping ability and absorbency. Thus, there remains a continuing need in the art for a clumping litter that forms a mechanically stable and absorbent agglomerate that is easy to manufacture.
DEFINITIONS
The term “anionic polyacrylamides”, as used in the present specification and claims, is intended to mean a group of water soluble, high charge density, high molecular weight macromolecules with a molecular weight of at least 5,000,000 to 30,000,000; preferably at least about 10,000,000.
The term “grist” as used in the instant specification and claims is intended to mean the milled cellulosic material produced prior the formation of the pellet during the pelletization process. The grist can be comprised of one or more sources of softwoods, e.g. pine, cedar, fir, spruce and combinations thereof, since these materials have been found to innately contain odor-neutralizing and microbial resistant properties. Moreover, the grist can be obtained in any form such as wood chips, husks, hulls, shavings or sawdust, straw and combinations thereof, preferably from materials reclaimed from outside processes (i.e. lumber yard).
The terms “cellulosic fines” and “densified wood saw dust”, are both used interchangeably in the instant specification and claims and are intended to mean the byproducts produced during the pelletization process or the superfluous cellulosic material generated during the manufacture of lumber or paper products which pass through at least one 10 to 30 mesh (U.S. Standard) screen. The cellulosic fines can include, among other things, small pellet pieces and any grist that did not form into proper pellets.
The term “near instantaneous” as used in the instant specification and claims, is intended to mean a period of time of less than 2 minutes.
The term “clump hardness” as used in the instant specification and claims, refers to the adhesiveness created by the homogenous mixture which allows the clump to remain substantially intact after being dropped from a height of one foot 5 minutes after formation of the clump.
SUMMARY OF THE INVENTION
In order to overcome the problems encountered by the prior art, the instantly disclosed invention is directed toward a clumping animal litter composition and a process of manufacturing the same. The litter is formed from cellulosic material that can be obtained from one or more sources of softwoods by any pelletizing process known in the art, for example the aforementioned method taught in U.S. Pat. No. 5,927,049 to the present inventors. During the formation of the pellets, the pellets are then moved across a sifting screen such that some of the cellulosic fines that separate from the pellets can be recycled as part of an mixture which includes an absorbent polymer (i.e. anionic polyacrylamide), dry powdered gum and grist. Alternatively, other sources of cellulosic fines generated from other manufacturing processes (e.g. lumber mill) can be used in the mixture.
It has been discovered by the present inventors that high molecular weight anionic polyacrylamides impart properties desirable in a clumping litter (i.e. faster clumping speed and clump hardness) as compared with lower molecular weight copolymers of acrylamide and acrylic acid (also known as acrylate), commonly used in the prior art. These high molecular weight macromolecules are known for their excellent absorptive capacity for aqueous media (e.g. typically upwards of 400× the weight of the polymer) with minimal tackiness.
Suitable absorbent polymers for use in the present invention include anionic polyacrylamides, a group of high charge density, water soluble, high molecular weight macromolecules produced through the polymerization of acrylamide and an anionically charged co-monomer, formed by any polymerization method known in the art. Some examples of anionically charged co-monomers include, sodium acrylate, potassium acrylate and other salts of acrylic acid and derivatives thereof known in the art.
The preferred anionic polyacrylamide is supplied under the designation CLEAROUT P6400 (manufactured by Chemtall Inc., GA, USA). CLEAROUT P6400 is a fine white powder with an approximate bulk density of 0.8 and viscosities of; 1800 cps @ concentration of 5.0 g/L; 700 cps @ concentration of 2.5 g/L; 300 cps @ 1.0 g/L, (as measured by a Brookfield viscometer at 25° C.). The intrinsic viscosity (IV) is about 22 dL/g. The dissolution time of the polymer in DI water @ 5 g/L, 25° C. is 60 minutes. The polymer has range of anionically charged co-monomers of about 20 to 40 mole %.
Examples of suitable gums or gum derivatives for use in the instant invention include guar gum. Particularly preferred guar gums include hydroxypropyl guar, carboxymethyl guar, carboxymethyl hydroxypropyl guar, and combinations and/or derivatives thereof known in the art. Other suitable gums include xanthan gum, locust bean gum and the like.
Accordingly, it is a principle objective of the instant invention to provide a clumping litter and process for the formation thereof providing a homogenous admixture of anionic polyacrylamide polymer, gum, grist and optionally, cellulosic fines, thereby providing a clumping litter with both enhanced absorption and clumping properties.
An additional objective of the invention is to produce a clump that is of sufficient hardness as to be readily removed by automated litter boxes, while able to readily disperse when introduced into the household plumbing system.
A further objective of the instant invention is to provide a manufacturing process whereby the litter produced makes use of the superfluous cellulosic fines created during the pelletization process that were heretofore unused, thereby providing a more economical and environmentally friendly product.
Another objective of the present invention is to provide an animal litter composition that has inherent odor controlling properties.
It is still a further objective of the invention to provide an animal litter composition and method of manufacture that employs industrial or agricultural byproducts, thereby providing an environmentally desirable litter.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objectives and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic representation of a method for producing animal litter according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
An illustrative, but non-limiting, example of a method that simultaneously manufactures both a non-clumping type organic fiber pellets and a clumping type organic for use as animal litter is illustrated in the schematic view 10 of FIG. 1 . As described herein, the clumping type process depends upon the by-products generated during the manufacture of the non-clumping litter, however, the grist and cellulosic fines could be obtained from other independent sources which produce grist and suitably sized cellulosic fines, i.e. lumber yards. It is noted that other conventional pelletizing apparatus and methods may be utilized.
A preferred source of the cellulosic component, preferably, albeit not limited to, shavings of yellow pine wood 12 are delivered to a receiving depot 14 where it is off-loaded and placed into a kiln 16 . Once in the kiln 16 , the wood 12 is subjected to a temperature of about 120° F. to 200° F., at low consistent humidity, for a period of time, until the desired moisture level is achieved. The kiln 16 causes the wood 12 to reach uniform moisture content, preferably less than 8%. After the wood 12 has been cured, the material is transferred to a hammer mill 18 and ground into grist 20 . The grist 20 is collected in a first surge chamber 22 . The initial curing results in dimensional variances, produced by shrinkage during drying, and are eradicated during the grinding process. This results in a grist 20 that is uniform, evenly compressible, and conducive to holding a fixed shape. Additionally, the uniform nature of the grist 20 ensures that the pellets formed therefrom will bond well together.
The grist 20 is stored in the first surge chamber 22 , until a portion of it is conveyed via a transfer feeder 24 to a conditioning chamber 26 to later form pellets 30 . While the other portion of the grist 20 ″ is transferred to a low shear mixer 50 for addition with gum, absorbent polymer and optionally cellulosic fines. The portion of the grist 20 that is transferred to the conditioning chamber 26 is sprayed with an aqueous solution, preferably steam, for approximately 3-4 seconds to form a grist 20 having uniform moisture content.
After being exposed to the aqueous solution, the moistened grist 20 ′ flows into a pellet mill 28 , where the moistened grist 20 ′ is processed into a uniform pellet 30 . During the pelletization process, the moistened grist 20 ′ is exposed to increased pressure and temperature for a short period of time. More specifically, the moistened grist 20 ′ is pressurized at about 60 Kpsi for approximately 4 to 10 seconds in the temperature range of about 180° F. to about 250° F.
The pellets 30 are then transferred to a cooler 32 where the pellet temperature drops to ambient temperature. This cooling step advantageously allows the pellets 30 to coalesce before further processing.
Once the pellets 30 have cooled, the pellets 30 pass through a shaker 34 having at least one sifting screen 36 , (e.g. a 10-mesh screen), to remove any materials that did not form into a proper pellet. As the pellets 30 move across at least one sifting screen 36 , the cellulosic fines 30 ′ are separated from the pellets 30 for later addition as part of a mixture that is combined with the grist 20 ″ in the low shear mixer 50 . Optionally, a portion or all of the cellulosic fines 30 ′ can be returned to the feeder 24 and mixed with grist 20 exiting from the first surge chamber 22 . In this way, the returned fine particles 30 ′ are combined with fresh grist 20 to form additional pellets 30 .
Pellets 30 exiting the shaker construction 34 are collected in a second surge chamber 38 , in preparation for bagging. From the second surge chamber 40 , pellets are deposited into bags 42 . The bags 42 travel on a bag conveyor 44 though a heat sealer 46 that closes the bags. The sealed bags 42 ′ are then transported to remote location for sale and use as a non-clumping animal litter.
Into the low shear mixer 50 is added at least one dry powdered gum, preferably a guar gum or guar gum derivative, at a concentration of about 5.0% to 20.0% (wt/wt), preferably at about 10% (wt/wt) based on the weight of the mixture; a dry powder of the anionic polyacrylamide polymer at a concentration of about 0.1% to about 1.0% (wt/wt), preferably at about 0.3% (wt/wt), based on the weight of the mixture; a grist at a concentration of about 100% to 30% and recycled cellulosic fines 30 ′ at about 0% to 70%, preferably about 30% (wt/wt), based on the weight of the mixture; such that the total percentage adds up to about 110%. The mixture can optionally contain any desired additive discussed below. After addition of the aforementioned components, the mixer 50 is run for a predetermined amount of time, at least 10 minutes, under conditions well known to those skilled in the art, in order to provide a uniform mixture.
The clumping litter mixture exiting the mixer 50 is collected in a third surge chamber 52 , in preparation for bagging. From the third surge chamber 52 , the mixture is released into a bagger unit 54 , wherein the mixture is deposited into bags 42 . The bags 42 travel on a bag conveyor 44 ′ through a heat sealer 46 ′ that closes the bags. The sealed bags 42 ″ are then transported to remote locations for sale and use as animal litter. Although illustrated herein as two separate conveyors and sealers, it is contemplated that the same conveyor and/or sealer can be used in the manufacture of both the clumping and non-clumping litter.
Without limiting the scope of the present invention, suitable low shear mixers include drum mixers, cement mixers, auger mixers, vibrating bed mixer or other means of mixing known in the art. These can be batch or continuous feed mixers.
It is contemplated by the instant invention to provide at least one additive during the mixing step described above, at about 0% to about 20% of the weight of the mixture. Non-limiting examples of additives include, but are not limited to oils or extracts of fragrances, antimicrobial agents, deodorants, disinfectants, colorants (i.e. pigments, dyes, lakes), and combinations thereof. Other suitable additives include oxidizers, such as sodium perborate and/or calcium peroxide, to neutralize the volatile odors (i.e. mercaptan, amines, skatole gases) emitted from the waste. Addition of at least one of the aforementioned additives during the formation of the pellet would produce pellets that comprise the characteristics of the additive throughout, e.g. color, fragrance, etc.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings/figures.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | The instant invention is directed towards a method of preparing a clumping animal litter comprising a combination of a high molecular weight polymer, a gum, and cellulosic components. The invention particularly relates to a method of preparing a clumping animal litter that comprises a homogenous mixture of anionic polyacylamide, a guar gum, grist and optionally cellulosic fines in combination with one or more sources of cellulosic material, thereby providing a litter with enhanced absorption, clumping size and hardness. | 0 |
This application claims the benefit of Provisional application Ser. No. 60/462,464, filed Apr. 11, 2003.
FIELD OF THE INVENTION
The present invention relates to exercise equipment. More particularly, this invention pertains to an adjustable kettlebell of an improved, compact design that can employ standard barbell plates.
BACKGROUND OF THE INVENTION
In the specification, “dumbbell” defines an exercise device with two weight sections, connected by a handle section, while “kettlebell” defines a single mass section (often spheroidal) attached to single looped handle section. While many exercises can be performed with both kettlebells and dumbbells, some motions are more comfortably performed with a kettlebell or provide a unique benefit that is distinct from the nearest dumbbell equivalent. However, several kettlebell exercises such as the one arm clean (OAC) and the one arm snatch (OAS) require a degree of technique to avoid the kettlebell bashing against the user's forearm. The impact force is confined to a relatively small contact area, and bruising and discomfort can often result.
Limitations of Existing Adjustable Kettlebell Designs
In both the OAS and OAC exercise motions, a solid kettlebell provides a rounded surface that distributes both the impact and resting load of the kettlebell's mass. The primary disadvantage of a solid kettlebell design is that several kettlebells of varying weights are required to accommodate a range of exercises and strength levels. Previous adjustable kettlebell designs have had deficiencies in that they employ nonstandard weights and/or fail to provide adequate roundedness and comfort in the final configuration.
A first adjustable kettlebell design was created by CALVERT (described in U.S. Pat. No. 1,316,683 issued to Milo Barbell Company). It comprises a handle attached to an outer shell surrounding a set of specialized weights. The following features and deficiencies of the design used in CALVERT are addressed by the improvements of the present invention. In CALVERT, (1) non-standard weight plates are required; and (2) the handle clearance, the distance between the handle and the point of contact between the forearm and the mass section, is fixed.
Another adjustable type of kettlebell design is WOOD (described in U.S. Pat. No. 1,917,566 issued to Robert Alfred Wood). WOOD describes four major configurations of prior art designs. WOOD describe a design with an accommodation for standard barbell plates inside of an outer shell. Wood discloses the two cups of the outer shell with the edges presented outwards. WOOD also discloses a continuous stack of plates secured by collars to a bar, all within the confines of the attachment member. In another configuration, WOOD discloses a modified form of the handle, assembled with several of the discs at each end of the bell configuration, the cup members being omitted.
WOOD does not reveal or describe several important features, namely, (1) a configuration that approximates the smooth surfaces found in the solid forged kettlebell without requiring a separate outer shell member; (2) a configuration where plates of the weight stack straddle the attachment members; (3) a configuration free of stop collars which avoids wide, awkward protrusions; and (4) a “solid” configuration that prevents sway of the main weight section with regard to the handle, along with an attachment mechanism that provides for an adjustable handle clearance. While WOOD contemplates a configuration with a solid handle (a wire bail), it does not describe a means to combine the solid handle with an adjustable handle clearance. Furthermore, adding additional chain links to the configurations described by WOOD will only increases the relative sway.
Another design for an adjustable kettlebell was implemented by GRACE (Gracefitness). It involves a gnurled handle, a set of specialized bevel discs, and a set of twisted steel bars functioning as a means of attachment between the weight discs and the gnurled handle. The following features and deficiencies of the GRACE design are addressed by the improvements of the present invention. GRACE requires (1) specialized beveled plates are required to form the rounded surface near the line of contact; (2) that the handle clearance is a fixed distance from the contact point; and (3) the plate axis is perpendicular the handle's axis, hence adjusting the number of weights changes the point of contact.
Two more adjustable designs that use standard barbell plates, are manufactured by Piedmont Design Associates (PDA). The deficiencies of the PDA designs are as follows: (1) the use of retaining collars results in significant gaps in the spacing of the weight plates that straddle the attachment member; (2) the use of retaining collars results in significant protrusions on the outside of the bell configuration; (3) the handle clearance between the handle and the bar is fixed. Another kettlebell design has been designed by IRONMIND (Ironmind). It implements the plate axis to be perpendicular to the handle axis, but requires careful consideration of the weight stack configuration to avoid having the weight plate edges come to rest with the forearm during some exercises. This design and instructions from manufacturers indicate their awareness of the shortcomings of this arrangement and discourage all exercise motions that involve the weight resting on the forearms.
SUMMARY AND OBJECT OF THE INVENTION
In light of the deficiencies, shortcomings and drawbacks of the known kettlebell designs, it is therefore an object to provide an improved kettlebell weightlifting device which includes an adjustable configuration that provides for a plurality of standard weight discs forming a weight stack with a central plate axis.
It is further object of the current invention to provide a supporting bar aligned along the plate axis, this axis being nominally parallel to the axis of the grip section of the handle.
It is another object of the current invention to provide a rounded grip section that affords comforting grip to the user.
It is also an object of the current invention to provide attachment members that afford significantly reduced gaps between weight discs that straddle said attachment sections.
It is further desirable that these attachment members are structured as to provide an adjustable distance between the grip section and the plate axis.
These and other objectives, characteristics and advantages of the present invention will be disclosed in more detail with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a partially exploded elevation view of one embodiment of the present invention.
FIG. 1B is a side view of an implementation of an attachment member illustrated in FIG. 1A from the perspective of reference character AA.
FIG. 1C is a side view of another implementation of an attachment member illustrated in FIG. 1A from the perspective of reference character AA.
FIG. 2 is an elevation view of the present invention highlighting the flexure of the attachment structure.
FIG. 3 is a side view of one embodiment of the present invention, showing the rounded handle, weight discs, and the “forearm”.
FIGS. 4A–4C are a schematic representation of the present invention, showing three additional configurations in accordance with the current invention, showing a narrow configuration with large plates and hemispherical end caps in FIG. 4 A, a narrow configuration with small plates and hemispherical end caps in FIG. 4B , and a narrow configuration with small plates, hemispherical end caps and a protective band in FIG. 4C .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A shows an elevation view of one embodiment of the present invention in partial disassembly. A curved and rounded handle assembly is comprised of a grip section 1 and an attachment member or “blade” 14 . The “blade” 14 has an asymmetric cross-section and intersects the stack of disc weights 18 with a minimal gap 16 introduced between weight plates. For example, the attachment member in FIG. 1A illustrates an asymmetric cross-section, wherein the attachment member is formed with a cross-section that has a greater breadth in a direction perpendicular to a weight plate axis than in a direction parallel to the weight plate axis. The subassembly of the bolts 34 , 35 , washers 91 and the elongated nut 28 forming a support bar 70 for the weight stack.
In this particular embodiment, an elongated hexnut 28 with a captive washer 90 welded to one end, is passed through a central disc stack 96 from the left until the captive washer 90 meets the outside face of the left blade, while the right bolt 35 is passed through an outside washer 91 and rightmost weight assembly 92 and threaded into the hexnut 28 from the right, and the left bolt 34 is passed through the leftmost weight assembly 94 and threaded into 28 from the left. As the bolts are tightened down, the gap 88 between the outside weight assemblies 94 and 92 and center weight stack 96 reduces to the thickness of the attachment members 14 —the final configuration forming a single, physically tight assembly. The subassembly of the bolts 34 , 35 and the elongated hexnut 28 forming a support bar 70 assembly for the weight stack. Section AA # 1 shows the cross section of the blades 14 with distinct holes 20 for different positions of the bar. Section AA # 2 shows the cross section of the blades 14 with a scalloped hole pattern 22 that provide for a finer adjustment of support bar positions. The adjustable hand clearance 98 feature is demonstrated with the center line 24 aligned with holes AA # 1 , and the center line 25 aligned with sections AA # 2 . Distinct holes 20 , or small nibs 23 in the hole pattern 22 can provide a hard mechanical stop for the hexnut 28 . Alternately, the design can rely solely on the friction of a tightened support bar to set and maintain a specific handle clearance 98 .
In FIG. 1A , the support bar 70 is comprised of the left bolt 34 , elongated nut 28 with captive washer 90 and right bolt 35 . With various combinations of outside bolts ( 34 and 35 ) and a 4″ long hexnut 28 , the length of the support bar can safely span a range of 4″ to 10″. Other features of this invention may include the following additional elements:
1) since the captive washer 90 provides access to the internal thread of the hexnut 28 , the right weight assembly 92 can be modified without rearranging either the core 96 or the left weight assembly 94 ; 2) additional combinations of inside and outside bolts can provide additional lengths, if necessary; 3) either or both outside weight assemblies may be omitted.
Alternately, the support bar can be configured as a variety of other mechanical arrangements that effectively result in a shaft of adjustable length. Moreover, a support bar can be comprised of a solid or hollow tube along with standard securing mechanisms, such as spring, spiral clamps or large pitch spiral threads, with the proviso that such configurations can introduce additional protrusions past the outside weight assemblies.
By defining an attachment member 10 with various hole configurations of 20 or 22 (see FIG. 1A–1C ) the present invention allows for an adjustment of the distance between support bar 70 axis 24 and the grip axis, and provides the key improvement that the user can adjust the optimum contact point 32 independently of the diameter of the weight plates that are used.
FIG. 2 illustrates another aspect of the present invention. The blade section 14 is part of a single piece of bent spring material 74 (preferably spring steel), that is embedded in a partially hollow grip-section 1 with outside profile 82 . In the implementation in FIG. 2 , because the attachment members are formed from a springy material, the attachment members have an inherent resilient mechanical compliance, as well as an asymmetric mechanical compliance. Further, in the FIG. 2 , a bar 74 is bent to a profile that fits snugly against the internal webs 80 of an otherwise hollow grip section 1 which could be constructed by joining two halves of either stamped metal or molded material (for example, ABS plastic). The internal webs 80 function to secure part of the bar member 74 between pivot points 76 . In the implementation in FIG. 2 , the attachment members are formed with an internal pivot point 76 . Below the pivot points 76 , there is an internal clearance 98 that allows the bar 74 to flex within the hollow grip-section 1 .
As the bolt 35 is threaded against the elongated hexnut 28 , the blades 14 flex into a new profile 78 . Additionally, if the nominal hex pattern 22 is cut into the blade attachment members 14 , then the hexnut 28 can be restrained from spinning even if the core weight stack 96 width is greater than the hexnut's length. This safety feature prevents the inadvertent loosening of one bolt while the user tightens the other bolt. Additionally, by setting the pivot point 76 far from the bottom of the grip-section 1 , the present invention achieves greatly increased mechanical compliance of the blades 14 , allowing the blades to clamp tightly against a central plate assembly 96 of varying width without excessive stress being placed on the blades or the grip-section 1 .
FIG. 3 shows the side view of the kettlebell configuration, with a grip-section 1 leading into the attachment member blades 14 that intersperse the weight stack. The inner stack of weights is comprised of larger weight discs 18 (e.g., 10 pounds), while the outer edges of the stack are comprised of smaller weight discs 17 (e.g., 5 pounds).
In this view, the contact point 32 between the forearm 40 and the weight stack shows the critical nature of the hand clearance (the distance between the support bar axis 24 and the grip axis). If this clearance is too small then the weight's leverage against the wrist can impose excessive pressure at the contact point. If this clearance is too large, then the flipping action (described in the OAS and OAC motions above) of the kettlebell allows for excessive acceleration of the weight stack prior to terminating at the contact point 32 .
FIGS. 4A–4C show some additional configurations of the present invention. Configuration 64 in FIG. 4A shows a weight stack comprised of four ten pound discs 18 along with hemispherical end caps 48 all aligned on centerline axis 44 . The hemispherical end caps 48 would have a deep countersunk hole that would allow for bolt head and support bar (not shown in this drawing) to pass through the majority of the hemispherical end cap. The final configuration nearly approximates the hemispherical shape of the original solid kettlebell. The hemispherical end caps could be made of any material. A metal cap would provide additional weight, while caps made of plastic, foam, wood or other light material provide the desired shape without significant addition weight or requirement for a specialized forging.
Configuration 66 in FIG. 4B , shows a weight stack comprised of four 5 pound discs 17 along with smaller hemispherical end caps 49 all aligned on centerline axis 46 . Substantially less weight is involved (20 vs 40 pounds), but the optimal contact point is preserved by adjusting the centerline 46 . The smaller hemispherical end caps 49 have all the characteristics of their larger counterparts 48 in configuration 64 .
Configuration 68 in FIG. 4C , shows a weight stack comprised of four 5 pound discs 17 along with the larger hemispherical end caps 48 , and a protective band 50 around the weight stack, all aligned on centerline axis 44 . The weight stack of 17 , spherical end caps 48 and protective band 50 comprising an entirely spheroidal shape of relatively low weight and large size, are envisioned for the less aggressive user. The hemispherical caps and/or protective band can be manufactured out of a dense shock absorbing foam for additional comfort and protection.
While there have been shown and described, pointed fundamental novel features of the invention as applied to embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the invention, as herein disclosed, may be made by those skilled in the art without departing from the spirit of the invention. In particular all weights and dimensions introduced in the specification were presented for illustrative purposes, and variations in said weights and dimensions are anticipated and will not affect the utility of the present invention. It is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. It is the intention, therefore to be limited only as indicated by the scope of the claims appended hereto. | This invention pertains to an improved adjustable kettlebell that has a stack of standard weight plates, a rounded grip section, a support bar serving to hold the weight stack, and flexible attachment members with cutouts for the support bar. The flexible attachment members provide a mechanically compliant clamping arrangement to accommodate weight stack of varying widths, and the cutouts allowing adjustment to the relative distance between the grip axis and the support bar axis. The improved adjustable kettlebell of the current invention serves as a close physical approximation to a solid cast kettlebell with a wide combination of standard weight plates. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to webs of record members, tags, labels and method of making same.
2. Brief Description of the Prior Art
The following patent documents are made of record: U.S. Pat. Nos. 4,727,055; 5,389,414; 5,833,273; 6,737,140; U.S. design patent application Ser. No. 29/186,393; and German Gebrauchsmuster G 92 16 694.6.
SUMMARY OF THE INVENTION
A preferred embodiment provides a composite web of pairs of tags and labels manufacturable from an adhesive-coated tag stock web and a release liner web, wherein the tags and labels can be printed in pairs in a suitable printer such as a thermal printer and severed from the composite web in pairs, and wherein the tags and labels are releasable from the release liner and the tag of each pair has a tab foldable and adhesively adhered to a portion of the remainder of the tag, and wherein the portion of the tag beyond the tab is masked off by adhesive deadener to provide a non-tacky tag.
BRIEF DESCRIPTION OF THE DIAGRAMMATIC DRAWINGS
FIG. 1 is a top plan view of a fragmentary portion of a composite web of record members comprised of tags and labels;
FIG. 2 is an enlarged fragmentary sectional view taken along line 2 - 2 of FIG. 1 ;
FIG. 3 is a top plan view of a release liner of the composite web of FIGS. 1 and 2 ;
FIG. 4 is a bottom plan view of the tag stock web;
FIG. 5 is a top plan view of the front of a printed tag of the composite web shown imprinted in FIG. 1 ;
FIG. 6 is a bottom plan view of the tag shown in FIG. 5 ;
FIG. 7 is an enlarged sectional view of the tag with its tab folded about a fold line onto a portion of the tag;
FIG. 8 is a fragmentary view of the tag with its tab folded onto a portion of the tag; FIG. 9 is a top plan view of the printed label shown in unprinted form in FIG. 1 ;
FIG. 10 is a front elevational view showing the label of FIG. 9 adhered to a polyethylene garment-containing bag suspended by a hanger;
FIG. 11 is a rear elevational view of the label and bag suspended by the hanger;
FIG. 12 is a top plan view of an alternative form of label from the label illustrated in FIGS. 1 , 2 , 4 , 9 , 10 and 11 ;
FIG. 13 is a top plan view of a portion or tab of the label shown in FIG. 12 detached from the remainder of the label; and
FIG. 14 is a top plan view of a portion of the label shown in FIG. 12 from which the tab has been removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference initially to FIGS. 1 and 3 , there is shown a composite web generally indicated at 20 of record members or tags 21 and record members or labels 22 . The tags 21 are disposed end-to-end and are part of a web generally indicated at 23 of tags 21 . The labels 22 are disposed end-to-end and are part of a web generally indicated at 24 of labels 22 . Underlying the webs 23 and 24 is a release liner generally indicated at 25 shown to be in web form. The tags 21 and labels 22 is formed from a web of tag stock preferably of the type for producing hang tags. Hand tags are of a type which can be hung from garments and the like such as by means of a plastic fastener of the type sold by Paxar Americas, Inc. under its trademark TAGGER TAIL®. The tag stock can be of a single ply or of more than one ply as illustrated in U.S. Pat. No. 4,727,055. The tags 21 and the labels 22 are shown to be connected end-to-end, however, the tags 21 and the labels 22 are separable in pairs by cutting along cut lines CL, as is preferred. As such, both the tag stock web 26 and the underlying release liner web 25 can be completely severed simultaneously along the cut line CL. Alternatively, the tag stock web 26 can be severed along the cut line CL and the release liner web 25 can be uncut or partially severed along the cut line CL for manual separation of a pair of a tag 21 and a label 22 , but this is not the most preferred construction.
Typically the tags 21 and the labels 22 are printed in a suitable printer (not shown) such as a thermal printer or in a laser printer illustrated in U.S. Pat. No. 5,389,414 and thereafter one pair of a tag 21 and a label 22 which are side-by-side and the underlying portion of the release liner web 25 are severed from the web 20 . The web 20 is preferably fed through the printer in the direction of arrow A.
As shown in FIG. 1 , the tag web 23 and the label web 24 are formed by at least partially severing the tag stock web 26 longitudinally between its side edges 27 and 28 , as indicated at 29 . The side edges 27 and 28 and the line of at least partially severing 29 are preferably parallel. The tags 21 are illustrated to be slightly wider than the labels 21 . It is most preferred to only partially sever the web 26 longitudinally to maintain the integrity of the composite web 20 . In particular, the web 26 is preferably completely severed as shown in FIGS. 1 , 2 and 4 , except for frangible ties or lands indicated at 30 disposed at longitudinally spaced locations along the web 26 , and as such the web 26 is considered to be partially severed along the line 29 . The lands 30 help prevent the tag web 23 and the label web 24 from shifting relative to each other not only during the manufacturing method but also during printing in a printer.
With reference to FIG. 2 , the tag stock web 26 , a coating of adhesive 31 , a coating of adhesive deadener 32 , a coating of release material 33 such as silicone, and a release liner 34 are shown exaggeratedly thick for clarity. The adhesive 31 is of the pressure sensitive or tacky type and is coated onto and adheres to a face 35 of the tag stock web 26 . Adhesive deadener or detackifier 32 is coated onto the adhesive under portions of the tag web 23 . The liner 25 fully underlies both the tag web 23 and the label web 24 .
Each tag 21 is shown to include a main tag section or portion 21 a and tabs 21 b and 21 c . The detachable tab 21 b is connected to the tag portion 21 a by a line of weakening or partial severing 36 . The tab 21 c is connected to the tag portion 21 a by a line of weakening or partial severing 37 . The tag portion 21 a has a through-hole 38 . There are also through-holes 39 in the release liner web 25 aligned with the holes 38 in the tag stock web 26 . The tabs 21 b have one or more slits 38 ′ shown to be cross-hair slits through the tab stock 26 . As is preferred, the release liner web 25 is free of any cuts except for the holes 39 .
Each label 22 in the label web 24 has lines of weakening or partial severing 40 and 41 . The line of partial severing 40 is much closer to one cut line CL than the other cut line CL and extends transversely or perpendicular to the long or longitudinal direction of the web 20 . The line of partial severing 41 extends obliquely to the longitudinal direction, and in particular is shown to extend from the end of the intersection of the lines of partial severing 29 and 36 to one end of the line of partial severing at side edge 28 . The slope of the line of partial severing 41 preferably matches the slope of a conventional triangular-shaped wire garment hanger 53 ( FIGS. 10 and 11 ) having sloped portions 54 which terminates at a hook (not shown).
With reference to FIG. 4 , the underside of the tag web 26 is shown. As is preferred, the entire underside of adhesive 31 of the tag web 23 is shown masked off or deadened by the coating of adhesive deadener or detackifier 32 except for almost all of the tab 21 b and a portion 42 of the tag portion 21 a . In addition, the adhesive deadener 32 is coated onto the underside of the label web 24 on both sides of each cut line CL between borders 43 and 44 . The adhesive deadener 32 on the label web 24 extends from side edge 28 to the line of partial severing 29 . The adhesive deadener 32 extends longitudinally from the borderline or border 45 in the tab web 23 downwardly to a borderline or border 44 in the tag web 23 as viewed in FIG. 4 . The adhesive deadener 32 in the label web 23 exists only between borderline or border 43 and borderline or border 44 that straddle each cut line CL. It is seen that the adhesive 31 outside the adhesive-deadened areas or zones indicated at 32 releasably holds the tag stock web 26 to the release liner web 25 during manufacture and while the web 26 is being advanced through the printer. The areas deadened by the adhesive deadener 32 are in a generally L-shaped configuration as shown in FIG. 4 . The lines of partial severing 36 , 37 , 40 , 40 a and 41 are shown by dash-dash lines, while the borders 43 , 44 and 45 are shown by dot-dash lines. The partial severing lines 36 , 37 , 40 , 40 a and 41 ′ can be provided by perforating, scoring, creasing, crushing or any other suitable way.
FIG. 5 shows the front side of the tag 21 as having been printed. FIG. 6 shows the underside of the tag 21 . It is noted that throughout, borders 43 , 44 and 45 are not cut lines or lines of complete or partial severing. FIG. 6 shows that the distance between borderline 44 and the line of partial severing 36 is most preferably equal to the distance between the line of partial severing 36 and the borderline 45 . Also, the area of the tab 21 b between the borderline 44 and the line of partial severing 36 and the area of the portion 42 are preferably equal. Therefore, when the tab 21 b is folded about line of partial severing or fold line 36 , the undeadened adhesive 31 exists only between the tab 21 b and the zone or portion 42 of the tag 21 . The tag portion 21 a beyond end 46 of the folded tab 21 b is non-tacky as best shown in FIG. 7 . Accordingly, no outer surface of the tag is tacky because all of the adhesive is covered by the tab 21 b or is masked-off by the adhesive deadener 32 .
As best shown in FIGS. 9 through 11 , the label 22 has been printed on the printer. The main portion of the label 22 is disposed between the line of partial severing 40 and end edge 48 of the label 22 . A tab 51 is formed by the line of partial severing or fold line 41 . The entire underside of the label 22 is preferably coated with adhesive 31 , and the adhesive 31 on the label 22 is undeadened except for a narrow margin between the cut line CL and the borderline 44 at one end portion of the label and a narrow margin between the cut line CL and the borderline 43 at the other end portion of the label 22 , as best shown in FIG. 4 . FIG. 10 shows the label 22 adhesively adhered to a polyethylene wrapping 52 for a garment which is hung on a generally triangular wire hanger 53 having a hook (not shown). The hanger 53 has two sloping wire portions 54 only one of which is partially shown. The angle the partial severing line 41 makes with the rest of the label 22 preferably matches the slope of the sloping wire hanger portion 54 . The label 22 is visible from the front of the wrapping 52 in FIG. 10 , except for the tab 51 , while the tab 51 is visible along with the rear of the wrapping 52 . The front part of the label 22 and the tab 51 can be color coded with a preprinted stripe or the like for ease of recognition. The partial severing 40 can be used as a fold line when used with a hanger (not shown) having a horizontal rung, in which case the tab 49 as well as the tab 51 are folded about fold line 40 and both the tab 49 and the tab 51 are folded onto and adhered to the rear side of wrapping 52 . In the event the label 22 is applied to a wrapped garment that will lie flat and will be stacked with other wrapped garments, the label 22 can be applied to the wrapping without folding any tab 49 or 51 .
The embodiment of FIGS. 12 through 14 is identical to the embodiment of FIGS. 1 through 11 , except as referenced below. The same reference characters are used in the embodiment of FIGS. 12 through 14 as is the embodiment of FIGS. 1 through 11 to designate like components with the addition of reference character “a”. The tag 22 a has a rectangular tab 55 which is the same size as the portion 49 and the tab 51 combined. The tab 55 can be folded about the line of partial severing 40 a and used with a hanger with a horizontal rung. The tab 55 can be folded so as to be at the rear of the garment wrapper. Alternatively, the tab 55 can be detached from the rest of the label 22 indicated at 56 . Once the tab 55 is detached it can be used as a separate label at a different location in the wrapping or elsewhere. The label part 56 can be applied to the wrapping in a vertical manner as shown.
The tag stock web 26 is preferably made of a paper or plastics material which is strong enough to serve as a hand tag. Because the tag 21 is doubled over at the tab 21 b as best shown in FIGS. 7 and 8 , the tag 21 has a double thickness at the tab 21 b . The tag 21 is thus stronger at the attacher hole 56 formed by the hole 38 and the slits 38 ′ which are aligned with the hole 38 . The tag material adjacent the slits 38 ′ grips the attacher needle of a tag attacher illustrated for example in U.S. design patent application Ser. No. 29/186,393. Accordingly, the tag stock can be thinner or of a lighter gauge than if the attacher hole 56 were through tag stock of single thickness. This results in a saving of tag stock.
The starting materials for making the composite web 20 are a release coated liner web 25 and tag stock web 26 . If desired, that liner 34 can be acquired in roll form and subsequently coated with a suitable uniform release coating such as silicone or a waxy release coat. The tag stock 26 is coated with the pressure sensitive or tacky adhesive 31 and the adhesive 31 is preferably applied in a uniform manner along and across the web 26 . This is known as a “full gum” coating. If desired, the adhesive 31 can be applied in a patterned coating.
The adhesive-coated tag stock web 26 is then pattern-coated with adhesive deadener 32 , for example, in a pattern as best shown in FIG. 4 . Thereafter, the release liner web 25 and the tag stock web 26 with its adhesive coated and partial adhesive deadener overcoat are laminated to provide the composite web 20 . Although the composite web 20 is shown to be “one-wide”, with one tag and one label side-by-side across the web 20 , the composite web 20 could initially be two-wide, three-wide or wider. Thereafter, the wide web could be slit into narrow one-wide webs. After lamination, the composite web 20 is preferably partially severed longitudinally along line 29 , that is, preferably leaving spaced lands 30 to help maintain the webs 23 and 24 in registration with each other and to help maintain the webs 23 and 24 adhered to the release liner web 25 until ready to be removed by the user. Although the tag web 23 and the label web 24 can be completely severed during production along cut line CL without cutting into or severing the release liner web 25 , it is preferred to cut the one tag 21 and one label 22 disposed side-by-side from the end portion of the web 20 following printing in the printer. It is noted that when a tag 21 and a label 22 and the underlying release liner 25 are cut from the remainder of the web 20 , the tag 21 and the label are easily manually peeled from the release liner 25 and the lands 30 are easily manually torn to separate a tag 21 from a label 22 . The lands are frangible and do not interfere with manual separation of the tag 21 and its side-by-side label 22 . When printing a paired tag 21 and its side-by-side label 22 , the tag 21 and the label 22 can be printed with the same or some of the same information so as to match the information on one with the other. Alternatively, the tag 21 and the label 22 can have different printed information.
According to a specific embodiment of method of making a composite web of record members, certain steps are: providing a longitudinally extending release liner 25 in web form having a liner 34 and a release coating 33 , providing a longitudinally extending web of printable tag stock 26 having a face 35 with a tacky adhesive 31 , applying adhesive deadener 32 in a pattern to the adhesive 31 to provide masked-off portions of the tag web 23 , laminating the tag stock web 26 to the release liner web 25 , at least partially severing the tag stock web 26 longitudinally between side edges 27 and 28 of the tag stock web 26 to provide a tag web 23 and a label web 24 in side-by-side relationship, the web 20 having tags 21 and labels 22 severed in pairs with the tag of each pair having a tab 21 c , wherein when the tag 22 of a pair is releasable from the release liner 25 , the tab 21 b is foldable and can be adhesively adhered to a portion of the remainder of the tag 21 a , and the portion of the tag 22 beyond the folded tab 21 b being masked-off with adhesive deadener to provide a substantially non-tacky tag. It is preferred that the adhesive deadener also be applied on both sides of the cut line CL of the label 22 as well as to the tag 21 so that when the cutter of the printer cuts a printed tag and label pair from the web 20 , the cutter cuts through deadened or detackified adhesive -which is less problemsome than cutting through undeadened tacky adhesive.
It is preferred to completely deaden or detackify the adhesive in the areas or zones depicted in the drawings and described herein. Thus, there is no exposed tacky planar surface on the tag 21 . By way of example, not limitation, a suitable adhesive deadener or detackifier is: UV Flexo Adhesive Deadner with Extra Brightener PT#AD1000FB sold by RAD-Cure Corp., 9 Audrey Place, Fairfield, N.Y. 07004 U.S.A.
In that the adhesive 31 and the adhesive deadener 32 are substantially clear and transparent, the customer is not aware that the tag 21 has deadened adhesive on its outer surface.
If desired, the adhesive 31 can be patterned, for example, either the adhesive area of the tab 21 b or the adhesive area of the portion 42 of tag portion 21 a can be free of adhesive 31 , if desired.
Other embodiments and modifications of the invention will suggest themselves to those skilled in the art, and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims. | There is disclosed a composite web of record members and a method of making same, the composite web provides tag/label pairs comprised of a tag and a label which can be feed through a printer and in which a tag/label pair can be cut from the tag web with its underlying release liner. The tag web 20 is simple to manufacture using readily available materials. The label 22 can be adhesively adhered to garment wrappings and the tag is rendered non-tacky by use of a patterned adhesive deadener. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a transaction system in which a portable token is used in conjunction with another device, often termed a terminal, to perform a transaction of some kind. At present, commonly available portable tokens are of a very simple passive kind and are often termed credit cards or service cards, the latter being usable in conjunction with data terminals to permit the withdrawal of cash from a bank account or the like. Tokens which are presently in common usage are passive, in the sense that they do not possess on-board processing or computing capability but instead carry an identity code which is compared by the co-operating data terminal with a code which is entered manually by the bearer of the token. This identity code comparison acts merely as a security check to confirm that the bearer of the token is indeed entitled to conduct the transaction. It has been proposed to enhance the usefulness and sophistication of such a token by including within it a data processing capability which would greatly extend the range of transactions and functions which it could be used to perform. The presence of such a capability on-board the token makes the interaction between it and the terminal much more critical and introduces difficulties which are not of real significance for a conventional passive credit card or cash dispenser card. The present invention seeks to provide an improved transaction system.
SUMMARY OF THE INVENTION
According to a first aspect of this invention, a transaction system includes a terminal; a token having an on-board data processing capability, means for inductively coupling the token with the terminal to permit data communication therebetween; means for transmitting data from the terminal to the token via a modulated carrier signal; and means for transmitting data from the token to the terminal by modulation of the level of the carrier signal at the terminal by the token as it draws power from the terminal.
This method of passing data from the token to the terminal avoids the need to include an autonomous power transmitter on board the token. Instead, the on-board data transmitter is entirely passive in the sense that it is merely necessary for it to modulate the load of a circuit tuned close to the frequency of the carrier signal which is transmitted to it by the terminal.
The system can take many forms, and the terminal may be a fixture associated with a retail outlet, a bank, or possibly mounted on a vehicle for the purpose of collecting fares or exacting tolls. It is envisaged that the transaction token itself will be very small, in the form of a thin device akin to the dimensions of a credit card so that it is easily portable and can be carried by a user without causing any inconvenience. To enable its bulk and weight to be minimised and to extend its useful operating life, preferably the power utilised by the on-board processors is obtained via said inductive coupling from the terminal, although if the token carries a volatile memory a small back-up electric cell may be needed to ensure preservation of the data during intervals between transactions.
According to a second aspect of this invention, a transaction system includes a terminal; a token having an on-board data processing capability; means for inductively coupling the token with the terminal to permit data communication therebetween and means associated with the terminal for transmitting a carrier signal and for detecting a variation in the power demand thereof which is indicative of the presence of an inductively coupled token.
This provision avoids the need for the terminal to continuously radiate the carrier signal at full power, regardless of whether the token is present. The terminal can normally operate on a very low level stand-by power and it is only when its inductive coupling system detects the presence of a token seeking to communicate with it that the power is raised to the operational level.
Since the power needed to energise the on-board processors of the token is derived from the terminal, means are provided on the token for monitoring the reception of this power to enable an orderly start-up of the processors to be initiated, and to provide an orderly shut-down in a manner which ensures preservation of data even in the event that the supply of power abruptly ceases due to the withdrawal of the token during the course of a transaction.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described by way of example with reference to the accompanying drawings, in which:
FIG. 1 shows part of a terminal intended to co-operate with a token,
FIG. 2 shows the organisation of the processing arrangement on the token,
FIG. 3 shows parts of the token which co-operates with the terminal, and
FIG. 4 is an explanatory diagram.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 there is shown therein in schematic form a terminal which forms part of the system. The terminal is a permanent fixture in a building or vehicle and is intended to co-operate with a token or card having processing capabilities, and which is therefore sometimes referred to as a Smart Card. Parts of the token itself are shown in some detail in FIG. 3. Only those circuit parts of the terminal relevant to the way in which it co-operates with the token, and transmits and receives data therebetween, are shown in FIG. 1. Data which is to be transmitted to the token is received at an input port 1 and is fed to a level shifter and amplifier 2 which renders the data, which is in a binary format, suitable for transmission to a variable frequency tuned circuit 3 so as to provide a frequency modulation of an output frequency, with the frequency modulation being representative of the information content of the data. The output of the tuned circuit 3 feeds an amplifier 4, the output of which is fed back via a feed-back loop 5 to the input of the variable tuned circuit 3 so as to constitute an oscillator arrangement. The frequency modulated output of the amplifier 4 is fed to a power amplifier 6, and thence to a tuned circuit 7 which consists of a capacitor 8 and an inductive loop 9. The inductive loop 9 is of some importance as it is this which co-operates with the token. In practice, the loop is fairly large, possibly of the order of 15 cms by 15 cms, and consisting of a considerable number of conductive turns so as to enhance the inducticve coupling with a similar but smaller coil carried by the token. The loop is set into the surface of the terminal on which the token is to be placed. If necessary, a location recess or the like is formed on the surface to ensure correct positioning of the token with respect to the loop.
The data is transmitted to the token as a frequency modulation, that is to say for binary digital data, a logic `1` state is represented by the transmission of one frequency from the tuned circuit 3, and a logic `0` state is represented by the transmission of a different frequency from the tuned circuit 3. It is arranged that the resonant frequency of the tuned circuit 7 lies between those two frequencies which represent the two logic states, so that the voltage level at point 10 is the same whichever frequency is being transmitted. This condition can be achieved by adjusting the value of the capacitor 8, and it has the effect of preventing the transmitted frequency modulation being converted directly into an amplitude modulation which could interfere with or be confused with the amplitude modulation signals originating with the token.
Prior to the transmission of the data which is applied to port 1, the terminal senses the proximity of a token by monitoring the power drawn by the token from the tuned circuit 7. The way in which the token modifies the power demand is explained in greater detail with reference to FIG. 3, but for the present purpose it is sufficient to note that the voltage at the point 10 decreases when a token is brought into close proximity with the inductive coil 9. During stand-by periods, a low-power oscillator 11 energises the tuned circuit 7 but being of low-power, its output voltage at point 10 drops significantly when the power radiated from the inductor 9 is absorbed by the token. The voltage at point 10 is monitored by a voltage monitor 12, which in response to a dip in volage level, energises the amplifier 6 so as to enable full power to be transmitted via the inductive loop 9.
To guard against the possibility of the voltage monitor inadvertently being triggered in response to passing bodies which are not a co-operating token, it is convenient to include a time reset within the voltage monitor 12 so that after a period of a second or two the power is returned to that of the stand-by low-power oscillator 11 in the event that a transaction is not commenced.
Data is therefore transmitted from the terminal to the card by means of frequency modulation of the carrier signal generated by the tuned circuit 3. By way of contrast, data passing from the card to the terminal consists of amplitude modulation of the same carrier signal which is radiated by the inductive loop 9. Data received in this way by the tuned circuit 7 is fed via a low-pass filter 15 to an amplifier 16. The following amplifier 17 acts as a comparator to compare the amplitude variation from the amplifier 16 with an integrated average level at point 18. The resulting variation in output level is fed via a switch 14 to a data output port 19. The switch 14 is implemented in the form of a comparator which is rendered inoperative when data is present on input port 1. It is necessary to render the switch 14 inoperative whilst data is being transmitted from the terminal to the card, since although the data is transmitted nominally in the form of a frequency modulation, nevertheless some degree of amplitude modulation may inadvertently occur and his may cause interference with, or corruption of, information being provided at the terminal 19.
The organisation of the processing capability on the token is illustrated in FIG. 2 in which a central processor 20 communicates with a program memory 21 via a latch 22 and with a data memory 23. An address decoder 24 links the processor 20 with the memories 21 and 23. The organisation and operation of this processing arrangement may be fairly conventional. The processing system derives its power from the energy transmitted by the inductive coil 9 of the terminal illustrated in FIG. 1, but to permit retention of volatile memory whilst a token is not within range of the terminal, a small back-up electric battery cell 25 may be provided. As its sole function is to simply preserve memory, its power requirements are minimal, and a small cell will have a very long useful lifetime. Use of a non-volatile memory, such as an electrically alterable read only memory (EAROM), obviates the need for the cell 25.
Data processed by those parts of the token which are to be described subsequently with reference to FIG. 3 are present on lead 26 as input data, whereas processed output data is provided on lead 27. Because the processor 20 derives its operational power from its proximity with the terminal, it is necessary to ensure an orderly start-up and shut-down of the processing arrangement as power becomes available and as power is withdrawn from it. Thus when the proximity of the terminal is detected, a signal is provided over reset lead 28 to initialise the processor 20 and to permit an orderly commencement of processing activity and communication with the terminal. Conversely, when the supply of power ceases, possibly by the token being abruptly withdrawn from the terminal by a user, an interrupt signal is presented over lead 29 and this gives a short interval enabling the processor 20 to close down without inadvertent loss of date. An orderly shut-down procedure need only take a millisecond or two during which power is available from a capacitive storage system, which is also illustrated diagrammatically in FIG. 3.
With reference to FIG. 3, the token consists of a small piece of rectangular plastic card shaped after the manner of a currently available cash-card or the like. It contains two inductive loops 30 and 31 connected in series, one of which is placed upon the upper surface of the card and the other of which is placed upon the lower surface of the card, the coils being rectangular and running around the perimeter of the card itself. The coils are preferably provided with a thin protective plastic coating. The size of the loops and the card which carries them are arranged to be somewhat smaller than the co-operating coupling inductive loop 9 of the terminal, so that it is merely necessary for the card to be placed on a receiving surface of the terminal with the coils 30 and 31 lying within an area bounded by the loop 9. In this way, the token receives the power which is radiated by the loop 9, and it is this absorption of power which is detected by the voltage monitor 12 of the terminal, thereby causing the terminal to transfer from low-power stand-by to full power operation.
The energy received by the token shown in FIG. 3 is accepted by a tuned circuit 32 consisting of a capacitor 33 in addition to the coils 30 and 31. The power so obtained is passed to a rectifier and voltage regulator 34 which is operative to generate a regulated voltage which is made available to other parts of the token shown in FIG. 3 and also at port 35 for utilisation by the processor system illustrated in FIG. 2. A large smoothing capacitor 36 is provided at the output of the voltage regulator 34 to give some degree of power storage. This energy is utilised during shut-down of the processor as indicated previously and permits a required regulated voltage level to be available at port 35 for a millisecond or so after reception of inductively coupled power ceases.
As previously mentioned, data is transferred from the token to the terminal by causing an amplitude modulation at point 10 of the level of the carrier frequency radiated by the terminal. This is achieved by applying the data for transmission to port 39 which operates a transistor switch 37 to bring a load 38 into and out of circuit in shunt with the coils 30 and 31, thereby modifying the impedance of the tuned circuit 32.
In this example, load 38 is a capacitor, so as to minimise resistive losses, and when it is switched into circuit as the switch 37 is made conductive it modifies the resonant frequency of the tuned circuit 32. Under both conditions, the tuned circuit 32 has fairly sharp resonance curves. These are shown in FIG. 4, the curve 60 corresponding to the condition existing when the switch 37 is non-conductive, and curve 61 applying when switch 37 is conductive. The carrier frequency received by the tuned circuit 32 from the terminal is indicated by point 62 on the frequency axis of FIG. 4, and this is equivalent to the transmission of the carrier having no frequency modulation. It is arranged that this frequency lies between the peak resonant frequencies of the two curves 60 and 61, so that at this frequency the signal level 63 produced across the capacitor 33 is the same whether or not the capacitor 38 is switched into circuit. This avoids an unwanted additional amplitide variation being imposed on the signal level which is sensed by the regulator 34. However, as the level 63 corresponds to different phase values depending on whether the tuned circuit is operating on curve 60 or 61, the effect on the tuned circuit 7 at the terminal is different in the two cases, as a different resultant phase vector is produced at the tuned circuit. Thus the signal level fed to the low pass filter 15 will vary as an amplitude modulation representing the received data, in response to the modulation imposed on the power which is drawn from the tuned circuit 7 by the tuned circuit 32 although the level of the power drawn will remain substantially constant whilst the signal level at point 10 varies due to the modulation of the phase.
The signal received by the tuned circuit 32 from the terminal is also fed to a power detection circuit 40 which consists primarily of two threshold comparators 41 and 42, the first of which monitors the received input voltage at a point 48 of a potentiometer 43, 44. When the potential on point 48 exceeds a reference value, a reset signal on output port 39 is altered to initiate operation of the processor 20. Thus the port 39 of FIG. 3 is connected to the lead 28 of FIG. 2. Comparator 41 has hysteresis so that it does not respond to minor or momentary changes or interruptions in the power received by the tuned circuit 32, and so that the reset signal reverts to its original state at a much lower input voltage level than that at which it initiates operation of the processor. It reverts at a voltage value which is less than that at which an interrupt signal is generated on port 49. In effect, therefore, the comparator 41 has a hysteresis loop in the sense that the state of the signal at port 39 reverts to its original value at an input voltage level which is lower than that at which operation of the processor is initiated. The threshold comparator 42 monitors the potential 45 on potentiometer 46, 47 to detect withdrawal of the applied power. On detection of loss of voltage, the interrupt signal is generated at port 49 which is connected to lead 29, thereby causing an orderly shut-down of the processor whilst residual power is still available on capacitor 36 to permit this to be done. Thus the interrupt signal occurs at a voltage within the hysteresis loop of the comparator 41.
The power received by tuned circuit 32 also of course, contains frequency modulation during those periods when data is being transmitted from the terminal to the token, and this is fed to the signal detector 50, which consists of a phase lock loop 51, comprising a phase detector 52, a low-pass filter 53 and a voltage controlled oscillator 54. The phase lock loop 51 is operative in known manner to extract the received data. The level of the received data is controlled by means of the adaptive threshold comparator 55 which consists of an integrator circuit 56 feeding into a comparator 57. The demodulated data output is provided on port 58 which in effect is the same as lead 26 which is shown in FIG. 2.
It will be appreciated therefore, that the token is almost wholely autonomous, requiring no major power supply and being operative whenever it is placed in close proximity to an inductively radiating terminal having the correct frequency. This permits both the token and the terminal to be constructed in a very robust fashion having a very high degree of electronic integrity rendering it resistant to physical attack or fraud. These considerations may be of some significance if the token is used for transactions having appreciable values. The invention need not, however, be used for transactions having a monetary value, and the token can be used as a security pass or the like to enable the bearer to operate a door or automatic barrier to gain access to a restricted area. In this instance, the token can, if desired, record the nature of the area entered and the time of entry. | A transaction system enables a portable token to co-operate with a fixed terminal. The token is inductively coupled to the terminal, and receives data from the terminal via a frequency modulated carrier signal. Data is sent from the token to the terminal by amplitude modulation of the carrier signal from the terminal, i.e. by modulating the power driven by the token from the terminal. The power needed to energize the on-board processing capability of the token is also obtained from the terminal via the inductive coupling. The token includes an arrangement for commencing processor operation in an orderly manner when it is brought into the proximity of the terminal, and for providing an orderly shut down when the token is withdrawn. | 6 |
FIELD OF THE INVENTION
[0001] The present invention is directed to heat exchangers, and in particular to radially fired heat exchangers with multiple rings of tubes.
BACKGROUND OF THE INVENTION
[0002] For many years, commercial water heaters have been constructed using burners and heat exchanger water flow tubing. Commercial water heaters must be capable of producing and heating water with tens of thousands, and even hundreds of thousands, of BTUs. Further, in modern commercial applications, the emission standards for water heaters are strictly regulated. Complete burning of fuel is controlled so that hydrocarbon emissions are very low. In many existing commercial water heaters, natural gas is burned in an environment of forced air.
[0003] Many direct-fired, commercial water heating systems are known in the industry. One commercially available system, disclosed in U.S. Pat. No. 4,261,299, utilizes a horizontal combustion chamber around which water flows through a double-walled shell that is wound repeatedly around the combustion chamber with spaces between each successive winding to accommodate a countercurrent flow of exhaust gases.
[0004] Another system, disclosed in U.S. Pat. No. 4,938,204, utilizes a dual tank design. One tank contains the primary heat exchanger in which a horizontally mounted conventional burner heats water flowing through two-pass, U-bend fire tubes. Exhaust gases that exit the primary heat exchanger at 350 degrees Fahrenheit to 400 degrees Fahrenheit are routed to a secondary heat exchanger where they are passed countercurrent to ambient makeup water to preheat the water before entering the primary exchanger. Makeup air is preheated to over 200 degrees Fahrenheit by passing it through ductwork which surrounds the exhaust gases exiting the secondary exchanger.
[0005] Some of the newer prior art systems utilize primary exchanger sections comprising a vertically-disposed, radially-directed, cylindrical burner in combination with a plurality of fixed length, copper-finned tubes arranged vertically around the burner. Water flows through the tubes, which are typically connected to headers located above and below the combustion zone, either in single or double-pass configurations. In some heaters, the copper-finned tubes are intermeshed and completely surround the burner to enhance heat transfer. Difficulties have been experienced with these heaters, however, because of the length of the tubing required to allow for effective heat exchange and the limited amount of expansion or contraction that can be accommodated with the fixed tube design.
[0006] U.S. Pat. No. 5,687,678 discloses a commercial water heater apparatus, including a housing, a radial-fired burner within the housing, a single continuous, multiple-loop, finned coil tubing heat exchanger for circulating water around the burner, having at least a first set of inner coils forming a coil trough therebetween and a second set of outer coils nested within the coil trough formed by the inner set of coils, the outer set of coils forming a second coil trough around the exterior thereof, and a coil baffle interposed in the second exterior trough for deflecting heat adjacent to the second set of coils.
[0007] Highly efficient transfer of heat energy from the burned fuel to the water has been an object of commercial water heater design for a number of years. In accomplishing the high efficiency heat transfer from the combustion products to the circulated water, in many systems a certain amount of water vapor in the combustion gases will be condensed from the combustion gas. This condensate is typically highly acidic, having PH values in the range of between 2 to 5, depending upon the chemical constituents of halogenated hydrocarbon in the natural gas and air mixture. For example, increased halogen content of the natural gas and air mixture can greatly increase the acidity of the condensate. Therefore, various commercial water heaters are simply designed to operate below the efficiency at which large quantities of condensate are likely to form so that the acidic vapors are discharged in vapor form in high temperature exhaust gas.
[0008] Notwithstanding the systems disclosed in the prior art, it would be beneficial to have a radial-fired heat exchanging apparatus which has a compact configuration and which can quickly and efficiently transfer heat to water passing through the tubes.
SUMMARY OF THE INVENTION
[0009] An exemplary embodiment is directed to a heat exchanger having a radial heat source. The heat exchanger has a first header, a second header, first tubes and second tubes. The first header is configured to allow liquid to enter and exit the heat exchanger. The second header is spaced from the first header and has at least one lower baffle provided therein. The first tubes extend from the first header to the second header, with the first tubes being spaced proximate to the redial heat source. The second tubes extend from the first header to the second header, with the second tubes being spaced from the radial heat source a greater distance than the first tubes. Liquid with the lowest velocity enters the second header through the second tubes proximate the lower baffle to provide for the shortest return path through the first tubes to equalize the flow rate through each first tube.
[0010] Another exemplary embodiment is directed to a heat exchanger having a radial heat source. A first header of the heat exchanger has a first chamber for receiving a liquid as the liquid enters the heat exchanger and a second chamber for receiving the liquid prior to the liquid exiting the heat exchanger. A second header is spaced from the first header. First tubes extend from the second chamber of the first header to the second header, with the first tubes being spaced proximate to the radial heat source. Second tubes extend from the first chamber of the first header to the second header, with the second tubes being spaced from the radial heat source a greater distance than the first tube. The circumferential spacing between the first tubes provides a gap allowing for the proper heating of the first tubes while allowing sufficient heat to reach the second tubes to properly heat the second tubes.
[0011] Another exemplary embodiment is directed to a heat exchanger having a radial heat source. The heat exchanger has a first header through which liquid enters and exits the heat exchanger. A second header is spaced from the second header and has at least one lower baffle provided therein. First tubes extend from the first header to the second header, with the first tubes being spaced proximate to the radial heat source. An enhancement device is positioned in respective tubes of the first tubes. The enhancement device creates a water vortex in the first tubes wherein a high velocity water stream which flows through the first tubes is in contact alternately with a hot side and then a cooler side of the first tubes, wherein boiling of the water in the first tubes is prevented.
[0012] Most copper-fin radially-fired heat exchangers in the market today obtain increased capacity by using longer tubes or increasing the number of tubes in a single ring. Using multiple rings of tubes as described herein effectively lengthens the tube linear distance without increasing the height of the heat exchanger. Consequently, the heat exchanger is half the size of a comparable single-ring heat exchanger.
[0013] Another exemplary added benefit of multiple rings is the increased heat transfer coefficient on the gas side of the tubes. This is due to the increased velocity of the gas since the flow area is reduced because the heat exchanger is shorter. Higher efficiency with less material is achieved.
[0014] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an isometric view of one embodiment of the heat exchanger assembly of the present invention, the heat exchanger being enclosed by a shell.
[0016] FIG. 2 is a cross-sectional view of the heat exchanger assembly of FIG. 1 , taken along the line 2 - 2 of FIG. 1 , showing finned inner tubes with enhancement device positioned therein.
[0017] FIG. 3 is an exploded perspective view of the heat exchanger assembly of FIG. 1 .
[0018] FIG. 4 is an exploded perspective view of a two-pass heat exchanger housed in the heat exchanger assembly of FIG. 1 .
[0019] FIG. 5 is a cross-sectional view of the inner and outer tubes of the heat exchanger taken along line 5 - 5 of FIG. 4 .
[0020] FIG. 6 is a top view of the heat exchanger of FIG. 4 .
[0021] FIG. 7 is a cross-sectional view of the heat exchanger of FIG. 4 , taken along the line 7 - 7 of FIG. 8 , showing outer tubes in cross-section.
[0022] FIG. 8 is a top isometric view of a top header of the heat exchanger of FIG. 4 .
[0023] FIG. 9 is a top view of the top header of the heat exchanger of FIG. 4 .
[0024] FIG. 10 is a bottom isometric view of the top header of the heat exchanger of FIG. 4 , showing chambers through which the liquid flows.
[0025] FIG. 11 is a cross-sectional view of the top header of the heat exchanger of FIG. 4 , taken along the line 11 - 11 of FIG. 9 , showing the inlet pipe and the inner and outer chambers.
[0026] FIG. 12 is an isometric view of a bottom header of the heat exchanger of FIG. 4 .
[0027] FIG. 13 is a top view of the bottom header of FIG. 12 .
[0028] FIG. 14 is a bottom view of the bottom header of FIG. 12 , showing a baffle provided therein to deflect the liquid to allow the bottom header to provide a reverse return configuration.
[0029] FIG. 15 is a cross-sectional view of the bottom header of the heat exchanger, taken along the line 15 - 15 of FIG. 14 .
[0030] FIG. 16 is an isometric view of a top tube sheet of the heat exchanger of FIG. 4 .
[0031] FIG. 17 is an isometric view of a bottom tube sheet of the heat exchanger of FIG. 4 .
[0032] FIG. 18 is an isometric view of an enhancement device which is inserted into the inner tubes of the heat exchanger.
[0033] FIG. 19 is a top isometric view of an exemplary alternate top header of the heat exchanger, the alternate header having baffles to allow the liquid to make four passes through the tubes.
[0034] FIG. 20 is a bottom isometric view of the alternate top header of the heat exchanger, showing chambers and baffles which control the flow of the liquid.
[0035] FIG. 21 is a bottom view of the alternate top header of FIG. 20 .
[0036] FIG. 22 is a bottom isometric view of an alternate bottom header of the heat exchanger, the alternate header having baffles to allow the liquid to make four passes through the tubes.
[0037] FIG. 23 is a top isometric view of the alternate bottom header of the heat exchanger.
[0038] FIG. 24 is a bottom view of the alternate bottom header of FIG. 22 .
DETAILED DESCRIPTION OF THE INVENTION
[0039] The radially-fired heat exchanger 10 of the present invention can be used in a gas-fired hot water boiler. In such a hot water boiler, air and fuel are pre-mixed and ignited through the radial-fired burner 8 . The closed-loop heat exchanger 10 is designed for counter-flow operation to optimize heat transfer.
[0040] In general, when heat is required (as indicated by water temperature), an operating temperature control switch signals to a micro-processor-based flame safeguard programmer. The programmer energizes a blower motor and an air-flow differential pressure switch, providing a specific prepurge time. This allows the boiler to purge any residual gas.
[0041] After the purge is complete and correct air flow is established, the programmer powers an ignition transformer, and a gas pilot is spark-ignited. When the pilot flame is detected by a UV sensor, a signal is sent to the programmer which then opens both main gas valves. The main burner 8 ignites and the pilot is de-energized. Alternatively, the radially-fired heat exchanger may use direct light technology. When the desired water temperature is reached, the operating control switch opens and the programmer closes both main gas valves.
[0042] When the water temperature is reduced by the load on the system, the operating temperature control switch will close again. This sequence recycles automatically to the start of the cycle provided that the limits on water flow and gas pressure are met.
[0043] A radial-fired, fan-assisted burner 8 with a screen-type diffuser fits vertically into the circular heat exchanger 10 . This vertical burner/heat exchanger 10 design produces a higher thermal efficiency than is possible with any conventional horizontal gas-fired boiler. Flame distribution is controlled by the pre-calculated free area of the screen. The fuel mixture is controlled by calibrated injection ports and an adjustable air shutter to produce a clean-burning blue flame. The burner 8 can be quickly and easily removed from the exchanger 10 for cleaning or inspection.
[0044] The radial-fired burner is designed to provide uniform radial jets of flame, the tips of which jets of flame are adjacent to but spaced apart from the innermost portions of the heat exchanger 10 . The heated gases from the flames flow generally upward, primarily radially outward, but also with a component of upward flow due to heat expansion at the flames and then subsequently a downward flow after the heated exhaust gas exchanges its heat to the heat exchanger tubing such that the exhaust gases move downward along the exterior of the heat exchanger tubing 12 , 14 to exhaust gases toward the lower end of the tubes and radially outward therefrom. Because of the completeness of the burning, the exhaust gases may be generally discharged with minimal impact on the environment, or, if additional purification is required by any particular governmental standards, may be further treated prior to discharge.
[0045] The centrally located burner 8 has a cylindrical burner surface, which is preferably formed of a thin sheet of pressed high-temperature metal fibers having perforations uniformly therethrough so that the forced gas and air mixture is forced out of the perforations through cylindrical burner surface where it is ignited and burns to produce heat, which is transferred to the tubes 12 , 14 of the heat exchanger 10 both by convection of the heated gases and also by radiation.
[0046] The heat exchanger 10 has integral tubes 12 , 14 , arranged vertically with removable cylindrical headers 16 , 18 . This tube configuration provides a high heat transfer ratio and a fast response to load requirements. Since the tubes 12 , 14 completely surround the burner 8 , ambient losses are eliminated. All the hot gases are forced over the tubes, maximizing heat transfer and producing the high efficiency.
[0047] With reference to FIGS. 1 through 18 , an exemplary first embodiment of the heat exchanger 10 is shown. The heat exchanger 10 has a top header 16 , a bottom header 18 , a first ring of tubes 12 , a second ring of tubes 14 , a top tube sheet 20 and a bottom tube sheet 22 . As best shown in FIGS. 2 through 7 , the first ring of tubes 12 and the second ring of tubes 14 extend between the top header 16 and the bottom header 18 . The top tube sheet 20 and the bottom tube sheet 22 cooperate with the tubes 12 , 14 to maintain the tubes 12 , 14 in position relative to each other.
[0048] As best shown in FIGS. 1 through 3 , shell halves 24 , 26 cooperate with reinforcing/fastening ribs 28 , flanges 30 , gaskets 32 and gaskets 34 to encase the heat exchanger 10 , thereby providing a sealed tight shell which retains the heat from the burner 8 and allows water or other liquids to flow through the headers 16 , 18 and tubes 12 , 14 .
[0049] The exemplary heat exchanger 10 shown has two rings of tubes 12 , 14 through which water or other liquid flows. In the embodiment shown, the tubes 12 , 14 are made from copper, but other material having the appropriate strength and heat stability and transfer characteristics can be used, such as, but not limited to, copper nickel, aluminum, stainless steel and alloys thereof. While two rings of tubes 12 , 14 are shown, any number of multiple rings may be used without departing from the scope of the invention.
[0050] The tubes 12 , 14 may have radially extending fins to allow for more efficient transfer of heat. As is shown in the drawings, the tubes 12 , 14 extend radially about an opening 36 in which the burner 8 is positioned. The inner tubes 12 are closer to the opening 36 and the burner 8 , while the outer tubes 14 are spaced further from the opening 36 . The location of the rings of tubes 12 , 14 is not arbitrary, but designed to provide maximum efficiency. If the diameter D 1 of the first ring is too small, the tubes 12 will be too close to the burner 8 , which will cause combustion problems, i.e. high carbon monoxide (CO). It is, therefore, not desirable to have the flames of the burner 8 contact any surface of the inner tubes 12 or the outer tubes 14 , but rather have the heated gases from the flames surround the tubes 12 , 14 , as previously described.
[0051] Referring to FIG. 5 , the circumferential tube spacing S 1 , S 2 from one tube 12 , 14 to another is critical for pressure design and gas flow design. If the gap or spacing S 1 between the inner tubes 12 is too wide, the inner tubes 12 would not be properly heated, resulting in an underperforming design. If the gap or spacing S 1 between the inner tubes 12 is too narrow, the outer tubes 14 would not be properly heated, again resulting in an underperforming design. Stated differently, the circumferential spacing between first tubes provides a gap which allows for the proper heating of the first tubes while allowing sufficient heat to reach the second tubes to properly heat the second tubes.
[0052] Once the proper diameter D 1 and proper spacing S 3 ( FIG. 7 ) of the inner tubes from the burner 8 is determined, and once the proper spacing S 1 between the inner tubes 12 is determined, the number of inner tubes 12 needed can be determined, as the diameter D 1 of the inner tube circle and the spacing S 1 determines the number of tubes 12 in the inner ring. In addition, once the proper spacing S 4 ( FIG. 7 ) of the outer tubes 14 from the inner tubes 12 is determined, and once the proper spacing S 2 between the outer tubes 14 is determined, the number of outer tubes 14 can be determined, as the diameter D 2 of the outer tube circle and the spacing S 2 determines the number of tubes 14 in the outer ring. The diameter D 2 of the second ring of tubes is dependent upon the diameter D 1 of the first ring of tubes. The circumference of each ring increases by about 3 times the diameter increase. The number of tubes provided in each additional ring is calculated using a similar method. The diameters of the inner tubes 12 and outer tubes 14 may be the same or may be different depending upon the flow characteristics required.
[0053] Referring to FIGS. 16 and 17 , once the proper spacing is determined, openings 38 , 39 are formed in the top tube sheet 20 and the bottom tube sheet 22 . The openings 38 , 39 are spaced to correspond to the spacing of the inner and outer tubes 12 , 14 . The tubes 12 , 14 are inserted into the openings 38 , 39 and are maintained in position relative thereto.
[0054] The number of tubes 12 , 14 in each ring determines the water velocity through them. This velocity must be high enough to prevent boiling and scaling problems, but low enough to prevent erosion. Therefore, when designing a multiple-ring radially-fired heat exchanger 10 , it is important to properly space the tubes 12 , 14 to obtain the optimum velocity of the liquid to facilitate maximum efficiency. As more tubes 14 are provided in the second ring, the velocity of the liquid in the tubes 12 , 14 becomes an issue. Consequently, the velocity in both rings must be adequate to allow for the proper heat transfer in both rings. If additional rings are provided, the system must be designed to allow for all tubes in all rings to have adequate velocity of the liquid. In the exemplary embodiment show, the optimum velocity is between 3 ft/s to 8 ft/s, although other flows are possible.
[0055] As shown in FIGS. 8 through 11 , the top or upper header 16 has an inlet pipe 40 which allows liquid to flow into an outer chamber 42 of the header 16 . An outlet pipe 44 extends from an inner chamber 46 to allow liquid to flow from the inner chamber 46 out of the heat exchanger 10 . In the exemplary embodiment shown in FIGS. 8 through 11 , the top header 16 is cast from material having the appropriate strength and heat resistant characteristics, such as, for example, cast iron. Because the top header 16 is cast, the transition 48 between the inlet pipe 40 and the outer chamber 42 and the outlet pipe 44 and the inner chamber 46 can be configured to have smooth surfaces and to optimize their geometry to reduce the pressure drop as the flow of the liquid is directed through these areas. All the surfaces of the top header 16 can be controlled to allow minimal pressure drop. In addition, as the inlet and outlet pipes 40 , 44 are cast, they may be made to have an oblong or oval configuration. This configuration also reduces the pressure drop associated with the moving liquid. Each of the multiple chambers 42 , 46 of the top header 16 must be configured to meet the flow requirements of the system, i.e., ensure adequate flow rate and velocity while minimizing pressure drop.
[0056] The top header 16 has openings or sensor wells 50 which extend into the outlet pipe 44 or other locations along the top header 16 . The wells 50 may have sensors 52 positioned therein for sensing water temperature, water level, flow rate, or any other relevant properties. As the top header 16 is cast, the wells 50 may be molded into the outlet pipe 44 to provide a direct path for the sensors 52 to be inserted at meaningful locations of the heat exchanger 10 , i.e., directly into the burner compartment.
[0057] While the top header 16 is shown as a cast, single piece, components of the top header may be manufactured as separate pieces and assembled together by welding or the like.
[0058] As shown in FIGS. 12 through 15 , the bottom header 18 has a chamber 54 and a baffle 56 . The bottom or lower header 18 is also cast from material having the appropriate strength and heat resistant characteristics, such as, for example, cast iron. Because the bottom header 18 is cast, all surfaces of the chamber 54 can be configured to have smooth surfaces and to optimize their geometry to reduce the pressure drop as the flow of the liquid is directed through these areas. The chamber 54 of the bottom header 18 must be configured to meet the flow requirements of the system, i.e., ensure adequate flow rate and velocity while minimizing pressure drop.
[0059] While the bottom header 18 is shown as a cast, single piece, components of the bottom header may be manufactured as separate pieces and assembled together by welding or the like.
[0060] In the embodiment shown in FIGS. 1 through 18 , the heat exchanger 10 is shown as a two-pass system. Relatively cool pressurized liquid enters the inlet pipe 40 and flows through the outer chamber 42 of the top header 16 into the outer ring of finned tubes 14 . The liquid is forced to flow into all of the tubes 14 of the outer ring. However, the pressure associated with the liquid entering the outer tubes 14 furthest from the inlet pipe 40 is less than the pressure associated with the liquid entering the outer tube 14 closest to the inlet pipe 40 . The liquid flows through the outer tubes 14 into the bottom header 18 . As the liquid flows through the outer tubes 14 , the heat generated by the burner 8 causes the temperature of the liquid to increase.
[0061] Once the liquid enters the bottom header 18 , the pressure of the liquid forces the liquid through the chamber 54 of the bottom header 18 and through the inner tubes 12 . The baffle 56 of the bottom header 18 causes the liquid with the lowest velocity to have the shortest return path through the inner tubes 12 and the liquid with the highest velocity to have the longest return path. Because of the reverse return configuration, the flow rate through each tube 12 is equalized. The bottom header 18 is designed to provide adequate resistance to flow to prevent “short circuiting” of the flow. The path of least resistance is the return tube closest to the supply tube.
[0062] The partially heated pressurized liquid is forced into all of the tubes 12 of the inner ring. The liquid flows through the inner tubes 12 into the inner chamber 46 of the top header 16 and out the outlet pipe 44 . As the liquid flows through the inner tubes 12 , the heat generated by the burner 8 causes the temperature of the liquid to continue to increase. As the inner tubes 12 are closer to the burner 8 , the change of temperature of the liquid in the inner tubes 12 is greater than the change of temperature of the liquid in the outer tubes 14 .
[0063] As the temperature of the surfaces of the inner tubes 12 which are closer to the burner 8 can be significantly greater than the temperature of the surfaces of the inner tubes 12 away from the burner 8 , it is beneficial to have a method to “mix” the liquid as it flows through the inner tubes 12 . In order to accomplish this, enhancement devices 60 , as best shown in FIGS. 2 and 18 , are used in the inner ring of tubes 12 to create a water vortex in the tubes 12 . This vortex ensures that there is a high velocity water stream in contact alternately with the hot side and then cooler side of the tube 12 . This action helps to prevent boiling of the water in the inner ring of tubes 12 .
[0064] Referring to FIGS. 19 through 24 , an alternate exemplary embodiment of a top header 116 and bottom header 118 is shown. In this embodiment, baffles 158 are provided in the outer chamber 142 of the top header 116 and baffles 156 are provided in the chamber 146 of the bottom header 118 , to convert the heat exchanger 110 from a two-pass to a four-pass. In this configuration, the inner and outer rings 112 , 114 are divided in half, allowing the liquid to flow through only half of the tubes in any ring at any time. This allows the liquid to make four passes through the tubes 112 , 114 rather than two as described above. Additional baffles may be added to alter the number of passes.
[0065] Most copper-fin radially-fired heat exchangers in the market today obtain increased capacity by using longer tubes or increasing the number of tubes in a single ring. Using multiple rings of tubes as described herein effectively lengthens the tube linear distance without increasing the height of the heat exchanger. Consequently, the heat exchanger 10 is half the size of a comparable single-ring heat exchanger.
[0066] An exemplary added benefit of multiple rings is the increased heat transfer coefficient on the gas side of the tubes. This is due to the increased velocity of the gas since the flow area is reduced as the heat exchanger 10 is shorter. Higher efficiency with less material is achieved.
[0067] While the invention has been described with reference to a preferred exemplary embodiment, it will be understood by those skilled in the art that various changes, alterations and modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the broadest interpretation of the appended claims to which the inventors are legally entitled. | The heat exchanger with a radial heat source has a first header, a second header, first tubes and second tubes. The first header is configured to allow liquid to enter and exit the heat exchanger. The second header is spaced from the first header and has at least one lower baffle provided therein. The first tubes extend from the first header to the second header, with the first tubes being spaced proximate to the radial heat source. The second tubes extend from the first header to the second header, with the second tubes being spaced from the radial heat source a greater distance than the first tubes. An enhancement device may be positioned in respective tubes of the first tubes to create a water vortex in the first tubes wherein boiling of the water in the first tubes is prevented. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a light beam gun device used with game players, more particularly, a wireless light beam gun device used with game player running shooting games; the wireless light beam gun device utilizes wireless transmission means, e.g., infrared (IR) or radio frequency (RF), to capture the blips on the screen or calculate the values of the blips on X and Y axes and then transmit back to the game player, thus increasing the space for users to move during shooting games, and the interaction and enjoyment for the user during the shooting game.
[0003] 2. Description of the Prior Art
[0004] Recently for video shooting games, the common joysticks are often replaced by light beam guns for aiming at the targets on the screen, so as to simulate the reality in the games.
[0005] Based on the prior arts, the conventional wired light beam guns, in accordance with the ways of the gaming software design run by game players, are categorized into the first-generation wired light beam gun, wherein the axis value of the aiming points from the light beam gun can be calculated by the accordance between the game player and the gaming software itself; and the second-generation wired light beam gun, wherein the axis value of the aiming points are to be calculated first by the light beam gun device, and then the axis value is to be transmitted back to the game player. Please refer to FIG. 1, which shows the block diagram of the first-generation wired light beam gun connecting to the game player. The signal cable of the first-generation wired light beam gun is directly connected to the joystick connector of the game player 1 ; when the user aims at an aiming point on the screen 2 , the photosensor 5 will then receive the blip signal produced from the aiming point hit on the screen 2 by the electron of the cathode-ray tube of the television 2 first, and then transmit the captured blip signals back to the game player 1 . The gaming software run by the game player 1 will be able to calculate the coordinates of the aiming point on the screen corresponding to the blip based on the blip signal in accordance with the video signal 10 of the game player 1 . Furthermore, during the state of the game player 1 reading the data from the light beam gun, the communication interface 3 in the wired light beam gun can transmit the data from the button 9 back to the game player 1 .
[0006] In addition, the design of the conventional second-generation wired light beam gun is to add a television video signal contact, thus the light beam gun, with the added contact, can utilize the HV_sync separator 7 to obtain the H_sync signal 212 or V_sync signal 211 . Subsequently please refer to FIG. 2, which is the block diagram of the second-generation wired light beam gun connecting to the game player. The signal cable of the second-generation wired light beam gun, directly connected to the joystick connector of the game player 1 , utilizes the HV_sync separator 7 to obtain the H_sync signal 212 as well as the V_sync signal 211 ; also the V_sync signal 211 can be used for resetting the Y coordinate counter 23 , which is used for counting the numbers of the H_sync signal 212 . When the photosensor 8 of the wired light beam gun receives the blip hit on the screen by the electron of the cathode-ray tube of the television 2 first, the photosensor 8 of the wired light beam gun is to keep the valued already counted by the Y coordinate counter 23 for Y data buffer 25 (which means that there already occurred several H_sync signals 212 in the period of time between resetting and reception of blips) until the arrival of the V_sync signal 211 obtained by the next video signal, and then the value stored in the Y data buffer 25 and the numbers counted by the Y coordinate counter are to be deleted.
[0007] On the other hand, the X coordinate data are to be decided by the period of time between any H_sync pulse wave to the next H_sync pulse wave, and the H_sync signal 212 is used for resetting X coordinate counter 22 , which is used for counting pulse waves produced by a high-frequency clock oscillator 6 . When the user aims at an aiming point on the screen, the photosensor 8 of the wired light beam gun then receives the blip signal hit on the screen by the electron of the cathode-ray tube of the television 2 , and such blip signal is to keep the value counted by the X coordinate counter 22 for the X coordinate data buffer 24 until the game player has read the X coordinate data, and then the value stored in the X coordinate data buffer 24 is to be deleted (which means there already occurred several pulses generated by the high-frequency clock in the period of time between deletion and reception of blip signals; in other words, it depends on the length of time between deletion and reception of blip signals). After procedures described above, the values of the aiming point corresponding to the X and Y coordinates are to be obtained by the wired light beam gun; thus the light beam gun, during the game player 1 reading data from the light beam gun, is to transmit the data of button 9 and the X and Y coordinates back to the game player 1 .
[0008] From the description of the workings regarding the first and second generation wired light beam guns, it is to be noticed that, whenever light beam guns are to conduct signal processing or calculate the coordinates of the X and Y axes, signal cables are always required to connect the signal transmission between the light beam gun and the game player 1 . Furthermore, during a shooting game, movement of the user is usually confined by the signal cable of the light beam gun, with the operating and stretching space of the user being limited; thus the user cannot fully enjoy the game, because the interaction between the user and the game and the overall enjoyment of the user are diminished.
SUMMARY OF THE INVENTION
[0009] In view of the drawbacks of the aforementioned prior arts, the invention provides a light beam gun, with a wireless transmitting device and a wireless receiving device to replace the signal cable of the conventional wired light beam gun, thus not only expanding the space for the user to move during the shooting game, but also increasing the interaction between the user and the shooting game and the overall enjoyment. As a result, the invention enables the user to fully enjoy the game, thus elevating the playability of the game.
[0010] The main object is to provide a wireless light beam gun device and method thereof, whereby the numbers of pulses of the V_sync signals from the video signals are first to be counted respectively at both the end of the wireless game player and the end of the wireless light beam gun, and then, based on the ratio of both numbers of pulses, the blip coordinate data are to be calculated in the cycle of video signals, or the blip signals generated at the end of the game player are to be reduced.
[0011] Another object of the invention is to provide a wireless light beam gun device and method thereof, whereby the parameter data of the video signal cycles are to be calculated, and then, based on the ratio of pulses of the video signals at both the end of the game player and the wireless light beam gun, the blip coordinate data are to be obtained.
[0012] Yet another object of the invention is to provide a wireless light beam gun, whereby the parameter needed for calculating the video signal cycles can be captured based on the V_sync signals.
[0013] Since the user, when using the conventional wired light beam gun during the shooting game, can only adjust the space for movement in accordance with the length of the signal cable of the light beam gun, without being able to make larger motions, thus diminishing the interaction between the user and the game player and the overall enjoyment, the invention therefore utilizes the wireless devices like infrared or radio frequency to replace the signal cables of the conventional light beam guns, comprising the device at the end of the game player and the device at the end of the light beam gun, wherein the device at the end of the game player receives the video signals on the screen, and then utilizes, by using the V_sync signals, the ratio value of the number of pulses counted respectively at both the end of the game player and the end of the light beam gun, to calculate the blip coordinate data in the video signal cycles, or reduce a blip signal; whereas the video signal cycles can be calculated in the wireless light beam gun through a set of parameter data. The wireless light beam gun of the invention can not only prolong the lifespan of usage for the light beam gun, but also enable the user to fully enjoy the shooting game, with the operation of the light beam gun being handy and dexterous for the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims and accompanying drawings that are provided only for further elaboration without limiting or restricting the present invention, where:
[0015] [0015]FIG. 1 shows a block diagram of the conventional first-generation wired light beam gun being used in shooting games;
[0016] [0016]FIG. 2 shows a block diagram of the conventional second-generation wired light beam gun used in shooting games;
[0017] [0017]FIG. 3A shows a wireless game player end device of the second-generation light beam gun of the invention, wherein the circuit block diagram for capturing parameter is contained;
[0018] [0018]FIG. 3B shows an circuit block diagram of the device at the end of the second-generation wireless light beam gun of the invention;
[0019] [0019]FIG. 4A shows another embodiment of the wireless game player end device of the second-generation light beam gun of the invention, wherein the circuit block diagram for capturing parameter is contained;
[0020] [0020]FIG. 4B shows an circuit block diagram for another embodiment of the wireless light beam gun end device of the second-generation light beam gun of the invention;
[0021] [0021]FIG. 5A shows a wireless game player end device of the first-generation wireless light beam gun of the invention, wherein the circuit block diagram containing gate circuit is included;
[0022] [0022]FIG. 5B shows a block diagram of the device at the end of the first-generation wireless light beam gun of the invention;
[0023] [0023]FIG. 6A shows another embodiment of the wireless game player end device of the first-generation light beam gun of the invention, wherein the circuit block diagram having gate circuit is contained;
[0024] [0024]FIG. 6B shows an circuit block diagram for another embodiment of the wireless light beam gun end device of the first-generation light beam gun of the invention;
[0025] [0025]FIG. 7A shows an circuit block diagram of the wireless game player end device of yet another embodiment of the second-generation wireless light beam gun of the invention;
[0026] [0026]FIG. 7B shows an circuit block diagram of the wireless light beam gun end device of yet another embodiment of the second-generation wireless light beam gun of the invention;
[0027] [0027]FIG. 8A shows an circuit block diagram of the wireless game player end device of a further embodiment of the second-generation wireless light beam gun of the invention;
[0028] [0028]FIG. 8B shows an circuit block diagram of the wireless light beam gun end device of a further embodiment of the second-generation wireless light beam gun of the invention;
[0029] [0029]FIG. 9 shows an circuit block diagram of a further embodiment of the invention; and
[0030] [0030]FIG. 10 shows a circuit block diagram of a further embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The invention provides a method for calculating coordinates, used in the second-generation light beam gun to generate the blip coordinate data corresponding to the aiming point on a screen, and then output to a game player; such a wireless light beam gun comprises a wireless game player end device and a wireless light beam gun end device. The aforementioned method comprises:
[0032] Providing with a video signal to the wireless game player end device, for capturing the parameter data needed for calculating the video signal cycles;
[0033] Providing with an oscillator counting circuit of the wireless game player end, for counting the largest pulse number of the V_sync signals of the video signals;
[0034] Providing with an oscillator counting circuit on the wireless light beam gun end, for counting the largest pulse number of the V_sync signals of the video signals; and
[0035] Calculating the blip coordinate data calculated from the video signal cycles by the parameter data out of the blip signals collected in the wireless light beam gun end device, according to the ratio for both the largest pulse number of the V_sync signals of both the wireless game player end device and the wireless light beam gun end device.
[0036] According to the method for calculating coordinates of the invention, please refer to FIG. 3A and 3B, which respectively show the circuit block diagram of the wireless game player end device and the wireless light beam gun end device of the second-generation light beam gun of the invention. In this embodiment of the invention, all the signal triggering is of the front edge triggering. When the game player end of the wireless light beam gun receives the video signal 10 transmitted from the game player 1 to television, PC CRT Monitor or CRT TV, it is to utilize the HV_sync separator 7 to extract out the V_sync signal 211 and the H_sync signal 212 , and then utilizes the V_sync signal 211 to activate the M_Total counter 202 ; before activation, the game player end of the wireless light beam is to keep first the value counted by the M_Total counter 202 in the M_Total buffer 203 . After activation, the M_Total counter 202 then begins to count the number of pulses generated by the high-frequency clock oscillator 6 . In order for the calculating circuit to come up with more accurate numbers, the embodiment of the invention gives both the parameter capture circuit 207 and the M_Total counter 202 the same high-frequency clock oscillator 6 . At this time the parameter capture circuit 207 is, according to both the V_sync signal 211 and the H_sync signal 212 , to extract the four parameters needed for calculating the video signal cycles (the four parameters are the number of the horizontal scanlines, the width of the high H_sync signal, the width of the low H_sync signal and the width of the V_sync signal 211 ), and then store them, along with the value in the M_Total buffer 203 , into the data buffer 206 , followed by transmitting the aforementioned data, along with the modulated V_sync signal 211 , to the wireless receiving device 5 of the wireless light beam gun end via the wireless transmitting device 4 ; after the light beam gun end has received the value from the data buffer 206 and the V_sync signal 211 , the demodulated V_sync signal 104 is to be accordingly based to activate the s_Total counter 105 , and then the M_Total buffer data decoder 103 is to be saved into the M_Total buffer 203 ; before activating the s_Total counter 105 , the wireless light beam gun end is to first keep the value counted by the s_Total counter 105 in the s_Total buffer 106 . After being activated, the s_Total counter 105 then begins to count the pulses generated by the high-frequency clock oscillator 6 . Before the V_sync signal 211 arrives, the photosensor 8 , if receiving the blip on screen 2 , is to save the value in the s_Total counter 105 into the S_Buffer 101 . Since the number of pulses oscillated each time by the high-frequency clock oscillator 6 shall not be identical, when calculating the high-frequency clock between the game player end and the light beam gun end, a ratio calculation circuit is needed to convert the actual light pulse signal position latched by the game player end of the light beam gun. Take the invention as an example, the count value saved in the s_Total buffer 106 is not to be identical to the calculated value saved in the M_Total buffer, thus the light beam gun can obtain a ratio value by using the aforementioned parameters, s_Buffer, value of the M_Total buffer and the value of the s_Total buffer, via the ratio calculation circuit 112 as follows:
Ratio Value=s_Buffer*(M_Total buffer/s_Total buffer) (1)
[0037] The aforementioned ratio value can be stored in the s_Buffer 102 , and at this time the wireless light beam gun end can utilize the s_Buffer 102 and the four parameters (the number of the horizontal scanlines S, the width of the high H_sync signal T H , the width of the low H_sync signal T L and the width of the V_sync signal 211 T c ) received previously to calculate the actual coordinate value of the X and Y axes. Before describing in detail coordinates of the X and Y axes, a video time cycle T is to be defined first, which is comprised of the width of the V_sync signal 211 T c , the number of the horizontal scanlines S, the width of the high H_sync signal T H , and the width of the low H_sync signal T L . Because the video time cycle T of the game player 1 is to be fixed at the production stage, the coordinate values of the X and Y axes can be calculated by the calculation circuit 108 of the X and Y axes 108 and then save the coordinate value into the data buffer of the X and Y axes 110 and 109 , which is to be presented as follows:
(s_Buffer 1 −T c )/(T H +T L )=Y . . . R(remainder) R−T H =X (2)
[0038] Wherein T H <T L
[0039] Through the aforementioned procedure, the data of the X and Y axles can be obtained. And then the wireless light beam gun end, under the means of the encoding/packaging unit 111 , is to wirelessly transmit the data of the X and Y axles, along with the state of the button 9 , to the game player end of the wireless light beam gun. Afterwards the game player end of the wireless light beam gun, after demodulating and decoding, can communicate with the game player under the communication format of the game player 1 . Please continue refer to FIG. 3A and FIG. 3B, wherein the wireless light beam gun end device shown in FIG. 3A comprises an HV_sync separator 7 , used for extracting out the V_sync signal 211 and the H_sync signal 212 from the video signal 10 , and the V_sync signal 211 obtained can be used for activating the M_Total counter 202 and the S_Total counter 105 ; a V_sync modulator circuit 201 , used for modulating the V_sync signal 211 so as to expedite the wireless transmission between the game player end and the light beam gun end; a parameter capture circuit 207 , used for capturing the four parameters needed to calculate the coordinate value of the X and Y axes according to the aforementioned synchronized signals; an M_Total counter 202 , used for counting the clocks oscillated by the high-frequency clock oscillator 6 , and the contents in the M_Total counter 202 are not to be deleted until the next V_sync signal 211 arrives; an M_Total buffer 203 , used for storing the value obtained by the M_Total counter 202 before being deleted; a data buffer 206 , used for storing the four parameters extracted by the M_Total buffer 203 and the parameter capture circuit 207 ; a wireless transmitting device 4 , used for transmitting the value in the data buffer 206 and the modulated V_sync signal 201 to the light beam gun end; whereas shown in FIG. 3B the wireless light beam gun end then comprises a demodulator circuit 204 , which demodulates the data transmitted from the game player end of the light beam gun along with the high-frequency clock oscillator 61 ; a photosensor 8 , used for sensing the blips on the screen and then generating pulse waves; an s_Total counter 105 , used for counting the clocks oscillated by the high-frequency clock oscillator 6 , and the contents in the s_Total counter 202 are not to be deleted until the next demodulated V_sync signal 104 arrives; before activating the s_Total counter 105 the wireless light beam gun end is to store the value counted by the s_Total counter 105 in the s_Total buffer 106 . Before the next V_sync signal arrives, the photosensor 8 , if receiving the blip on screen 2 , is to save the value in the s_Total counter 105 into the S_Buffer 101 ; an S_Total Buffer 106 is used to store the value counted by the S_Total counter 105 before being deleted; an M_Total buffer decoding circuit 103 is used for demodulating the value in the M_Total Buffer 203 transmitted from the game player end of the light beam gun; an M_Total Buffer 203 is used for storing the aforementioned demodulated value; an s_Buffer 101 is used for saving the value in the s_Total counter 105 into s_Buffer 101 , if the photosensor 8 of the light beam gun receives blips on the screen 2 ; a ratio calculating circuit 112 is used for capturing the values in the s_Buffer 101 , S_Total buffer 106 and the M_Total buffer 203 , and then the converted value is to be stored in the s_Buffer 102 through the ratio formula (1); an X/Y calculating circuit 108 is used for calculating the accurate X and Y coordinates via the formula ( 2 ) by combining the value of the s_Buffer 1 102 and the four parameter values (the width of the V_sync signal 211 T c , the number of the horizontal scanlines S, the width of the high H_sync signal T H , and the width of the low H_sync signal T L ); the X and Y coordinate data buffer 109 and 110 are used to store the X and Y axle coordinate values calculated previously; an encoding/packaging unit 111 is then used for encoding the values in the X and Y coordinate data buffer 109 and 110 and the switch data with the means of packaging, and then a wireless transmitting device 4 is used for transmitting the encoded data to the game player end of the wireless light beam gun. Furthermore, the game player end of the wireless light beam gun further comprises a wireless receiving device 5 used for receiving the X and Y coordinate data and the data encoding data; a demodulator 204 is used for demodulating the data received by the wireless receiving device 5 through adding the high-frequency clock oscillator 6 , and then an X/Y switch data decoder 205 is used for decoding the data demodulated previously. Therefore, the second-generation wireless light beam gun of the invention, based upon the synchronized signals separated by the video signal 10 , utilizes the parameter capture circuit 207 to acquire the four parameter values needed for calculating X and Y axle coordinates, and then the four parameter values along with the values in the M_Total buffer 203 are to be simultaneously transmitted to the wireless light beam gun end to do the ratio calculation and the X and Y coordinate calculation, thus the X and Y coordinates are to be calculated, a process that is the primary characteristic of this embodiment of the invention.
[0040] Please continue refer to FIG. 4 and FIG. 5, which show the further embodiment of the second-generation wireless light beam gun of the invention, wherein the light beam gun still includes the wireless light beam gun end device and the game player end device, with the game player end device of the light beam gun further receiving the values of the s_Total buffer 106 and the s_Buffer 101 of the light beam gun end, so as to implement the ratio calculating circuit 112 and the X/Y calculating circuit 108 . In this embodiment of the invention, when the photosensor 8 of the wireless light beam gun end receives the blips on the screen 2 , the s_Total counter 105 is to save the values counted into the s_Buffer 101 , and then encode the values inside the s_Total Buffer 106 and the encoded switch data together and transmit to the game player end of the wireless light beam gun, and when the game player end of the light beam gun receives the encoding data, such encoded data are to first be through the circuits of demodulator 204 and the decoder 208 , and through the ratio calculating circuit 112 , along with the values in the M_Total buffer 203 , thus acquiring a ratio value that is to be save in the M_Buffer 209 which, along with the four parameter values captured by the parameter capture circuit 207 , is to be transmitted to the X/Y calculating circuit 108 to convert the coordinates, with the result of which saved in the X/Y data buffer 110 and 109 to communicate with the game player via communication interface 3 .
[0041] Please continue refer to FIG. 4A and 4B, wherein the game player end device of the wireless light beam gun in FIG. 4A, apart from the primary components in FIG. 3A, further includes an encoding circuit 208 , used for encoding the _Total buffer 106 , s_Buffer 101 and the switch data; a ratio calculation circuit 112 , used for calculating a ratio value from the s_Total buffer 106 , s_Buffer 101 and the M_Total buffer 203 according to the ratio formula (1); an sM_Buffer 209 , used for saving the ratio value calculated by the ratio calculation circuit 112 ; an X/Y calculating circuit 108 , used for calculating the accurate values of the X/Y coordinates from the four parameter values captured by the parameter capturing circuit 207 and the ratio value saved in the M_Buffer 209 via the calculation formula (2); and an X/Y data buffer 110 and 109 , used for saving the X/Y coordinate values calculated previously. The light beam gun end in FIG. 4B then includes a demodulating circuit 104 , used for demodulating the V_sync signal 201 transmitted from the game player end of the light beam gun with the addition of the high-frequency clock oscillator 61 ; a photosensor 8 , used for sensing the blips on the screen 2 to produce pulses; an s_Total counter 105 , used for counting the clock oscillated by the high-frequency clock oscillator 61 , and the values counted by the s_Total counter 105 are not to be deleted until the arrival of the V_sync signal 211 after the next demodulation. Before the arrival of the V_sync signal 211 , the photosensor 8 of the wireless light beam gun, if receiving the blips on the screen 2 , shall immediately save the values in the s_Total counter 105 into the s_Buffer 101 ; an S_Total buffer 106 , used for saving the values counted by the s_Buffer 105 before being deleted; an s_Total Buffer 106 , used for saving the values in the s_Total counter 105 into the s_Buffer 101 as soon as the photosensor 8 of the light beam gun receives the blips on the screen 2 ; an encoding/packaging unit 113 , used for encoding the values in the s_Total buffer 106 and s_Buffer 101 along with the switch data with the means of packaging; and a wireless transmitting device 4 , used for transmitting said packaging to the game player end of the wireless light beam gun. Therefore, the embodiment of the invention is to set up both the ratio calculation circuit 112 and the X/Y calculation circuit 108 inside the game player end of the wireless light beam gun, thus when the photosensor 8 of the light beam gun end receives the blip signals, the procedures needed are only to save the values counted by the s_Total counter 105 into the s_Buffer 101 , and such values are, along with the s_Total buffer 106 , transmitted to the game player end of the wireless light beam gun to do ratio calculation and the X and Y coordinate calculation, thus acquiring the accurate X and Y coordinates, a process that is the primary characteristic of this embodiment of the invention.
[0042] The invention provides a signal producing means, used in the first-generation wireless light beam gun, wherein the blip signal relative to the aiming point is produced to output to a game player; such a wireless light beam gun comprises a wireless game player end device and a wireless light beam gun end device. The aforementioned method comprises:
[0043] Providing with a video signal to the wireless game player end device, and separating and acquiring the V_sync signal;
[0044] Providing with an oscillator counting circuit of the wireless game player end, for counting the largest pulse number of the V_sync signals of the video signals;
[0045] Providing with an oscillator counting circuit of the wireless light beam gun end, for counting the largest pulse number of the V_sync signals of the video signals;
[0046] Calculating the ratio for the blip signal connected by the wireless light beam gun end device producing the blip signal in the video signal cycles, according to the ratio for both the largest pulse number of the V_sync signals of both the wireless game player end device and the wireless light beam gun end device; and
[0047] Producing a reducing blip signal in said video signal cycles and outputting to said game player, according to said ratio of producing the blip signal in the video signal cycles.
[0048] According to the method for producing signals of the invention, please refer to FIG. 5A and 5B, which respectively show the circuit block diagram of the wireless game player end device and the wireless light beam gun end device of the first-generation light beam gun of the invention. In this embodiment of the invention, all the signal triggering is of the front edge triggering. When the game player end of the wireless light beam gun receives the video signal 10 transmitted from the game player 1 to television, PC CRT Monitor or CRT TV 2 , it is to utilize the HV_sync separator 7 to extract out the V_sync signal 211 and the H_sync signal 212 , and then utilizes the V_sync signal 211 to activate the M_Total counter 202 ; before activation, the game player end of the wireless light beam is to keep first the value counted by the M_Total counter 202 in the M_Total buffer 203 . After activation, the M_Total counter 202 then begins to count the number of pulses generated by the high-frequency clock oscillator 6 . Then the values of the M_Total buffer 203 are to be saved in the data buffer 206 , followed by transmitting the aforementioned data, along with the modulated V_sync signal 211 , to the wireless receiving device 5 of the wireless light beam gun end via the wireless transmitting device 4 ; after the light beam gun end has received the value from the data buffer 206 and the V_sync signal 211 , the demodulated V_sync signal 104 is to be accordingly based to activate the s_Total counter 105 , and then the M_Total buffer data decoder 103 is to be saved into the M_Total buffer 203 ; before activating the s_Total counter 105 , the wireless light beam gun end is to first keep the value counted by the s_Total counter 105 in the s_Total buffer 106 . After being activated, the s_Total counter 105 then begins to count the pulses generated by the high-frequency clock oscillator 6 . Before the V_sync signal 211 arrives, the wireless light beam gun, if receiving the blip on screen 2 , is to save the value in the s_Total counter 105 into the S_Buffer 101 . Thus the light beam gun can obtain the s_Buffer 1 by using the aforementioned parameters, s_Buffer, value of the M_Total buffer and the value of the s_Total buffer, via the ratio calculation circuit 112 as follows:
s_Buffer 1 =s_Buffer*(M_Total buffer/s_Total buffer) (1)
[0049] After acquiring the value the s_Buffer 1 102 , the wireless light beam gun end is to transmit such value, along with the switch data, to the game player of the wireless light beam gun via the wireless transmitting device 4 ; when the game player end of the wireless light beam gun receives the data transmitted from the light beam gun end, the demodulator 204 is used for demodulating such data and then the value of the first-level buffer of the game player end s_Buffer 214 is to be saved in the second-level buffer, and then the value of the s_Buffer 214 transmitted from the light beam gun end is to be saved in the first-level buffer of the s_Buffer 1 214 of the game player end. At this time the second-level buffer of the s_Buffer 1 214 the values counted by the M_Total counter 202 are to be transmitted to the Gate 213 , and as soon as the value counted by the M_Total counter 202 is identical to that in the second-level s_Buffer 214 , the M_Total counter 202 is to output a high electric-potential signal to the pulse generator 215 so as to reduce and produce a light pulse and then directly output to the game player 1 .
[0050] Please continue refer to FIG. 5A and FIG. 5B, wherein the game player end of the wireless light beam gun in FIG. 5A, apart from comprising a part of the primary components in FIG. 3A (like HV_sync separator 7 , M_Total counter 202 , M_Total Buffer 203 , modulator circuit 201 , demodulator circuit 204 and the data buffer 214 ), further includes an s_Buffer 1 buffer 214 having the second-level buffer assembly, wherein the first-level buffer is used for saving the ratio value of the transmission from the light beam gun end to the game player end of the light beam gun, whereas the second-level buffer is used for saving the value saved by the first-level buffer of the previous picture. When receiving the data transmitted from the light beam gun end (s_Buffer 1 and the switch data), the value of the first-level buffer is to be saved in the second-level buffer first, and then the value of the s_Buffer 1 is to be saved in the first-level buffer; a gate circuit 213 , which is a member similar to a logical gate circuit; when signals from the input end arrive, such circuit is to do the Boolean algebraic calculation on signals from the input end, and then output a pulse signal to the pulse generator 215 . To take the invention for example, the values of the M_Total counter 202 in the game player end of the light beam gun and of the second-level buffer of the s_Buffer 214 are to be directly transmitted to the gate circuit 213 , so not until the value counted by the M_Total counter 202 is identical to that in the second-level s_Buffer 214 does the gate circuit 213 begin to output a high electric-potential (pulse) to the pulse generator 215 ; otherwise the output of the gate circuit 213 is constantly to be in the state of low electric potential. The output truth table of the gate circuit 213 is similar to that of the ordinary XOR (exclusive or gate) logical gate member; a pulse generator 215 , used for reducing and generating a light pulse and directly output to the game player 1 according to the output of the gate circuit 213 . Whereas the wireless light beam gun in FIG. 5B includes a V_sync demodulator 104 , used for demodulating the V_sync signal 211 transmitted from the game player end of the light bean gun adding the high-frequency clock oscillator 6 ; a photosensor 8 , used for sensing blips on the screen 2 to produce pulses; an s_Total counter 105 , used for counting the clock oscillated by the high-frequency clock oscillator 61 , and the s_Total counter 105 keeps counting until the arrival of the next V_sync signal 211 , and then the value counted is to be deleted; before deletion of the value counted, the wireless light beam gun end is to save the value counted by the s_Total counter 105 in the s_Total buffer 106 . Before the arrival of the next V_sync signal 211 , the photosensor 8 of the wireless light beam gun, if receiving blips on the screen 2 , is immediately to save the value in the s_Total counter 105 in the s_Buffer 1 01 ; an S_Total buffer 106 , used for saving the value counted by the s_Total counter 105 before deletion; an M_Total buffer decoding circuit 103 , used for demodulating the value in the M_Total buffer 203 transmitted from the game player end of the light beam gun; an M_Total buffer 203 , used for saving the demodulated value; an s_Buffer buffer 101 used for saving the value in the s_Total counter 105 in the s_Buffer 101 as soon as the photosensor 8 of the light beam gun receives blips on the screen 2 ; a ratio calculation circuit 112 , used for capturing the values in the s_Buffer 101 , S_Total buffer 106 and the M_Total buffer 203 , and then convert the values through the ratio formula (1) and save in the s_Buffer 1 102 ; an s_Buffer 1 buffer 102 , used for saving the ratio value converted by the ratio calculation circuit 112 ; a buffer 114 , used for saving the switch output data and the value in the s_Buffer 1 buffer 102 and such data and value are to be transmitted by the wireless transmitting device to the game player end of the wireless light beam gun. Therefore, the first-generation wireless light beam gun is to utilize a gate circuit 213 as preamp input member, thus when the wireless light beam gun end receives the blip signal and does the ratio calculation with other parameters (s_Buffer, S_Total buffer and M_Total buffer), such ratio value is to be transmitted back to the game player end of the light beam gun; at this time the M_Total counter 202 of the game player end, after being deleted by the V_sync signal 211 , is to continuously count the pulses oscillated by the high-frequency clock oscillator 6 , until the value counted is identical to that in the second-level buffer of the s_Buffer 214 , and the gate circuit 213 is to output a high electric potential to the pulse generator 215 to reduce the blip signal to the game player 1 , a process that is the primary characteristic of the invention.
[0051] Please continue refer to FIG. 6A and 6B, which are the block diagrams of the further embodiment of the first-generation wireless light beam gun of the invention. In this embodiment, the game player device of the light beam gun further receives the values of the s_Total buffer 106 and the s_Buffer 101 to implement the ratio calculation circuit 112 and reduce the blip signals. In the invention, after the game player end of the wireless light beam gun has transmitted the modulated V_sync signal 211 to the wireless light beam gun end, the light beam gun end is to activate the s_Total counter 105 according to the demodulated V_sync signal 211 adding the high-frequency clock 6 ; yet before the activation of the s_Total counter 105 the value in the s_Total counter 105 is to be saved first in the s_Total buffer 106 by the wireless light beam gun end. The s_Total counter 105 , after being activated, is to count the pulses oscillated by the high-frequency clock oscillator 61 , and before the arrival of the next V_sync signal 211 , the wireless light beam gun, if receiving blips on the screen 2 , is immediately to save the value in the s_Total counter 105 in the s_Buffer 101 , and form a package 113 along with the s_Total buffer 106 and the encoded switch data. Such package is then transmitted to the game player end of the light beam gun. And when the game player end of the wireless light beam gun receives such package, it is to be through the demodulator 204 and the decoding circuit 208 and be inputted, along with the value in the M_Total buffer 203 to the ratio calculation circuit 112 . And then after being calculated by using the ratio formula (1), the converted ratio value is to be saved in the M_Buffer 209 . At this time when the value counted by the M_Total counter 202 is identical to that in the M_Buffer 209 , a high electric-potential pulse is to be outputted to the pulse generator 215 to reduce the blip signal and directly outputted to the game player end 1 .
[0052] Please continue refer to FIG. 6A and 6B, wherein the wireless light beam gun device shown in FIG. 6B is identical to that shown in FIG. 4B, and the game player end device of FIG. 6A further includes an HV_sync separator 7 , used for extracting the V_sync signal 211 and the H_sync signal 212 from the video signal 10 , and the extracted V_sync signal 211 can be used for activating M_Total counter 202 and the S_Total counter 105 ; a V_sync modulator 201 , used for modulating the V_sync signal 211 , so as to expedite the wireless transmission between the light beam gun end and the game player end of the light beam gun; an M_Total counter 202 , used for continuously counting the clock oscillated by the high-frequency clock oscillator 6 until the arrival of the next V_sync signal 211 , and then the value in the M_Total counter 202 is to be deleted; an M_Total buffer 203 , used for saving the value counted in the M_Total counter 202 before being deleted, a demodulator 204 , used for demodulating the data transmitted from the light beam gun end adding the high-frequency clock 61 ; a ratio calculation circuit 112 , used for capturing the values in the S_Buffer 101 , the S_Total buffer 106 and the M_Total buffer 203 , and converting such values via the ratio formula (1) and save the converted values in the M_Buffer 209 ; an M_Buffer 209 , used for saving the ratio values calculated by the ratio calculation circuit 112 ; a gate circuit 213 , which is a member similar to a logical gate circuit, when signals are inputted from the inputting end, the gate circuit 213 is to do the Boolean algebraic calculation on such inputting signals, and then output a pulse signal to the pulse generator 215 ; a pulse generator 215 , used for reducing and producing a light pulse and directly output to the game player 1 according to the output from the gate circuit 213 . Therefore, the first-generation wireless light beam gun of this embodiment of the invention sets up a ratio calculation circuit 112 and a gate circuit 213 at the game player end of the light beam gun, thus when the light beam gun end receives blip signals, it is to transmit the values in the s_Total buffer 106 and the s_Buffer 101 to the game player end of the light beam gun, and utilize the ratio calculation circuit 112 and the gate circuit 213 to drive the pulse generator 215 to reduce and output a blip signal to the game player 1 , a process that is the primary characteristic of this embodiment.
[0053] Please refer to FIG. 7A and 7B, which are the block diagrams of the light beam gun end device and the game player end device of the wireless light beam gun of the invention, wherein when the game player end of the wireless light beam gun receives the video signal 10 transmitted from the game player 1 to television, PC CRT Monitor or CRT TV 2 , it is to utilize the HV_sync separator 7 to extract out the V_sync signal 211 and the H_sync signal 212 ; then the H_sync signal 212 can be used for activating the X axle counter, and the V_sync signal 211 is used for activating the M_Total counter 202 and the Y axle counter. Before activation, the game player end of the wireless light beam is to keep first the value counted by the M_Total counter 202 in the M_Total buffer 203 . After activation, the M_Total counter 202 then begins to count the number of pulses generated by the high-frequency clock oscillator 6 . Then the values of the M_total buffer 203 are to be saved in the data buffer 206 , followed by transmitting the aforementioned data, along with the modulated V_sync signal 211 , to the wireless receiving device 5 of the wireless light beam gun end via the wireless transmitting device 4 ; after the light beam gun end has received the value from the data buffer 206 and the V_sync signal 211 , the demodulated V_sync signal 104 is to be accordingly based to activate the s_Total counter 105 , and then the M_Total buffer data decoder 103 is to be saved into the M_Total buffer 203 ; before activating the s_Total counter 105 , the wireless light beam gun end is to first keep the value counted by the s_Total counter 105 in the s_Total buffer 106 . After being activated, the s_Total counter 105 then begins to count the pulses generated by the high-frequency clock oscillator 6 . Before the next V_sync signal 211 arrives, the wireless light beam gun, if receiving the blip on screen 2 , is to save the value in the s_Total counter 105 into the S_Buffer 101 . Thus the light beam gun can obtain the s_Buffer 1 by using the aforementioned parameters (s_Buffer, values in both the M_Total buffer and the s_Total buffer) via the ratio calculation circuit 112 as follows:
s_Buffer 1 =s_Buffer*(M_Total buffer/s_Total buffer) (1)
[0054] After acquiring the value the s_Buffer 1 102 , the wireless light beam gun end is to transmit such value, along with the switch data, to the game player of the wireless light beam gun via the wireless transmitting device 4 ; when the game player end of the wireless light beam gun receives the data transmitted from the light beam gun end, the demodulator 204 is used for demodulating such data and then the value of the first-level buffer of the game player end s_Buffer 214 is to be saved in the second-level buffer, and then the value of the s_Buffer 214 transmitted from the light beam gun end is to be saved in the first-level buffer of the s_Buffer 1 214 of the game player end. At this time the second-level buffer of the s_Buffer 1 214 the values counted by the M_Total counter 202 are to be transmitted to the Gate 213 , and as soon as the value counted by the M_Total counter 202 is identical to that in the second-level s_Buffer 214 , it is to output a high electric-potential signal so as to latch the X/Y data buffer that contains the counting values from the X/Y axle counter of the game player end of the light beam gun; at this time the values in the X/Y data buffer are the actual X/Y coordinates, which are to be outputted, along with the decoded switch data, to the game player.
[0055] Please continue refer to FIG. 7A and 7B, wherein the embodiment of the wireless light beam gun end device is identical to that of the wireless light beam gun end device shown in FIG. 5B, and the game player end device in FIG. 7A not only includes parts of the primary components (not including the pulse generator), but also includes an X axle counter, used for counting the number of the high-frequency clocks 61 , and conducting the activation motion temporarily when the next H_sync signal arrives; a Y axle counter, used for counting the number of the H_sync signals, and conducting the activation motion temporarily when the next H_sync signal arrives; and an X/Y data buffer, used for saving the values counted by the X/Y axle counter.
[0056] When the user aims at an aiming point on the screen, the photosensor 8 of the wireless light beam gun end is to receive the blip signal produced from the aiming point hit on the screen 2 by the electron of the cathode-ray tube of the television 2 first, and then such signal is to latch the value counted by the s_Total counter 105 at this time in the s_Buffer 101 ; after being through the ratio calculation circuit, the data is to be transmitted to the game player end of the light beam gun; and after decoding and demodulating, the game player end of the light beam gun is to utilize the gate circuit to reduce the blip signal and latch the value counted by the X/Y axle counter in the X/Y data buffer. Lastly the value in the data buffer and the decoded switch data are both outputted to the game player, a process that is the primary characteristic of this embodiment.
[0057] Please refer to FIG. 8A and 8B, which are the block diagrams of the further embodiment of the second-generation wireless light beam gun of the invention, wherein the game player device of the light beam gun further receives the values of the s_Total buffer 106 and the s_Buffer 101 to implement the ratio calculation circuit 112 and reduce the blip signals. In the invention, after the game player end of the wireless light beam gun has transmitted the modulated V_sync signal 211 to the wireless light beam gun end, the light beam gun end is to activate the s_Total counter 105 according to the demodulated V_sync signal 211 adding the high-frequency clock 6 ; yet before the activation of the s_Total counter 105 the value in the s_Total counter 105 is to be saved first in the s_Total buffer 106 by the wireless light beam gun end. The s_Total counter 105 , after being activated, is to count the pulses oscillated by the high-frequency clock oscillator 61 , and before the arrival of the next V_sync signal 211 , the wireless light beam gun, if receiving blips on the screen 2 , is immediately to save the value in the s_Total counter 105 in the s_Buffer 101 , and such value, along with the s_Total buffer 106 and the encoded switch data, are all transmitted to the game player end of the light beam gun. When the game player end of the light beam gun receives said data, it is to be through the demodulator 204 and the decoding circuit 208 and be inputted, along with the value in the M_Total buffer 203 to the ratio calculation circuit 112 . And then after being calculated by using the ratio formula (1), the converted ratio value is to be saved in the M_Buffer 209 . At this time when the value counted by the M_Total counter 202 is identical to that in the M_Buffer 209 , a high electric-potential pulse is to be outputted so as to latch the X/Y data buffer that contains the counting values from the X/Y axle counter of the game player end of the light beam gun; at this time the values in the X/Y data buffer are the actual X/Y coordinates, which are to be outputted, along with the decoded switch data, to the game player.
[0058] Please refer to FIG. 8A and 8B, wherein the embodiment of the wireless light beam gun end device shown in FIG. 8B is identical to that of the wireless light beam gun end device shown in FIG. 6B, and the game player end device in FIG. 8A not only includes parts of the primary components shown in FIG. 6A (not including the pulse generator), but also includes an X axle counter, used for counting the number of the high-frequency clocks 61 , and conducting the activation motion temporarily when the next H_sync signal arrives; a Y axle counter, used for counting the number of the H_sync signals 212 , and conducting the activation motion temporarily when the next H_sync signal arrives; and an X/Y data buffer, used for saving the values counted by the X/Y axle counter.
[0059] When the user aims at an aiming point on the screen, the photosensor 8 of the wireless light beam gun end is to receive the blip signal produced from the aiming point hit on the screen 2 by the electron of the cathode-ray tube of the television 2 first, and then such signal is to latch the value counted by the s_Total counter 105 at this time in the s_Buffer 101 ; after being through the ratio calculation circuit, the data is to be transmitted to the game player end of the light beam gun; and after decoding and demodulating, the game player end of the light beam gun is to utilize the gate circuit to reduce the blip signal and latch the value counted by the X/Y axle counter in the X/Y data buffer. Lastly the value in the data buffer and the decoded switch data are both outputted to the game player, a process that is the primary characteristic of this embodiment.
[0060] Please refer to FIG. 9, which shows the block diagram of the further embodiment of the invention. The main characteristic of the invention is to replace several monitor synchronized-value calculating circuits like M_Total counter, M_Total buffer, S_Total counter and S_Total counter in the prior arts with a game player 1 that is capable of acquiring and controlling the synchronized values on the screen 2 . Since all the pictures of the game are produced and controlled by the game player 1 , the game player 1 can easily acquire the monitor related data 205 like M_Total and other horizontal synchronized values, and utilize the game-control interface to transmit the data to the game player end of the wireless light beam gun; at this time the game player end of the wireless light beam gun is to convert such data, by using the X/Y calculation circuit, so that the position of the blips are to be acquired and transmitted back to the game player 1 .
[0061] Please continue refer to FIG. 9, wherein it is shown that the wireless light beam gun device of this embodiment comprises a V_sync modulator 201 , used for modulating the V_sync signals; a game player 1 , used for producing all the pictures of the game and acquire the related data 205 in the monitor; a communication interface 3 , used for transmitting the related data 205 in the monitor to the ratio calculation circuit 112 to convert, so that the actual blip signal or the blip coordinates can be acquired; an X/Y calculation circuit, based upon the X/Y calculation formula as follows:
M_Buffer=S_Buffer* (M_Total/S_Total)
[0062] used for converting the related data 205 in the monitor into the blip coordinates; a demodulating circuit 204 , used for demodulating data transmitted from the light beam gun end adding the high-frequency clock oscillator 6 ; a buffer and the S_Total/S_Buffer/switch data decoder 208 , used for decoding the demodulated data and transmitting the data transmitted from the light beam gun end to the ratio calculation circuit 112 to calculate the actual coordinates. Therefore, the wireless light beam gun of the embodiment utilizes the data in the monitor produced by the game player 1 , along with the data transmitted from the light beam gun end, to calculate the actual X/Y coordinates by using the X/Y calculation circuit, a process that is the characteristic of this embodiment.
[0063] Please continue refer to FIG. 10, which shows the block diagram of the further embodiment of the invention. In the preferred embodiment of the invention, because all the pictures of the game are to be produced and controlled by the game player 1 , the game player 1 can easily acquire the related data in the monitor like M_Total; at this time only the procedure of directly transmitting back the values of the S_Total and S_Buffer received by the receiver to the game player 1 , the game player 1 can convert by itself the X/Y coordinates of the blips.
[0064] Please continue refer to FIG. 3, the wireless light beam gun device of this embodiment accords with the game player 1 , which can produce all the video signals of the game pictures; the wireless game player end device of the wireless light beam gun device comprises a V_sync signal modulating circuit 201 , used for modulating the V_sync signals; a demodulating circuit 204 , used for demodulating the data transmitted from the light beam gun end adding the high-frequency clock oscillator 6 ; a buffer and the S_Total/S_Buffer/switch data decoder 208 , used for decoding the demodulated data and transmitting, via the communication interface 3 , the data transmitted from the light beam gun end back to the game player 1 to calculate the actual coordinates.
[0065] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, those skilled in the art can easily understand that all kinds of alterations and changes can be made within the spirit and scope of the appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein. | The wireless light beam gun of the invention can be used with screens and shooting game software, comprising a wireless game player end device and a wireless light beam gun end device, wherein the wireless game player end device first receives the video signals from the screen, and then utilizes the ratio value from the number of pulses counted by v_sync signals between the wireless game player end device and a wireless light beam gun end device, to calculate the blip coordinate data or reduce a blip signal within the cycle of video signals; the cycle of video signals can be calculated and obtained in the wireless light beam gun end device through a set of parameter data. The invention utilizes the wireless transmitting device to replace the conventional signal wire of the wired light beam gun, thus, during shooting games, preventing the user from being confined by the space limitation, and increasing the interaction between the user and the game the user is playing. | 0 |
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to an automotive vent window and, in particular, to a window for the retrofit installation in the roof of an automotive vehicle.
2. Brief Statement of the Prior Art
Roof vent windows have found increasing popularity in automotive vehicles. The window panels typically are hinged at their leading edge and have extendable locking levers along their rear edge to support the window in an extended position and to lock the window in its closed position. The increased visibility and the greatly increased air circulation through the car are major factors in the rapidly increasing popularity of this window.
One of the features which is commonly desired by consumers is that the window panel be removable and the ease of removal of the window is a factor which is considered in the selection and purchase of the windows by the public.
There have been some patents which have recently issued on window designs for automotive vehicles such as U.S. Pat No. 3,974,753, and which shows windows formed of extruded frame members which are cold rolled into generally rectangular configurations. The structure of this invention permits such manufacturing of the frame and trim ring members and provides a window having an easily removable window panel.
BRIEF STATEMENT OF THE INVENTION
The invention comprises an automotive roof vent window having a construction that permits facile removal of the vent window panel after its installation. The removability of the vent window panel is achieved by use of a latch mechanism pivotally secured to a mounting bracket on the frame of the window with a pin that fits in slotted apertures of the mounting bracket and which has end flats to index with the slot and permit its withdrawal when the flats are aligned with the slots. The pin is fixedly secured to a lever having resilient detenting tabs which engage against an abuttment of the bracket to secure the lever and its dependent pin against rotation, thus firmly capturing the pin within the apertures of the bracket and safely securing the assembly.
The invention also comprises hinge members on the leading edge of the assembly which are permanently and pivotally secured to the frame member and which are removably secured to the roof vent panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the FIGURES of which:
FIG. 1 is an elevational, sectional view of the roof vent window in the panel open position;
FIG. 2 is an illustration similar to FIG. 1, showing the removal of the window panel;
FIG. 3 illustrates an alternative structure for the frame and trim ring members of the assembly;
FIG. 4 is a perspective view of the pin lever of the latch mechanism in its locked position;
FIG. 5 is a perspective view of the pin lever in its open or pin extraction position;
FIG. 6 illustrates the extraction of the pin and disassembly of the latch mechanism;
FIG. 7 is a perspective view of the hinge used in the invention; and
FIG. 8 illustrates the disassembly of the hinge.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, the roof vent window of the invention is shown in elevational cross-sectional view as installed in the roof of a vehicle. The vehicle roof 10 is modified to include a generally rectangular opening into which is seated the window frame member 12. The opening is cut into the roof of the vehicle following a guide or template which closely conforms to the abuttment edge 14 of frame 12. Trim ring 16 is coextensive with frame 12 and is secured thereto by a plurality of self tapping sheet metal screws 18 which are received in the groove 20 of flange 22 carried by the frame 12. The vent panel 22 is pivotally mounted to the frame 12 by one or more hinge plates 24 along the leading edge of the panel. At its trailing edge, the panel carries one or more latch mechanisms generally indicated at 26 which are pivotally mounted to latch mounting brackets 28 carried along the inner trailing edge of frame 12. As will be explained in greater detail hereinafter, the latch mechanism 26 is a folding latch mechanism which is effective in permitting the pivotal movement of the panel through arc from 0° to about 40°, preferably from 1° to about 35° and which will fold into a locked position when the panel is in its closed position.
The frame member 12 and the trim ring 16 are extruded metal forms, typically of aluminum. These members are formed into a generally rectangular form such as shown in the aforecited U.S. Pat. No. 3,974,753 by stretch forming the metal extrusions and the corners are arcuate with a sufficient radius of curvature to permit this metal forming step. The frame member 12 has a generally upwardly open channel 30 having a web 32 and opposite and parallel sides 34 and 36. The inboard side 36 of this channel carries an outwardly facing arcuate channel 38 along its upper edge which has an open, coextensive slot 40. The opposite side 34 carries a peripheral, flat flange 42 dependent from its upper edge.
The trim ring, also of extruded metal form, is an angle member having a base 44 and an upright side 46. The trim ring has a plurality of spaced apertures 48 which receive the screws 18 that extend into self-tapped apertures in flange 22. The apertures 48 in the trim ring are aligned with the groove 20 of flange 22 that receives the self-tapping screws 18.
A resilient seal ring 50 which is formed of natural or synthetic rubber, polyurethanes and the like is received in the upwardly open channel 30. The undersurface of the peripheral flange 42 of the frame seats against seal ring 56 which is secured between the undersurface of flange 42 and the upper surface of the roof 10. The internal trim such as the headliner 58 of the vehicle is clamped against the inner surface of the roof by the upper edge of the trim ring 16.
The undersurface of flange 42 of the frame has a coextensive shoulder 14 which abuts the cut edge of the roof 10 and orients the frame in the assembly. Spacer blocks 60 are positioned in the channel which is formed between the shoulder 14 and the flange 22 of the frame to insure that the frame is not inadvertently installed with the roof edge projecting into this channel. A suitable material which can be used for the spacer blocks 60 is adhesively-backed polyvinyl chloride.
The undersurface of the web 32 of channel 30 of the main frame preferably has an inset portion 33 to provide a recessed surface for seating of the base 44 of trim ring 16 thereby providing a flush mounting of the trim ring to the frame and a pleasing appearance to the assembly.
As previously mentioned, the vent panel 22 is pivotally mounted along its forward edge to the frame 12 by one or more hinge plates 24. Preferably two, laterally disposed hinge plates 24, are employed. Each hinge plate 24 is secured to the leading edge of the vent panel 22 by a machine bolt 64 and has a downwardly bent portion 66. The bent portion 66 has a transverse slot (not shown) which receives a tongue 68 formed by two parallel slots in the upper edge of the arcuate channel 38. The structure of this hinge engagement is further illustrated and described with reference to FIGS. 7 and 8.
The folding latch mechanism 26 is mounted along the trailing edge 23 of the roof vent panel 22. Preferably two of the folding latch mechanisms 26 are employed, laterally disposed along the trailing edge 23. The latch mechanisms are fixedly secured to the roof panel 23 by bolt 70 having head 72, sealing washer 74 and washer 76 secured by lock nut 78. The bolt 70 has a shank portion 80 with flats 82 cut on its opposite sides and received within the end of the generally channel-shaped clasp member 84 of the latch mechanism 26. Pin 86 is permanently seated in aligned apertures through the side walls of the channel clasp member 84 and is received in an aligned aperture in the end of the shank 80 of bolt 70.
The opposite end of the clasp member 84 is pivotally mounted to toggle member 88 by permanently seated pin 90. The toggle member 88 pivotally carries pin 92 which is received in aligned apertures 94 in each of the arms 96 of latch mounting bracket 28. The apertures 92 in the arms 96 of the latch mounting bracket 28 open to a slot 98. As described in greater detail hereinafter, the pin 94 has distal and parallel flats 100 and 102 which can be aligned with the slots 98 of the bracket to permit retraction of the pin 100 from apertures 92.
The latch mounting brackets 28 are bifurcated with legs 104 and 106 which bear suitable means to attach to frame member 12 such as lip 108 on leg 104 which engages against the off set shoulder 110 in the undersurface of the frame member. The leg 106 has a shoulder, not illustrated, which projects through a slot cut in the arcuate channel 38 and this shoulder has an aperture to align with the arcuate channel and receive a roll pin 112 to fixedly secure the latch mounting bracket to the frame 12.
Referring now to FIG. 2, the removal of the vent panel will be illustrated and described. As shown in FIG. 2, the pin 92 has been rotated to permit its flats 100 and 102 to be aligned with groove 98, thereby permitting extraction of the pin through slots 98 from the aligned apertures 94 of the mounting bracket 28. The rotation of the pin to this position is achieved by the movement of the lever 114 which is fixedly secured to the pin. The lever has resilient detent means in the form of tabs 116 which resiliently engage with the outside shoulder of the lip 108 of the mounting bracket in the manner illustrated in FIG. 1 whereby the lever is firmly locked in a position securing the flats of pin 92 out of alignment with the slots 98.
The panel 22 can be detached from its hinged engagement with the leading edge of the assembly by loosening of the thumb nut 120 which is threadably engaged on the machine bolt 64. The latter is permanently secured to the vent panel 22 by nut 122 and sealing washer 124.
The embodiment of FIG. 2 illustrates a slightly different configuration of the trim ring 16'. In this illustration, the trim ring has its offset, peripheral flange 21' separated from the peripheral flange 42 of frame 12 by a substantial distance, e.g., from 3/8 to about 3/4 of an inch and the like. This structure is suited for fitting to double roof vehicles which have an upper roof 10 and a spaced-apart lower roof 10'. In this embodiment, a spacer block 27 is inserted between the spaced-apart edges of the roof panels 10 and 10'. Preferably, the spacer block 27 is adhesively backed to permit its permanent installation between the roof panels.
The material which is ideally suited for use as the spacer block 27 comprises a plastic foam material commercially available under the trade designation Ethafoam from the Dow Chemical Co., Midland, Mich. The latter is a cross-linked, rigid polyethylene foam of an intermediate density and a high compressive strength.
Referring now to FIG. 3, there is illustrated an alternative structure for the trim ring used in the assembly. As there illustrated, the main frame 12 has the same configuration as shown in FIG. 1, however, the trim ring 15 has a generally channel shape with an outwardly formed channel 17 and a downwardly dependent angle 19. This trim ring is for applications such as vans and the like which have a relatively thick roof panel, e.g., up to about 11/2 inches in thickness. The roof panel is formed of the conventional metal roof with a thick headliner or insulation 11. The downwardly dependent angle 19 of the trim ring 15 secures the inward edge of the headliner in the assembly.
The operation of the releasable latch mechanism will be described with reference to FIGS. 3-5. FIG. 3 is a perspective view of the latch mounting bracket which is shown, secured to the undersurface of the frame 12 with its associated trim ring 16. The mounting bracket has a pair of parallel legs 104 and 104' which have the previously mentioned aligned bores 94 that releasably receive the opposite ends of pin 92. Pin 92 is pivotally secured in the end of the toggle member 88 which is slotted at 118 to receive the lever 114. Lever 114 has a hook-shaped end 121 which resiliently binds about pin 94. Lever 114 is generally T-shaped with a cross bar 123 that has resilient, bent tabs 116 and 116'. As previously mentioned, these tabs engage against the outer shoulders of lips 108 and 108' of the mounting bracket 28, serving as resilient detents to lock the lever 114 in the position illustrated in FIG. 3.
The removal of the panel is effected with the panel in its raised or upright position as illustrated in FIG. 1. The removal is accomplished by grasping cross bar 122 of lever 114 and swinging lever 114 in the direction indicated by the arrowhead line 125. This movement rotates pin 92 to that position shown in FIG. 5 where the distal flats 100 and 102 of the pin are aligned with the groove 98. The pin 92 can then be extracted from the aligned apertures 92 and 92' simply by movement in the direction by the arrowhead line 126 of FIG. 6.
The disengagement of the leading edge of the panel from the assembly is illustrated in FIG. 7 and 8. As shown in FIG. 7, the leading edge of the panel 22 is pivotally secured in the assembly by the hinge plate 24. Plate 24 has the bent portion 66 which has a slot 67 that receives a tongue portion 37 that is formed by a pair of parallel grooves 35 and 39 in the arcuate channel 38 shown in FIG. 1. The panel 22 is freed from the hinge plate 24 by loosening thumb nut 120 as shown in FIG. 7 to permit the bot 64 to pass through the distal slot 128 intersecting the aperture 130 of the hinge plate 24.
The invention has been described with reference to the illustrated and presently preferred mode of practice. It is not intended that the invention be unduly limited by this description of the presently preferred embodiment. Instead, it is intended that the invention be defined by the means, and their obvious equivalents, set forth in the following claims. | There is disclosed an automotive roof vent window designed for ease of retrofit installation and ease of removal of the vent window panel after installation. The vent window has a main frame and clamping trim ring secured thereto with self tapping screws. The vent window panel is pivotally mounted to the main frame by hinged brackets having a slotted aperture which receives threaded pins permanently carried by the vent window panel and clamped to the brackets by thumb nuts. The opposite edge of the window panel is secured by a toggle latch assembly that is pivotally engaged to a mounting bracket of the window frame by a pin removably seated in slotted apertures of the bracket. The pin has indexing flats to permit its withdrawal when rotated to align the flats with the slots of the apertures. The pin is securely locked in the assembly by a dependent lever having resilient detenting tabs. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit under 35 USC §119 of Japanese Patent Application No. 2010-116559, filed on May 20, 2010, in the Japanese Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field
The present invention relates to a method of manufacturing a semiconductor device that includes a drift layer formed of an alternating conductivity type layer including an n-type column and a p-type column, both extending in perpendicular to the major surface of a semiconductor substrate. The n-type column and the p-type column are arranged alternately and repeatedly in parallel to the major surface of a semiconductor substrate such that the n-type column and the p-type column are adjoining to each other. Hereinafter, “super-junction” refers to the alternating conductivity type layer, and “super-junction semiconductor device” refers to the semiconductor device including an alternating conductivity type layer.
2. Description of the Related Art
A super-junction MOSFET (hereinafter referred to as a “SJ-MOSFET”) that is a vertical power MOSFET including a drift layer provided with a super-junction structure is one known super-junction semiconductor device.
In FIG. 6 , a cross sectional view of a SJ-MOSFET, the drift layer thereof provided with a super-junction structure is formed of alternating conductivity type layer 104 including n-type column 101 and p-type column 103 , both extending in perpendicular to the major surface of heavily doped n + silicon semiconductor substrate 100 . The n-type column 101 and p-type column 103 are arranged alternately and repeatedly in parallel to the major surface of heavily doped n + silicon semiconductor substrate 100 . The SJ-MOSFET also includes p-type base region 105 , n-type source region 106 , gate insulator film 107 , polysilicon gate electrode 108 , interlayer insulator film 109 made from boro-phosphosilicate glass (BPSG), source electrode 110 , surface protector film 111 , and drain electrode 112 .
Even if the impurity concentrations in the p-type and n-type columns are set to be higher than the impurity concentrations in the usual power semiconductor device of the same breakdown voltage class, depletion layers expand from the pn-junction between the p-type and n-type columns to both sides in the OFF-state of the device, depleting the p-type and n-type columns at a low electric field strength. Therefore, it is possible to provide the super-junction semiconductor device with a higher breakdown voltage.
As a result, the super-junction semiconductor device exhibits excellent semiconductor device performances. In detail, the super-junction semiconductor device facilitates reducing the ON-state resistance, that is in the tradeoff relation against the breakdown voltage, to a value not only low enough to transcend the tradeoff relation but also low enough to transcend the theoretical limit of the material.
For manufacturing the super-junction structure, the method combining a multi-step epitaxial growth and ion implantation (hereinafter referred to simply as the “multi-step epitaxial growth method”) has been developed and the SJ-MOSFETs having the super-junction structure formed by the multi-step epitaxial growth method are manufactured.
In detail, an n − layer (not shown) that will work as a buffer layer is formed on heavily doped n + silicon semiconductor substrate 100 in FIG. 6 . Then, a trench having a side wall perpendicular to the substrate surface is formed by anisotropic dry-etching and such an etching technique as an alignment mark used for positioning in the subsequent steps in the section on the n − layer surface (not shown), in which a scribe line is planned.
Then, a non-doped epitaxial layer is grown, an n-type ion-implanted region is formed, a photoresist is patterned using the alignment mark, and a p-type ion-implanted region is formed by selective ion implantation through the photoresist opening. The step of growing a non-doped epitaxial layer, the step of forming an n-type ion-implanted region, and the step of forming a p-type ion-implanted region are repeated a predetermined number of times such that an upper p-type ion-implanted region is positioned on the lower p-type ion-implanted region.
As described above, the multi-step epitaxial growth method is a method that repeats the steps of growing a non-doped epitaxial layer, patterning a resist, and implanting impurity ions to pile up p-type ion-implanted regions and n-type ion-implanted regions in the same respective sites. Then, the multi-step epitaxial growth method thermally drives the p-type and n-type ion-implanted regions to expand and connects the p-type ion-implanted regions and the n-type ion-implanted regions in perpendicular to the substrate major surface, for forming an alternating conductivity type layer.
It is important for the multi-step epitaxial growth method to position the ion-implanted region of a conductivity type in the upper layer exactly on the ion-implanted region of the same conductivity type in the lower layer. Since the alignment mark described above is necessary as a reference for the exact positioning, it is required for the alignment mark to have a clear shape.
In growing an epitaxial layer on the silicon wafer 120 , in which a trench-shaped alignment mark is formed, the trench pattern for the alignment mark will be deformed if the growth rate is too high. The trench pattern for the alignment mark is deformed, for example, as follows. As silicon epitaxial layer 122 is grown on the alignment mark shaped with trench 121 (the cross sectional view thereof is shown in FIG. 2( a )), the alignment mark is deformed, as schematically described in FIG. 2( b ), such that what is left is not any horizontally flat section, left but a triangular cross section or a curved cross section (not shown) caused in the alignment mark. The alignment mark's lack of any horizontally flat section tends to be caused when the silicon epitaxial layer 122 growth rate is high.
If a pattern similar to trench 121 , formed before silicon epitaxial layer 122 is grown, is not formed in the silicon epitaxial layer 122 surface but the deformed pattern as described above is caused in silicon epitaxial layer 122 , it will be difficult to automatically detect the alignment mark with a detector and the alignment will be conducted hardly or an alignment deviation will be caused.
If an alignment deviation is caused, the ion-implanted regions of the same conductivity type in the upper and lower layers will deviate easily from each other, the columnar regions in the alternating conductivity type layer will be extended neither in perpendicular to the substrate surface nor straightly, and the semiconductor device performances will be impaired.
In the multi-step epitaxial growth, an epitaxial layer is grown repeatedly many times and the treatment steps also tend to be repeated many times. For reducing the treatment steps, it is preferable to form an alignment mark in a wafer, to grow an epitaxial layer on the wafer with the alignment mark formed therein and to conduct next patterning using the alignment mark transferred to the epitaxial layer without correction. It is also desirable for the epitaxial growth rate to be fast as much as possible from the view point of efficient manufacture. If an alignment mark pattern deformation after the epitaxial layer growth is expected, it will be necessary to correct the alignment mark size appropriately. If an alignment mark pattern deformation too large to correct is caused, it will be necessary to add the step of forming an alignment mark again. Alignment mark size correction or alignment mark reformation is not preferable, since manufacturing costs soar.
In view of such problems caused by the multi-step epitaxial growth method, Japanese Unexamined Patent Application Publication No. Hei. 5 (1993)-343319 proposes the following countermeasures. An epitaxial layer is grown multiple times on a heavily doped n + silicon semiconductor substrate. As for the alignment marks formed in the surface portions of the respective epitaxial layers for patterning the ion-implanted regions of a conductivity type and for piling up the ion-implanted regions of the same conductivity type exactly, a new alignment mark used for patterning the second epitaxial layer surface is formed at a position different from the position at which the alignment mark used for patterning the first epitaxial layer surface is formed. The new alignment mark improves the accuracy of aligning the ion-implanted regions of the same conductivity type rather than using the alignment mark transferred to the second epitaxial layer from the first epitaxial layer.
JP No. Hei. 5 (1993)-343319 also describes an etching method for sharpening the boundary of the transferred alignment mark blunted by every epitaxial layer growth to be clear enough for a next mask alignment.
Japanese Unexamined Patent Application Publication No. 2008-130919 describes the preferable use of KOH for an etchant that corrects the blunted alignment mark boundary to be sharp.
Japanese Unexamined Patent Application Publication No. 2009-188118 discloses that it is effective to set the alignment mark pitch to be from 8 μm to 10 μm for securing an automatic alignment mark detection, when an epitaxial layer of 20 μm in thickness is grown. In one of its drawings, an alignment mark of 4 μm×4 μm size is described at a pitch of 10 μm. The drawing indicates that the mesa region is 6 μm in width.
For the manufacture of a super-junction structure by the multi-step epitaxial growth method, it is important to prevent the ion-implanted region of a conductivity type in the upper epitaxial layer from deviating from the ion-implanted region of the same conductivity type in the lower epitaxial layer. However, the alignment mark shape deforms more depending on the epitaxial growth conditions as more epitaxial layers are deposited, resulting in a deformation too large to detect the alignment mark exactly. If the alignment mark is not detected exactly, it will be impossible to align the ion-implanted region of a conductivity type in the upper epitaxial layer on the ion-implanted region of the same conductivity type in the lower epitaxial layer properly.
In the situation described above, it will be possible to detect the alignment mark and to align the ion-implanted region in the upper epitaxial layer on the ion-implanted region in the lower epitaxial layer properly, if the deformed alignment mark size is corrected as described in JP No. Hei. 5 (1993)-343319. However, it becomes necessary to add the step of correcting the deformed alignment mark size.
It is possible to sharpen the blunted alignment mark boundary by the etching with KOH so that an alignment may be successful. It is also possible to form a new alignment mark so that an alignment may be successful. However, it will be necessary to add the step of new resist patterning or to add the step of etching to form a trench, if any of the methods described above is employed.
If the epitaxial layer growth rate is made to be low, the alignment mark will not be blunted nor deformed so much. However, since the epitaxial layer growth is repeated more times to obtain a higher breakdown voltage, the lower epitaxial growth rate impairs the manufacturing efficiency. Therefore, the lower epitaxial growth rate is not preferable.
In view of the foregoing, it would be desirable to obviate the problems described above. It would be also desirable to provide a method of manufacturing a super-junction semiconductor device that facilitates reducing the additional manufacturing steps. It would be further desirable to provide a method of manufacturing a super-junction semiconductor device that facilitates suppressing the shape change caused in the transferred alignment mark to be small enough, even if the epitaxial layer growth rate is high, such that the transferred alignment mark is detectable, when the alignment mark in the lower epitaxial layer is transferred to the upper epitaxial layer surface.
SUMMARY
According to an aspect of the invention, there is provided a method of manufacturing a super-junction semiconductor device, the method including the steps of:
(a) forming an alignment mark in a semiconductor substrate having a major surface coinciding with the (001) plane, the alignment mark including a trench having a side wall perpendicular to the substrate major surface;
(b) growing an epitaxial layer above the semiconductor substrate;
(c) patterning a resist using the alignment mark transferred to the surface of the epitaxial layer;
(d) implanting p-type ions and n-type ions;
(e) repeating a cycle including the steps (b) through (d) multiple times;
(f) conducting a thermal treatment for forming an alternating conductivity type layer including a p-type column and an n-type column, both extending in perpendicular to the substrate major surface, the p-type column and the n-type column being arranged alternately and repeatedly in parallel to the substrate major surface such that p-type column and the n-type columns are adjoining to each other; and
the step (a) including:
providing the alignment mark with a trench structure including parallel linear planar patterns, forming the alignment marks used in the multiple times of the cycles collectively at different positions, and setting the mesa region width between the adjacent trenches in the trench structure used for the alignment mark in each cycle to be one-fourth of the designed total epitaxial layer thickness at the end of the step (b) in each cycle or longer.
Preferably, the mesa region width between the adjacent trenches in the trench structure used for the alignment mark in each cycle is set to be one-third of the designed total epitaxial layer thickness at the end of the step (b) in each cycle or longer.
Preferably, the side wall of the trench in the alignment mark is the (110) plane or the (1-10) plane.
According to embodiments of the invention, a method of manufacturing a super-junction semiconductor device, that facilitates suppressing, with a few additional steps, the shape change caused in the alignment mark in the upper epitaxial layer transferred from the alignment mark in the lower epitaxial layer to be small enough to detect the transferred alignment mark, even if the epitaxial layer growth rate is high, is obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects and advantages will become apparent and more readily appreciated from the following description of embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1( a ) is a first cross sectional view describing the manufacturing process for manufacturing a super-junction semiconductor substrate according to one embodiment of the invention.
FIG. 1( b ) is a second cross sectional view describing the manufacturing process for manufacturing the super-junction semiconductor substrate according to one embodiment.
FIG. 1( c ) is a third cross sectional view describing the manufacturing process for manufacturing the super-junction semiconductor substrate according to one embodiment.
FIG. 1( d ) is a fourth cross sectional view describing the manufacturing process for manufacturing the super-junction semiconductor substrate according to one embodiment.
FIG. 1( e ) is a fifth cross sectional view describing the manufacturing process for manufacturing the super-junction semiconductor substrate according to one embodiment.
FIG. 2( a ) is a cross sectional view describing a trench-shaped alignment mark schematically.
FIG. 2( b ) is a cross sectional view describing a deformed trench-shaped alignment mark schematically.
FIG. 3( a ) describes the long-sided trenches and the deformation thereof caused by the epitaxial growth.
FIG. 3( b ) describes the square trenches and the deformation thereof caused by the epitaxial growth.
FIG. 3( c ) is the oblique view of the trenches with the plane indices of the trench side walls described thereon.
FIG. 4 describes whether the accurate resist pattern alignment is possible (OK) or not (NG) depending the one-fourth of the accumulated epitaxial layer thickness and the mesa region width between the adjacent trenches.
FIG. 5 is the top plan view of a silicon substrate describing the collective arrangements of trench-shaped alignment marks on a scribe line.
FIG. 6 is the cross sectional view of a SJ-MOSFET.
DESCRIPTION OF EMBODIMENTS
Now, embodiments of the invention will be described in detail hereinafter with reference to the accompanied drawings which illustrate the preferred embodiments of the invention. Although embodiments will be described in connection with a SJ-MOSFET exhibiting a breakdown voltage of 600 V, changes and modifications are obvious to the persons skilled in art without departing from the true spirits of the invention. Therefore, the invention is to be understood not by the specific descriptions herein but by the appended Claims thereof.
Referring to FIG. 1( a ), lightly doped n − epitaxial layer 2 , that will be a buffer layer, is formed on heavily doped n + silicon semiconductor substrate 1 , the major surface thereof is the (001) plane and the thickness thereof is 625 μm. In FIGS. 1( a ), 1 ( b ), 1 ( c ), 1 ( d ), and 1 ( e ), n + silicon semiconductor substrate 1 is represented by “n + Si substrate.” The laminate including n 30 silicon semiconductor substrate 1 , the surface thereof is treated, and an epitaxial layer or epitaxial layers deposited through the subsequent steps will be collectively referred to sometimes as the “wafer.”
Referring now to FIG. 1( b ), alignment mark 3 having a trench structure including parallel linear planar patterns is formed on scribe line 5 between semiconductor chip sections 4 . The trench in the trench structure is formed through n − epitaxial layer 2 in the wafer surface portion such that the trench side walls are the (110) and (1-10) planes.
Referring now to FIG. 1( c ), phosphorus-ion-implanted region 9 is formed on the wafer by growing non-doped epitaxial layer 6 and by implanting phosphorus ions through the entire non-doped epitaxial layer 6 surface. Resist 7 for selective boron ion implantation is patterned. Then, boron ions are implanted selectively using resist 7 for a mask at the dose amount of 1.0×10 13 cm −2 to form boron-ion-implanted region 8 .
Referring now to FIG. 1( d ), the step of growing non-doped epitaxial layer 6 , the step of forming phosphorus-ion-implanted region 9 , the step of pattering resist 7 for selective boron ion implantation, and the step of implanting boron ions at the dose amount of 1.0×10 13 cm −2 for forming selective boron-ion-implanted region 8 are repeated multiple times.
Referring now to FIG. 1( e ), a thermal diffusion is conducted, after the preceding steps are repeated multiple times, to connect the ion-implanted regions vertically such that p-type column 10 a and n-type column 10 b , both 50 μm in depth, are formed. If a SJ-MOSFET that includes a drift layer formed of an alternating conductivity type layer including p-type column 10 a and n-type column 10 b , both 50 μm in depth, is formed, a breakdown voltage of the 600 V class will be obtained.
Now the reason why alignment mark 3 in the n − epitaxial layer 2 surface is preferable will be described with reference to FIGS. 3( a ), 3 ( b ), and 3 ( c ). Alignment mark 3 has the trench structure including parallel linear planar patterns formed of the trench side walls, which are the (110) and (1-10) planes.
When an epitaxial layer is grown on the wafer, in which an alignment mark having a trench structure is formed, the epitaxial layer growth rates on the trench side walls are different depending on the crystal planes thereof. Therefore, the trench changes the shape thereof greatly as the epitaxial layer grows. FIG. 3( a ) describes the planar pattern of a trench having side walls, the crystal planes thereof are described in FIG. 3( c ). In the trench described in FIG. 3( a ), the trench end portion on the (110) plane tends to curve as the epitaxial layer grows but the deformation on the (−110) plane is relatively small. The trench having a square planar pattern as described in FIG. 3( b ) tends to deform to a circular one. Based on the results described above, a trench, the short vertical side wall thereof is the (110) plane and the long vertical side wall thereof is the (−110) plane, is employed, when the epitaxial layer major surface is the (001) plane.
It is harder to feed the raw material gas for the epitaxial growth uniformly on the trench side wall than on the flat surface. Although affected by the aspect ratio, the epitaxial layer tends to grow faster in the trench opening or in the trench bottom. When the flat surface is the (001) plane, a larger pattern deformation will be caused by the epitaxial growth on the long trench side wall slanting to the (−110) plane as compared with the epitaxial growth on the long trench side wall that is the (−110) plane. In short, the epitaxial growth on the long trench side wall slanting to the (−110) plane is not preferable. Therefore, the trench, the long side wall thereof is the (−110) plane, that is perpendicular to the epitaxial layer, the major surface thereof is the (001) plane, is employed.
In repeating the epitaxial growth and the resist pattering in subsequent to the alignment mark 3 formation according to the first embodiment, the accumulated film thickness accumulated by every epitaxial growth is 10 μm. Therefore, the accumulated film thickness after two cycles of epitaxial growth and resist patterning (hereinafter referred to simply as “cycles”) is 20 μm, 30 μm after three cycles, 40 μm after four cycles, and 50 μm after five cycles.
It has been found that the alignment mark will be detected securely and the patterning will be accurate, if the mesa region width between the adjacent trenches in the trench structure formed of parallel linear planar patterns used for the alignment mark in every patterning is set to be one-fourth of the accumulated film thickness. The results are described in FIG. 4 .
FIG. 4 describes whether the accurate resist pattern alignment is possible (OK) or not (NG) depending on the accumulated epitaxial layer thickness and the mesa region width between the adjacent trenches. In FIG. 4 , the horizontal axis represents the accumulated epitaxial layer thickness and the vertical axis the mesa region width between the adjacent trenches. In FIG. 4 , “possible” (OK) is indicated by ∘ and “not” (NG) by x. The single-dotted chain line indicates the boundary between the OK and NG alignments.
As FIG. 4 indicates, the alignments will be all OK, if the mesa region width between the adjacent trenches is set to be one-fourth of the accumulated epitaxial layer thickness or longer. The one-fourth of the accumulated epitaxial layer thickness is the boundary, beyond which a flat plane is remaining in the mesa region between the adjacent trenches. If a flat plane is remaining in the mesa region between the adjacent trenches, the alignment mark will be detected automatically with a detector and the alignment will be OK.
In applying the results described in FIG. 4 in practice, the mesa region width is set to be longer than the indication by the single-dotted chain line in FIG. 4 according to this embodiment considering the deviations and errors. In detail, the mesa region width is set to be 4 μm, 7 μm, 10 μm, 15 μm, and 25 μm corresponding to the one-third of the accumulated epitaxial layer thickness or longer.
According to one embodiment, five groups of alignment marks 11 , 12 , 13 , 14 , and 15 are formed collectively before the epitaxial layer growth on scribe line 5 between semiconductor chip sections 4 as shown in FIG. 5 , which is a top plan view describing the alignment mark arrangements. In each alignment mark group 11 , 12 , 13 , 14 , or 15 , the mesa region width is set as described above. In detail, the distances between the single-headed arrows, facing opposite to each other and drawn in alignment mark groups 11 through 15 , are 4 μm, 7 μm, 10 μm, 15 μm, and 25 μm.
The first through fifth epitaxial layers are grown, phosphorus ions are implanted through the entire surfaces of the first through fifth epitaxial layers, and boron ions are implanted selectively using the resist masks obtained by patterning the resists using the alignment marks 11 through 15 shown in FIG. 5 and transferred to the surfaces of the first through fifth epitaxial layers. Then, the impurities in the phosphorus- and boron-implanted regions are diffused thermally to form n-type columns and p-type columns.
The subsequent manufacturing steps are the same with the manufacturing steps for forming the conventional planar MOS structure. A field oxide film is formed by thermal oxidation, a gate oxide film is formed, and gate polysilicon is formed. Using alignment mark 15 , the gate polysilicon is patterned, and boron ions are implanted using the patterned polysilicon as a mask. Further, p-type base region 105 is formed by thermal diffusion. Thus, it is possible to align p-type column 103 , n-type column 101 , and p-type base region 105 exactly. Further, n-type source region 106 , interlayer insulator film (BPSG) 109 , source electrode 110 , and surface protector film 111 are formed. Finally, the wafer 100 back surface is polished and drain electrode 112 is formed to complete the wafer process for manufacturing the SJ-MOSFET exhibiting a breakdown voltage of 600 V and shown in FIG. 6 .
According to the one embodiment of the invention, the step of forming an alignment mark is conducted only once, even if the epitaxial layer growth rate in manufacturing a SJ-MOSFET by the multi-step epitaxial growth method is increased. Therefore, the manufacturing process may be shortened.
Although a few embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A method of manufacturing a super-junction semiconductor device facilitates suppressing the shape change caused in the alignment mark in the upper epitaxial layer transferred from the alignment mark in the lower epitaxial layer to be small enough to detect the transferred alignment mark with a few additional steps, even if the epitaxial layer growth rate is high. Alignment mark groups, each formed of trenches including parallel linear planar patterns and used in any of the multiple epitaxial layer growth cycles, are formed collectively on a scribe line between semiconductor chip sections; and the mesa region width between the trenches in each alignment mark group indicated by the distance between the single-headed arrows, facing opposite to each other and drawn in alignment mark groups is set to be one fourth of the designed total epitaxial layer thickness at the end of each epitaxial layer growth cycle or longer. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-Part of Application Ser. No. 850,878; filed Nov. 14, 1977, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to the treating of wells, and more particularly to a method for selectively restricting the flow of fluids through performations in an oil well casing by small balls or spheres of appropriate size.
2. Description of the Prior Art
It is a common practice in completing oil and gas wells to set a string of pipe, known as casing, in the well and use cement around the outside of the casing to isolate the various hydrocarbon productive formations penetrated by the well. To establish fluid communication between the hydrocarbon bearing formations and the interior of the casing, the casing and cement sheath are perforated.
At various times during the life of the well, it may be desirable to increase the production rate of hydrocarbons by acid treatment or hydraulic fracturing. If only a short, single, hydrocarbon-bearing zone in the well has been perforated, the treating fluid will flow into this productive zone. As the length of the perforated zone or the number of perforated zones increases, treatment of the entire productive zone or zones becomes more difficult. For instance, the strata having the highest permeability will most likely consume the major portion of a given stimulation treatment leaving the least permeable strate virtually untreated. Therefore, techniques have been developed to divert the treating fluid from the high permeability zones to the low permeability zones.
Various techniques for selectively treating multiple zones have been suggested including techniques using packers, baffles and balls, bridge plugs, and ball sealers.
Packers have been used extensively for separating zones for treatment. Although these devices are effective, they are expensive to use because of the associated workover equipment required during the tubing packer manipulations. Moreover, mechanical reliability tends to decrease as the depth of the well increases.
In using baffles and balls to separate zones, a baffle ring, which has a slightly smaller inside diameter than the casing, fits between two joints of casing so that a large ball, or bomb, dropped in the casing will seat in the baffle. After the ball is seated in the baffle, the ball prevents further fluid flow down the hole. One disadvantage with this method is that the baffles must be run with the casing string. Moreover, if two or more baffles are used, the inside diameter of the bottom baffle may be so small that a standard perforating gun cannot be used to perforate below the bottom baffle.
A bridge plug, which is comprised principally of slips, a plug mandrel, and a rubber sealing element, has been run and set in casing to isolate a lower zone while treating an upper section. After fracturing or acidizing the well, the plug is generally retrieved, drilled, or knocked to the well bottom with a chisel bailer. One difficulty with the bridge plug method is that the plug sometimes does not withstand high differential pressures. Another problem with this technique is that the placement and removal of the plug can be expensive due to associated rig costs.
One of the more popular and widely used diverting techniques uses ball sealers. In a typical method, ball sealers are pumped into the well along with formation treating fluid. The balls are carried down the wellbore and to the perforations by the fluid flow through the perforations. The balls seat upon the perforations and are held there by the pressure differential across the perforations.
Although ball sealer diverting techniques have met with considerable usage, the balls often do not perform effectively because only a fraction of the balls injected actually seat on perforations. Ball sealers having a density greater than the treating fluid will often yield a low and unpredictable seating efficiency, highly dependent on the difference in density between the ball sealers and the fluid, the flow rate of the fluid through the perforations, and the number, spacing and orientation of the perforations. The net result is that the plugging of the desired number of perforations at the proper time during the treatment to effect the desired diversion is left completely to chance.
Lightweight ball sealers are ball sealers having a density less than the treating fluid density and have been proposed to improve upon this seating efficiency problem. The treating fluid containing lightweight ball sealers is injected down the well at a rate such that the downward velocity of the fluid is sufficient to impart a downward drag force on the ball sealers greater in magnitude than the upward buoyancy force of the ball sealers. Once the ball sealers have reached the perforations, they all will seat and plug the perforations provided fewer balls are injected than there are perforations accepting fluid, thereby forcing the treating fluid to be diverted to the remaining open perforations. Although these lightweight ball sealers can be highly effective in improving diversion, one problem with using these ball sealers occurs when the downward flow of fluid in the casing is so slow, that the drag forces exerted on the balls by the treating fluid may not overcome the upward buoyancy force of the ball sealers and thus the ball sealers may not be transported to the perforations. This problem is generally experienced during treatments pumped at low rates and in particular matrix treatments such as matrix acidizing.
SUMMARY OF THE INVENTION
The present invention is intended to overcome the shortcomings of the various prior art techniques for using ball sealers to divert fluid between perforations in a cased wellbore. Broadly, the invention comprises transporting ball sealers to casing perforations in a carrier fluid system which comprises a leading fluid portion having a density greater than said ball sealers density and a trailing fluid portion having a density no greater than said ball sealers density.
One embodiment of this invention involves the injection into the casing of ball sealers, a dense fluid having a density greater than the balls, and a light fluid having a density less than the balls. The light fluid is introduced into the casing following the dense fluid. The ball sealers are introduced anytime after the initiation of injection of the dense fluid (including during the injection of the light fluid) prior to introduction of any additional dense fluids. Once the ball sealers, the light fluid, and the dense fluid are in the casing, the fluids are displaced down the casing and through the perforations not plugged by the ball sealers. Because the ball sealers sink in the light fluid and float in the dense fluid, the balls are transported down the casing to the perforations. The treating fluid can have any density; however, if the treating fluid is more dense than the ball sealers, it is preferred that at least a portion of the treating fluid be introduced into the casing above the lighter fluid and thereby displacing the light fluid, the ball sealers, and the dense fluid down the casing. By this method the treating fluid will be forced into those perforations not plugged by the ball sealers.
In another embodiment of this invention, a first fluid containing ball sealers having a density less than the first fluid is injected downwardly in the casing. The downward flow rate of the first fluid is sufficient to impart a downward drag force on the ball sealers greater in magnitude than the upward buoyancy force of the ball sealers. A sufficient amount of first fluid is injected such that substantially all the ball sealers are transported to and seated on the perforations by the first fluid. After introduction of the first fluid, a second fluid less dense than the ball sealers is injected into the casing. Once the balls reach the perforations, they will seat on perforations taking fluid, plug the perforations and cause the second fluid and any remaining first fluid to flow through the remaining open perforations. Preferably the dense, first fluid is the formation treating fluid.
The present invention provides an improved method for downwardly transporting ball sealers in the casing to achieve high seating efficiency of the ball sealers onto the casing perforations. This method is particularly applicable when the injection of treating fluid into the formation is at very low rates, such as during matrix treating, and the ball sealers have a density less than the treating fluid density.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration view in section of a well illustrating one embodiment of the present invention.
FIG. 2 is an illustration view in section of a well illustrating another embodiment of this invention.
FIG. 3 is an illustration view in section of a well illustrating the position of ball sealers at the completion of a treatment carrier out in accordance with one embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a wellbore, indicated generally by the numeral 10, which extends from the earth's surface 11 through an overburden 12 to a subterranean formation 13 which contains petroleum, gas and mixtures thereof. A string of casing 14 extends from the earth's surface 11 to the bottom of the wellbore 10. The space between the casing 14 and the wall of the wellbore is filled with cement 15. The cement 15 extends as illustrated from the bottom of the wellbore 10 to earth's surface 11. The casing 14 is capped by a suitable wellhead 16 to which is coupled a suitable flowline. The casing and the surrounding cement sheath are provided with a plurality of perforations 17 penetrating the formation 13. The well may be provided with a suitable packer 18 which isolates the production from formation 13 from the remainder of the well using a tubing string 20 which extends from the wellhead 16 through packer 18. The tubing string is provided with a suitable flowline (not shown) for the introduction and withdrawal of fluids to and from the well.
If the well does not have the desired productivity, it is common practice to treat the well to improve the well's production characteristics. This may be accomplished by acidizing, hydraulic fracturing or other methods which comprise forcing a treating material down the casing and into the producing formation through the perforations 17 in the casing. As mentioned above, it is sometimes desirable to selectively close those perforations through which fluid is flowing during the treating operation so that treating fluid is forced into the formation adjacent to other perforations in the casing.
Prior to illustrating any specific embodiments of this invention, it is appropriate that the following definitions be established to clarify the relative terminology used to describe ball sealer and fluid density characteristics. Namely, light or low density fluids refer to fluids having density less than the ball sealer density. Neutral density fluids refer to fluids having a density essentially equal to the density of the ball sealer density. Conversely, dense or heavy fluids herein refer to fluids having density greater than the ball sealer density. Similarly, light, lightweight, or low density ball sealers refer to ball sealers having density less than the wellbore fluid density. While heavy or dense ball sealers refer to ball sealers having density greater than the wellbore treating fluid density.
By way of illustrating one embodiment of the present invention, it will be assumed that the well is an oil production well which is to be treated by a matrix acidizing operation to increase the permeability of formation 13 near the wellbore. It is to be understood, however, that the following description of such an acidizing operation is merely exemplary in that the invention may be used in other well treating procedures, such as hydraulic fracturing or solvent surfactant stimulation treatments.
The acidizing of formation 13 is accomplished by first pumping through production tubing 20 a dense liquid 23 to fill the lower portion of the well at least up to a level adjacent the lower perforations to be plugged with ball sealers. After a suitable quantity of dense liquid 23 has been introduced into the well, a second dense fluid 21 containing the ball sealers 25 is pumped into the casing through the producing tubing 20. In the preferred embodiment of this invention, the second dense fluid 21 would be the treating fluid. After a suitable quantity of dense fluid 21 is injected, a light, third fluid 24 is introduced into the casing through the production tubing 20. Ball sealers 25 are also contained within this light fluid 24. Because the ball sealers are heavier than the light fluid 24 and lighter than the dense fluids 23 and 21, the balls will gravitate to the bottom of light fluid 24 and float at the top of dense fluid 21.
The light fluid 24 and dense fluid 21 may mix during flow down the well to form a zone having a density intermediate to the densities of the light and dense fluids. The ball sealers will tend to migrate to that region of mixing where the fluid density is equal to the ball density.
A sufficient amount of light fluid 24 should be pumped into the well such that the ball sealers below, or contained within, the light fluid 24 will travel with the light fluid 24 as the light fluid is displaced down the casing to the perforations. If the light fluid 24 is the treating fluid, continued injection of light fluid 24 will transport the ball sealers down the casing and many of the balls may seat onto the perforations in the presence of the light fluid. If the treating fluid is a dense fluid, it is preferred that after sufficient amount of light fluid 24 has been introduced into the casing, a displacement fluid, identified in the FIG. 1 by numeral 26, be injected into the casing to displace the previously injected fluids and the ball sealers to the perforations 17.
The dense fluid 21 is introduced into the well ahead of the light fluid and may be referred to as the leading fluid. Similarly, the light fluid 24 may be referred to as the trailing fluid. Included in these two classes of fluids (i.e. dense fluids and light fluids) are any fluids with the requisite density characteristics.
Suitable dense fluid 23 may include aqueous fluids such as calcium chloride and sodium chloride solutions and non-aqueous fluids such as ortho-nitrotoluene, carbon disulfide, dimethylpthalate, nitrobenzene and isoquinoline. The purpose of introducing the dense fluid 23 into the well is to insure that the fluid in the well below the perforations to be sealed has a density greater than the ball sealer density. The ball sealers will thus float on the dense fluid and will not sink to the portion of the well below the lowest perforation taking fluid, i.e. the rathole.
Dense treating fluids 21 may include any treating liquid with the requisite density characteristics. Suitable fluids may include acid solutions such as hydrochloric acid, hydrofluoric acid, formic acid, salt weighted acid solutions, as well as suitable dense hydraulic fracturing fluids and surfactant solutions used to stimulate the formation.
The light fluid 24 introduced into the casing may include any fluid having the requisite density characteristics. Suitable light fluids include field crudes, diesel oil, aromatic solvents, light hydrocarbon condensates, low salinity brines and fresh water. The light fluid 24 may be either miscible or immiscible with the dense fluids 23 and 21. However, the light fluid is preferably miscible with the displacing fluid 26 and immiscible with dense fluid 21.
The minimum volume of light fluid 24 introduced in the casing according to this invention will vary depending on the miscibility of the light fluid 24 with dense fluid 21 and displacing fluid 26, the distance the light fluid will carry the ball sealers, the number of ball sealers to be transported down the casing and the density differential between the light fluid and the ball sealers. If the production tubing 20 extends beneath the packer 18, (as shown in FIG. 1) a sufficient quantity of light fluid 24 should be injected into tubing 20 to fill the annular space 24 between the portion of the tubing below the packer and the casing 14 with light fluid 24. It is desirable to inject sufficient light fluid to fill annular space 27 to prevent trapping of ball sealers at an interface between light fluid 24 and the more dense fluids 23 or 21 at a level between the bottom of tubing 20 and the base of the packer 18.
Preferably, both fluids 21 and 24 are formation treating fluids and the ball sealers have a density greater than the resident formation fluids. After a suitable amount of the light fluid 24 has been injected into the formation, fluid injection may be stopped to permit pressure in the well to decrease. The ball sealers which unseat from the perforation will tend to gravitate to the bottom of the light fluid and thus be less likely to be produced from the well during production of formation fluids, particularly if the production fluids are low density fluids. The balls which sink to the bottom of the well may be used again to plug perforations in the casing by injecting into the casing additional dense fluid. The dense fluid will cause the ball sealers to float upwards toward the perforations where they may seat and again divert the fluid flow.
The ball sealers used in the practice of this invention should have a density between the light fluid 24 and dense fluids 23 and 21. Ball sealers suitable for this invention may have an outer covering sufficiently compliant to conform to the perforations and have a solid rigid core which resists extrusion into or through the perforations. The ball sealers are approximately spherical in shape but other geometries may be used. The density differential between the light fluid 24 and the ball sealers is preferably sufficient to allow the ball sealers to gravitate to the bottom of the light fluid as the light fluid flows downwardly in the casing. In a typical matrix treating process, the density differential between the light fluid 24 and the ball sealers is preferably about 0.03 g/cc or more at bottom-hole conditions. Similarly, the density differential between the dense fluid 21 and the ball sealers is preferably about 0.03 g/cc or more at bottom-hole conditions. For example, if the density of ball sealers is 1.00 g/cc, the dense fluid 21 should have a density of at least 1.03 g/cc and the light fluid 24 should have a density less than 0.97 g/cc at bottom-hole conditions. To achieve this controlled density situation according to this invention, the ball sealers may be constructed specifically to yield the appropriate densities. Alternatively, a suitable ball sealer, preferably having a density between 0.95 and 1.10 g/cc, may be selected and suitable fluids 21, 23, 24, and 26 having appropriate densities at the bottom-hole conditions may then be selected.
During treatment, the ball sealers used in this invention will not remain below the lowest perforation through which the treating fluid is flowing, due to the buoyancy of the ball sealers. At least a portion of dense fluid 23 first introduced in the casing gravitates to a position below the lowest perforation through which the treating fluid is flowing. Placement of dense fluid 23 in the rathole is facilitated by using a dense fluid which is immiscible with any wellbore fluid present in the rathole. Upon introduction of the dense fluid 23 in the casing below the packer 18, pumping is preferably stopped to promote the immiscible displacement from the rathole of any lighter fluids in the rathole. The dense fluid 23 below the lowest perforations accepting treating fluid remains stagnant; therefore, there are no downwardly directed drag forces acting on the ball sealers to overcome the buoyancy force of the ball sealers to keep them below the lowest perforations taking the injected fluid.
Ball sealers injected into casing in accordance with this invention will plug the perforations through which the dense fluids are flowing with 100% efficiency. Each and every ball sealer will seat and plug a perforation provided there is a perforation through which the dense fluid is flowing and that flow is sufficient to maintain the balls within the perforated interval.
The embodiment described above may be repeated to carry out multistage treatments of the formation. For example, the process may be repeated by using a treating fluid as a displacing fluid 26. The treating fluid would be followed by light fluids and ball sealers as described above.
In another embodiment of this invention a subterranean formation penetrated by a well is treated by introducing into the well ball sealers, a treating fluid having a density greater than the density of the ball sealers, and a neutral density fluid having a density essentially the same as the density of the ball sealers. The neutral density fluid is introduced into the casing following the dense fluid and the ball sealers are introduced anytime following the initiation of the dense fluid injection (including during the injection of the neutrally dense fluid) and prior to introduction of any additional dense fluids. Ball sealers are transported down the casing to the perforations by the neutral density fluid. It is important in the practice of this embodiment to select fluids and balls which will have essentially the same density throughout the range of temperatures and pressures encountered during transport of the ball sealers to the perforations. If the ball sealers become less dense than the "neutral" density fluid, transport of the ball sealers to the perforation will be dependent on the fluid flow velocity and the density contrast.
Still another another embodiment of this invention will be described with reference to FIGS. 2 and 3. FIG. 2 shows a well completed substantially the same as described in FIG. 1 and further shows a dense fluid 30 containing ball sealers 25 being injected down casing 14 through perforations 17. Preferably, the first fluid 30 is a formation treating fluid. The light, second fluid 31 is injected into the casing and caused to flow down tubing 20 to displace the dense fluid 30 into the formation through perforations which remain open to fluid flow.
The dense fluid 30 is injected into the casing to carry the ball sealers downwardly to the perforations and to seat the balls onto perforations taking fluids. A sufficient amount of the first fluid should be injected to insure that essentially all the ball sealers have seated onto the perforations and the formation treatment has been concluded before the ball sealers are contacted by the light, second fluid. This is because it is the flow of the dense fluid which seats the ball sealers onto the perforations with 100% seating efficiency. The dense fluid carrying the ball sealers should be injected down the casing at a rate sufficient to overcome the buoyancy of the ball sealers. Should the dense fluid flow down the casing at a slow rate, such as may occur during matrix acidization treatments, the dense fluid may contain viscosity increasing agents to increase the drag on the ball sealers as the dense fluid 30 flows down the well.
Once a sufficient amount of the dense fluid 30 has been introduced into the casing, the light 31 is injected into the casing. The light fluid displaces the dense fluid 30 into the formation and through the perforations that remain unplugged.
After displacing the light fluid 31 at least to the perforations and preferably into the formation, injection is stopped and the pressure in the casing is allowed to decrease. If the downhole pressure in the casing is allowed to decrease to and preferably below the formation pressure, the ball sealers will unseat from the perforations and will sink to the bottom of light fluid 31 (as shown in FIG. 3). FIG. 3 shows the balls in the rathole after the balls have unseated from the perforations and have sunk to the bottom of light fluid 31. The well may be placed on production and the balls will be more likely to remain in the rathole if the balls are adjacent to or below the lowest perforation through which fluids are being produced. The balls will be most likely to remain in the rathole if the ball sealers are more dense than the produced formation fluids.
The balls in the rathole, as shown in FIG. 3, may be used again for fluid diversion, provided a dense fluid is again introduced into the wellbore and displaced to the rathole. For example, the ball sealers may be used to plug the perforations in a sequence basically from the bottom of the well upwards by injecting a dense fluid into the well to cause fluid flow through the perforations. The dense fluid will displace the light fluid in the bottom of the wellbore and will cause the ball sealers situated in the rathole to migrate upwardly. As the ball sealers encounter fluid flowing through the perforations, the ball sealers will be carried onto the perforations by the dense fluid. At the appropriate time, usually upon completion of stimulation, a light fluid may be introduced into the casing to reposition the balls in the rathole after the balls unseat from the perforations as described above.
It may be seen that the present invention possesses a number of advantages over procedures now used to deliver ball sealers to perforations in the casing in a wellbore. With the process of the present invention, controlled density ball sealers and injection fluids can be utilized to effect improved diversion during well stimulation without using expensive equipment and to transport ball sealers to the perforations in a manner which is independent on flow rate in the casing.
EXAMPLE 1
The following example illustrates a specific procedure for performing the method of the present invention. In this hypothetical example, a well is drilled in a carbonate formation and treated with an aqueous acidizing solution to stimulate oil production. A 3,060 foot well is completed, generally as shown in FIG. 1, with 6-inch casing through an oil producing formation. A packer is run into the casing on 23/8 inch production tubing and set at the 3,000 foot level. A perforated interval located at the 3,025-3,050 foot level contains 50 holes.
The well is to be acidized with 28% hydrochloric acid (HCl) having an approximate density of 1.14 g/cc. The maximum allowable flow rate of the acid solution down the production tubing for matrix acidization treatment of this formation is determined to be 0.5 barrels per minute (BPM). Injection rates above 0.5 BPM may fracture the formation.
Ball sealers having a 7/8-inch diameter and having a density of 1.10 g/cc are used to restrict fluid flow through the perforations having the least resistance to fluid flow. The rising velocity of ball sealers in 28% HCl is determined to be about 30 feet per minute. In order for the 28% HCl to carry the balls down the production casing, the flow rate should be at least 0.86 BPM. Therefore, at matrix acidization rates, the 28% HCl will not transport the lightweight ball sealers down the production tubing to the perforations without using a displacement technique such as provided by this invention.
The practice of this invention may be carried out in accordance with the following sequence of steps:
1. Inject a 1.2 g/cc aqueous brine containing a NaCl--CaCl 2 mixture;
2. Inject 30 barrels of the 28% HCl (1.14 g/cc) into the production tubing;
3. Inject 6 barrels of 2% potassium chloride (KCl) brine having a density of 1.02 g/cc and containing 25 ball sealers (1.10 g/cc);
4. Inject 30 barrels of 28% HCl into the casing; and
5. Inject field crude oil into the casing to displace the HCl, KCl, NaCl--CaCl 2 solution and ball sealers down the casing to the perforations.
By practicing the above procedure, the ball sealers will tend to sink in the KCl brine, but float in the 28% HCl. In this fashion the balls will accumulate at the interface or transition zone separating the 28% HCl (Step 2) and the KCl brine (Step 3) and be transported to the bottom of the well with that interface independently of the overall fluid velocity. The balls will seat onto 25 perforations through which fluids are flowing. The remaining 25 perforations remain open for fluid flow and are treated with the 30 BBLS of 28% HCl injected during Step 4. The treatment is displaced using sufficient field crude to overdisplace all acid into the formation leaving the wellbore filled with the light field crude. As a result, upon completion of the above procedure, and upon relieving the differential pressure across the perforations, the ball sealers sink to the rathole. With the ball sealers in this location, the likelihood of producing ball sealers with the formation fluids is minimized.
EXAMPLE 2
The following field test illustrates another specific procedure for performing the method of the present invention. The test described in this example was performed in a well drilled to a depth of 15,608 feet. The lower portion of the well was completed with 7-inch casing through an oil producing formation. A packer was run inside the casing on 31/2 inch tubing and set at the 15,020 foot level. The well contained 568 perforations distributed over 5 zones as set forth in Table 1.
TABLE 1______________________________________Zone Depth (feet) Perforations______________________________________1 15161-15192 1282 15235-15245 803 15286-15298 964 15345-15366 1685 15406-15418 96______________________________________
In accordance with this invention, a diversion procedure was designed using ball sealers and fluids having controlled densities. Densities were chosen such that the ball sealers would be less dense than portions of the treating fluid and would be more dense than those fluids subsequently injected during waterflood operations. By this method 100% seating efficiency was anticipated during the treatment and the ball sealers would sink to the rathole during subsequent injection of waterflood fluids.
The practice of the invention was carried out in accordance with the procedure as summarized below:
(1) 100 barrels (BBLS) of water were pumped into the well at a rate of approximately 10 barrels per minute (BPM) to check pump equipment and to establish injectivity into the formation.
(2) 120 BBLS of brine having a density of 1.18 g/cm 3 and containing 120 lightweight ball sealers (1.11-1.13 g/cm 3 density) were introduced in an attempt to seal off 120 perforations in the upper, high permeability zones prior to the injection of acid-stimulation fluids.
(3) 320 BBLS of hydrochloric acid (HCl) consisting of stages of 15% HCl and 28% HCl, were injected containing 280 ball sealers injected at a rate of 1-2 balls per barrel of fluid. Three of the 28% HCl stages were tagged with radioactive sand having radioactivity of 5 millicuries.
(4) 180 BBLS of fresh water were introduced to overdisplace the treating fluids and radioactive sand into the formation.
(5) Injection was ceased and the pressure was allowed to decrease which permitted the ball to unseat from the perforations and sink to the rathole.
Several pressure increases were observed at the surface during injection of the acid solutions. These pressure increases were attributed to balls seating on perforations. Soon after each pressure increase a corresponding pressure decrease was observed which was attributed to a breakdown of a zone to acceptance of injection fluid.
A radioactivity measuring device was run in the casing after the stimulation procedure to record the location of radioactivity in the casing and hence the location of the radioactive sand. Radioactivity was detected in the vicinity of each of the five zones which indicated fluid had penetrated all of the zones.
Upon resuming the waterflood operation, surface monitored injection rates and pressures indicated that the ball sealers had unseated from the perforations and had migrated to the rathole as indicated generally by FIG. 3.
The principle of this invention and the best mode in which it is contemplated to apply that principle has been described. It is to be understood that the foregoing is illustrative only and that other means and techniques can be employed without departing from the true scope of the invention defined in the claims. | A method is disclosed for transporting ball sealers down a perforated casing of a well to affect fluid diversion when hydraulically treating a formation penetrated by the well. In this invention, ball sealers are transported to said perforations in a carrier fluid system comprising a leading fluid portion having a density greater than said ball sealers and a trailing fluid portion having a density less than said ball sealers. The ball sealers will be moved downwardly in the casing to the perforations and will seat onto the perforations through which fluids are flowing to divert fluid through the unplugged perforations. | 4 |
BACKGROUND OF THE INVENTION
(1) Technical Field:
This invention relates to key cutting machines and more particularly concerns a tubular key cutting machine wherein a key bite is milled into a key blank in a direction oriented radially to the key blank tube.
(2) Description of the Prior Art:
Tubular keys for operation of axial pin tumbler locks such as the type generally described in U.S. Pat. No. 3,504,748 are in general use and machines for cutting or machining such tubular keys have been heretofore proposed and are subject of several U.S. Pat. Nos. including 3,418,882; 3,818,798 and 4,022,107.
In each of these disclosures the tubular key blanks are mounted adjustably relative to a rotatable milling tool and the patents include indexing means by which the relative positioning of the tubular key blanks and the milling tool can be predetermined and repeatedly reset. In actual practice the indexing means disclosed in the prior art patents is not sufficiently accurate to consistently reproduce usable tubular keys. The lack of accuracy in the prior art devices is occasioned primarily by the plurality of parts that are movably interposed between the actual indexing means and the actual milling or cutting device and/or the tubular key blank.
SUMMARY OF THE INVENTION
In the present invention the tubular key blank is positioned in a collet that will accept and hold tubular key blanks of various diameters, the collet being mounted on a turntable which is carried by the key cutting machine, the collet and tubular key blank mounted therein being movable with the turntable to a position beneath a cutting tool which is positioned in spaced relation above the turntable. The cutting tool is provided with means for rotating it and it is movable vertically as well as horizontally and provided with limiting devices to insure the accuracy of the travel of the cutting tool. The tubular key cutting machine as disclosed will cut grooves completely around the periphery of various diameter keys and it will cut such grooves to any depth required and it will also cut away portions of the tubular key blank such as master cuts in any position and any depth required. The selection of the areas of the tubular key blank to be grooved or cut are determined by rotation of the collet and the key blank therein and the relatively few parts position the tubular key blank and the cutting tool in controlled accurate desirable relation.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the tubular key cutting machine with parts broken away and parts in cross section;
FIG. 2 is a front elevation of the key cutting machine with parts broken away and parts in cross section;
FIG. 3 is a top plan view of the key cutting machine seen in FIGS. 1 and 2;
FIG. 4 is a horizontal section on line 4-4 of FIG. 2;
FIG. 5 is a horizontal view of a portion of the key cutting machine and taken on line 5-5 of FIG. 1;
FIG. 6 is a horizontal section on line 6-6 of FIG. 1; and
FIG. 7 is a perspective elevation of a tubular key as formed by the key cutting machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
By referring to the drawings and FIGS. 1,2 and 3 in particular, it will be seen that a key cutting machine has been disclosed which comprises a base 10 having an inverted L-shaped frame secured thereto at one side thereof. The inverted L-shaped frame includes a vertical section 11 and a horizontal section 12.
The base 10 rotatably supports a turntable 13 journaled on a vertical member 14 as best seen in FIGS. 2 and 3 of the drawings. A bracket 15 is attached to the vertical section 11 of the inverted L-shaped frame by fasteners 16 and extends outwardly therefrom and supports a source of rotary motion such as an electric motor, not shown. The horizontal section 12 of the inverted L-shaped frame is positioned off center with respect to the vertical member 14 on which the turntable 13 is rotatably mounted, as best seen in FIGS. 2 and 3 of the drawings.
Bearings 17 rotatably position a vertically disposed spindle 18 in a sleeve 19 which is movable vertically in a bore 20 in a movable horizontal section 12A of the inverted L-shaped frame of the machine.
An apertured disc 21 is positioned beneath the lower end of the sleeve 19 and is urged thereagainst by a spring 22 which in turn is positioned in a housing 23 secured to the lower surface of the movable horizontal section 12A. The arrangement is such that the spindle 18 may be moved vertically in one direction by the spring 22 and in the opposite direction by a handle 24 which is pivoted by pivots 25 & 26 to a bracket 27 and to a secondary housing 28 in which a secondary bearing 29 is disposed about the upper end of the spindle 18. A pulley 30 is secured to the spindle 18 immediately above a third housing 31 which mounts a third bearing assembly 32 which is engaged on the upper end of the sleeve 19 and positions both the spindle 18 and the pulley 30 so that relatively free motion of the spindle 18 is possible. A drive belt 33 is trained over the pulley 30 and extends to the electric motor heretofore referred to (not shown) so that the spindle 18 can be rotated thereby. The lower end of the spindle 18 has mounting means 34 therein by which a cutting tool 35 is attached thereto. The upper end of the spindle 18 is held in the secondary housing 28 by a bolt 36.
It will thus be seen that vertical movement imparted the spindle 18 and the cutting tool 35 by the handle 24 will move the cutting tool 35 toward and away from the turntable 13 with downward movement of the handle 24 being opposed by the coil spring 22 which tends to urge the spindle 18 upwardly. The cutting tool 35 is also movable horizontally.
In order that a tubular key blank can be properly positioned for the formation of a tubular key such as seen in FIG. 7 of the drawings, a collet 37 is mounted in a bore 38 in the turntable 13 offcenter with respect to the vertical member 14 on which the turntable 13 is rotatabl- mounted on the base 10 and the collet is so devised that tubular key blanks of various diameters can be mounted therein and held thereby. The bore 38 is of larger diameter than the portion of the collet 37 which is received thereby and positions three mounting rings 39, 40 and 41 respectively therein, the rings being held in the bore 38 in the turntable by a threaded ring 42 which is engaged in a cylindrical body 43 of the collet 37 which is positioned within the area defined by the rings 39, 40 and 41. The rings 39 and 41 are annular and continuous and the ring 40 is split vertically at one side thereof and a portion of the same cut away as best seen in FIG. 6 of the drawings.
By referring to FIG. 1 and FIG. 6, which is a cross section on line 6--6 of FIG. 1, it will be seen that a set screw 44 in a threaded bore 45 in the turntable 13 locks the split ring 40 in position in the bore 38 at a point opposite the split therein.
Still referring to FIG. 6 of the drawings, it will be seen that a threaded opening 46 is formed inwardly of one of the split ends of the split ring 40 and a bore 47 of different diameters is formed in the other end of the split ring 40 so that it extends axially with respect to the threaded opening 46. A rod 48 having a shoulder 49 inwardly of its end has an extension 50 of reduced diameter relative to the shoulder 49, the extension being threaded and engaged in the threaded opening 46. The other end of the rod 48 extends outwardly of the turntable 13 and has a knurled knob 49' thereon so it may be revolved thereby. The cylindrical portion 43 of the collet 37 is thereby rotatably positioned in the bore 38 and actually engaged by the rings 39, 40 and 41 so that it can be rotated when the split ring 40 is loosened by counterclockwise motion imparted the rod 48 by the knurled knob 49 thereon and alternately secured in desired position by rotating the rod 48 clockwise as will occur to those skilled in the art.
A pin 51' is positioned in one side of the cylindrical portion 43 of the collet 37 and extends outwardly therefrom and registers in a slot in an apertured spacing plate 51 which surrounds the collet 37 and rests on the upper surface of the turntable 13 as best seen in FIGS. 1 and 5 of the drawings. Indicia is carried on the upper surface of the plate 51 and a marker 52 is affixed to the upper surface of a block 53 which is attached to the base 10 at one side of the turntable 13 as best seen in FIGS. 2, 3 and 5 of the drawings, the block 53 being of the same height as the turntable 13. In order that the turntable 13 may be indexed into predetermined locations relative to the base 10 and the rest of the tubular key cutting machine, a plurality of circumferentially spaced openings 54 are formed in the periphery thereof in even circumferentially spaced relation to one another. One of these is seen in FIG. 2 of the drawings and the block 53 is arranged with a bore 55 in which a slidable body member 56 is disposed, the body member 56 being threadably engaged on the end of a shaft 57 which in turn has a knurled knob on its outermost end by which it may be moved longitudinally. The body member 56 is urged inwardly of the bore 55 by a spring 59.
By referring now to FIGS. 1 and 5 of the drawings, the collet 37 will be seen to include the cylindrical portion 43 heretofore referred to, the upper inner portion of which is threaded to receive a sleeve 60 which has oppositely disposed longitudinally extending grooves 61 therein. The grooves 61 are slightly wider than the width of the flat handle portion 62 of the tubular key as seen in FIG. 7 of the drawings, the tubular body thereof being indicated by the numeral 63.
In FIG. 1 of the drawings, broken lines show the positioning of an inverted tubular key with the handle portion 62 engaged in the opposite disposed grooves 61 and the tubular body 63 extending above a pair of jaws 64 which are slidably disposed on the upper end of the bore 60 and held in movable relation to one another by a pair of oppositely disposed generally U-shaped springs 65 as best seen in FIG. 5 of the drawings. The inner adjacent ends of the jaws 64 are shaped with oppositely disposed 45° V-configurations and the outer opposite ends of the jaws 64 are beveled so as to partially underlie an inwardly curving surface 66 of a rotatable collet body 67 which is threadably engaged on the upper outer surface of the cylindrical portion 43 of the collet. Jaws 64 are keyed to the portion 43.
In FIG. 1 of the drawings, the cylindrical portion 43 of the collet 37 will be seen to enclose a cap 68 immediately beneath the bore 60 so that the end of the handle portion of a tubular key positioned in the grooves 61 in the bore 60 as heretofore referred to will rest on the cap 68. The cap 68 is urged upwardly by a spring 69 in the cylindrical portion 43 of the collet 37 on a ring 70.
It will thus be seen that the collet 37 being positioned off center on the turntable 13 of the tubular key cutting machine can be rotated when desired to a position where a tubular key blank can be easily positioned therein and moved downwardly relative thereto and secured in a lowered position by tightening the rotatable collet body 67 whereupon the turntable 13 may be rotated to a position immediately to one side of the cutter 35 and beneath a guide shoe 72 which is attached by fasteners 73 to one side of the horizontal section 12 as seen in FIGS. 1 and 3 of the drawings.
In such position, the rotatable collet body 67 is rotated slightly to relieve pressure on the jaws 64 holding the tubular key blank whereupon the spring 69 will move the same upwardly and into engagement with the guide shoe 72 thus establishing a desired predetermined relation of the tubular body 63 of the tubular key blank with respect to the cutter 35 whereupon the rotatable collet body 67 is tightened and the tubular key blank secured. The turntable 13 is then rotated to bring the tubular key blank into desired position below the cutter 35 so that downward movement of the cutter 35 will cut the desired grooves around the periphery of the tubular body 63 in any position and in any depth required.
It will be observed that the proper elevation of the tubular body of the key blank is very important in the formation of a properly grooved tubular key and that the location of the grooves in the periphery of the tubular body of the tubular key blank are equally critical. In order to insure the proper location of the grooves to be formed in the tubular body of the tubular key blank, the spacing plate 51 is placed on the turntable 13 around the collet 37 and aligned by placing a slot therein over the pin 50. The spacing plate 51 will thus move with the collet and when set at the indicia marks on the plate 51, the tubular key blank will rotate due to the desired circumferentially spaced location for the formation of the grooves in the periphery thereof.
Thus the tubular key blank is held in desired position in the collet 37 and the collet 37 after being rotated to the desired position as indicated by the indicia on the spacing plate 51 is locked in position in the turntable by the actuation of the means clamping the split band 40 to the cylindrical portion 43 of the collet.
The movement of the cutter 35 is also precisely controlled so that the depth of the groove formed in the tubular body 63 of the tubular key blank will be the exact depth desired. In order to control this setting of the tubular key cutting machine, the horizontal section 12 of the machine has a projecting hub 74 as seen in FIGS. 1,2 and 3 of the drawings, the hub 74 having a spring urged detent 75 therein which is arranged for registry with one of a plurality of circumferentially positioned apertures 76 in a depth cam 77, the periphery of which includes a plurality of cam extensions 78 arranged in circumferentially spaced relation and matching the pattern of the circumferentially spaced apertures 76. Each of the cam extensions 78 is of a different height. An adjustment screw 79 is threadably positioned in a threaded bore in a portion of the housing 31 which contains the bearing 32 and is positioned immediately adjacent the pulley 30 on the spindle 13. A lock nut and lever device 80 secures the adjustment screw 79 in adjusted position relative to the spindle 18 and the adjustment screw 79 is positioned so that its lower end will engage one of the cam extensions 78 and thus determine the depth to which the cutter 35 may move with respect to the tubular body 63 of the tubular key blank.
The position of the cutter 35 is also variable transversely of the tubular key cutting machine relative to the tubular key blank so that the width of the grooves to be formed therein can be accurately and desirably controlled. The adjustment means is best illustrated in FIGS. 2,3 and 4 of the drawings, and by referring to FIG. 4 in particular, it will be seen that the outermost portion of the horizontal section 12 is actually movable transversely with respect to the remainder thereof and the vertical section 11. In FIG. 4 of the drawings, the fixed portion of the horizontal section 12 will be seen to have a cut away area 81 therein with a pair of shafts 82 and 83 respectively, positioned thereacross. The outermost portion of the horizontal section 12 is illustrated in FIG. 4 of the drawings and indicated by the reference numeral 12A and it has a section 12B of narrower width than the remainder which is provided with transverse bores 84 and 85 in which the transverse shafts 82 and 83 are respectively positioned. The outermost portion 12A of the transverse section 12 is thereby capable of transverse movement and in order that this movement can be controlled a shaft 86 is threadably engaged in a threaded bore 87 in the narrower section 12B and extends outwardly in one direction, to the left in FIG. 4, and receives a lock nut 88, the inner portion of which is engaged against the side of the narrower section 12B as illustrated. The right end of the threaded shaft 86 is unthreaded and extends through a bearing 89 and indicia collar 90 and is engaged in an adjustment knob 91. In order to move the portion 12A of the horizontal section 12 transversely to control the width of the groove being formed by the cutter 35 in the tubular body of the tubular key blank, the lock nut 88 is loosened and the adjustment knob 91 rotated thus revolving the shaft 86 and causing relative movement of the outward section 21A of the horizontal section 12. When the desired setting has been obtained, the nut 88 is tightened. The collar 90 rotates around a hub portion of the adjustment knob 91 so that adjustment can be made to realign the collar according to a pointer 92 as best seen in FIG. 2 of the drawings.
In operation, a tubular key blank is positioned in the collet 37 and depressed as heretofore described. The collet is then tightened, the spacing plate 51 is positioned over the collet and the turntable 13 rotated to bring the tubular key blank beneath the spacing shoe 72 whereupon the collet is loosened to permit the tubular key blank to move into position thereagainst, the collet tightened, and the turntable rotated to bring the tubular key blank into cutting position and the turntable locked in position by the member 56 engaging an appropriate opening 54 therein. A depth cam 77 is then positioned on the hub 74 of the transversely movable outward portion 12A of the horizontal section 12 of the machine and rotated to the desired depth of the first cut. The exceedingly fine transverse adjustment of the outward portion 12A, the spindle 18 therein and the cutter 35 is then made with reference to the width of the groove to be cut in the first position as determined by the indicia on the collar 90 and the pointer 92, as heretofore described, whereupon the cutter 35 is rotated, the handle 24 depressed and the cutter 25 will move downwardly in the exact desired relation to the tubular body 63 of the tubular key blank to form the first groove in the periphery thereof to the exact desired depth and the exact desired width.
To form the second groove, the collet 37 is loosened and revolved with the spacing plate 51 to the second indicia position thereof relative to the pointer 52, the depth cam 77 reset if necessary, and the width setting adjusted by means of the knob 91 as indicated by the relative positions of the collar 90 and the indicia thereon with the pointer 92 whereupon the cutter can be again depressed and the second groove formed to the exact desired depth and width. The operation is repeated until the desired number of grooves are formed in the peripheral surface of the tubular body 63 of the tubular key blank. When completed, the member 56 is moved from the opening 54, the turntable 13 revolved, the collet 37 loosened, and the completed tubular key removed from the machine.
Those skilled in the art will observe that the precise adjustment of the tubular key blank relative to its positioning in the collet and more importantly the precise positioning of the cutter 35 relative thereto enables the machine to repeatedly repeat the accurate formation of tubular keys from a predetermined code by simply adjusting the machine and operating the cutter as hereinbefore described. | A tubular key blank is received in a rotatable, indexable chuck. The chuck is positioned below a selectively actuatable milling tool that is movable vertically and horizontally to mill grooves at designated positions in the key blank. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This invention claims the benefit of U.S. Provisional application 60/935,959 filed Sep. 7, 2007.
FIELD OF INVENTION
Novel poly(arylenebenzimidazole) compounds, such as those derived from di(1H-benzo[d]imidazol-2-yl)arene and derivatives thereof, are obtainable from a novel C—N coupling reaction at elevated temperatures.
BACKGROUND OF THE INVENTION
Polybenzimidazoles (PBI) are among the most thermally stable polymers known. 1-5 As well as high temperature stability, the polymers have excellent flammability resistance and high chemical resistance. They are very expensive polymers but have found uses as a high performance fiber and as a film, foam, paper and in membranes for polymer electrolyte membrane fuel cells. The most common structure is synthesized by reaction of biphenyl-3,3′,4,4′-tetraamine with isophthalic acid and these conversions have been carried out under a wide variety of conditions. 4
Poly (N-phenylbenzimidazoles) 6-8 have also been synthesized. They are more soluble and are reported to be more thermooxidatively stable than the parent PBI polymers since the NH group has been replaced by a phenyl group.
Several years ago, the present inventors found that high molecular weight polymers could be prepared from 4-(4-hydroxyphenyl)phthalazin-1(2H)-one by reaction with activated halides. 9,10 The N—C coupling reaction was unexpected since the NH group behaves like a phenolic OH group in this reaction. These polymers are excellent high temperature thermoplastics and are currently being commercialized in China.
The present inventors subsequently prepared bisphthalazinone structures from the monomers shown in Scheme 1 11 , however, these polymers were very difficult to process because of crystallinity and very high glass transition temperatures. This problem was recently alleviated by the synthesis of the more flexible monomers shown in Scheme 2. 12,13
There has been a great deal of recent effort centered on Pd-catalyzed C—N coupling reactions of NH groups with unactivated halides, 26,27 as well as methods to improve the standard Ullmann-type, copper-catalyzed, reactions. 28,29 These reactions generally require the use of aryl bromides or iodides and quite high yields have been obtained. These reactions have not been reported for the formation of high molecular weight polymers.
In a series of papers and patents, Hergenrother and associates described the synthesis of high performance polymers, poly(aryl ether)benzimidazoles, by the reaction of bisphenols containing benzimidazole moieties with activated halides. 14-17 The synthesis, properties and potential applications of this class of polymers has been extensively reviewed. 18
Connell found that isophthaloyl-containing poly(aryleneether benzimidazoles (PAFBI) exhibited high mechanical properties in the form of unoriented thin films and carbon fiber reinforced composites. 22
Poly (arylene ether)s containing N-arylenebenzimidazole groups were also prepared by the aromatic nucleophilic displacement reaction of two new bis(hydroxyphenyl-N-arylenebenzimidazole)s with activated aromatic difluorides in sulfolane at 200° C. in the presence of anhydrous potassium carbonate. 14,15,19-24 The polymers exhibited glass transition temperatures ranging from 264 to 352° C. and inherent viscosities from 0.79 to 1.99 dl g−1 and had very good thermal stability. 5,14
The polymers exhibited lower Tgs, tensile properties, and moisture uptake than poly(arylene ether benzimidazole)s, presumably due to the lack of hydrogen bonding. The preparation of these polymers, as illustrated in the example immediately below, is a very lengthy and expensive process and some of the intermediates are carcinogenic. 8
It is an object of this invention to provide novel polymers and copolymers.
It is another object of this invention to provide methods for the manufacture of the novel polymers and copolymers.
Novel polymers and copolymers of this invention have value resulting from their thermal stability and their ability to form films, including flexible films, by casting from solution, which films may be employed in a variety of applications, including high performance applications, for example as electrolyte membranes in fuel cells. In particular the excellent high temperature properties of the polymers and copolymers make them useful as films, matrices in carbon fiber reinforced composites and high performance adhesives.
A first aspect of the invention relates to novel polymers and copolymers thereof. The novel polymers are of the formula I
wherein Ar, Ar 2 , Ar 3 , and X are defined as follows:
Ar is a divalent radical selected from the group consisting of:
Ar 2 is a fused ring selected from the group consisting of:
Ar 3 is a divalent radical selected from the group consisting of:
X is a divalent radical selected from the group consisting of:
and (m+n) ranges from 1 to 10,000, preferably 1 to 1000, and more preferably 30 to 500, where m is an integer of at least 1, and preferably 30 to 500, and n is an integer from 0 to 9999, preferably 0 to 999, and more preferably 0 to 500.
In another aspect of the invention there is provide a process for preparing the novel polymers and copolymers by a novel carbon-nitrogen (C—N) coupling of benzimidazoles to activated halides at temperatures not below 160° C., ie a temperature of at least 160° C. The polymers are prepared by
a process which comprises the reaction step at a temperature of no less than 160° C., ie. a temperature of at least 160° C., wherein Ar, Ar 2 , X, m and n are as defined above, and Halogen is selected from F, Cl, Br and I, preferably F or Cl.
The copolymers are prepared by a process which comprises the reaction step
at a temperature of no less than 160° C., ie. a temperature of at least 160° C., wherein Ar, Ar 2 , Ar 3 , X, m and n are as defined above, and Halogen is selected from F, Cl, Br and I, preferably F or Cl.
DESCRIPTION OF THE INVENTION
In the preparation discussed supra in the Background of the Invention, of poly(arylene ether benzimidazole)s and poly(N-arylenebenzimidazole)s 21,22 both NH and OH groups are present in the monomers but only the OH reacts under the conditions used.
Surprisingly, it has now been found that, under similar conditions, but at higher temperatures, to those used for the preparation of poly(arylene ether benzimidazole)s and poly(N-arylenebenzimidazole)s, the NH group in benzimidazoles will undergo a C—N coupling reaction with activated halides to give novel polymers of high molecular weight, of the invention, as illustrated in the example below.
Accordingly, one aspect of the invention relates to a process which comprises the reaction step
at a temperature of no less than 160° C., as described above.
The process of this aspect of the invention is typically performed at a temperature of at least about 170° C. and typically at a temperature up to 320° C., such as at least about 180° C. or about 190° C., such as at about 200° C. or 210° C. Higher temperatures may be required depending on the halogen, in the starting compound, for example when the halogen is Cl, higher temperatures are typically required than for the corresponding reaction where the Halogen is F. The halogen may be selected from the group consisting of Br, Cl, I, and F, and more typically is selected from the group consisting of F and Cl.
Preferably, if X is SO 2 or CO, the halogen will be F, so as to avoid the higher temperatures required for other values of halogen, especially Cl. In the case where X is SO 2 or CO, and the Halogen is Cl, the reaction is typically carried out at a temperature of 250° C. to 320° C., in diphenylsulphone or benzophenone as solvent.
The process is suitably carried out in the presence of a base, such as K 2 CO 3 and further typically comprises the use of a solvent such as sulfolane or other aprotic dipolar solvents, or diphenylsulphone or benzophenone. The size of the polymer synthesized, as known to the skilled person, may vary depending on stoichiometries and concentration. Suitably, in the process of this aspect of the invention, m is an integer between 1 and 10,000, and preferably 1 to 1000, and more preferably m is 30 to 500.
In general the properties of the polymer depend on the total chain length and in particular the end to end distance. The terminal groups of the polymer will typically be NH groups of the benzimidazole, or cyclics may form.
A further aspect of the invention relates to copolymers of the formula
as described above.
A further aspect of the invention relates to a process which comprises the reaction step:
at a temperature of no less than 160° C., as described above.
The process of this latter aspect of the invention is typically performed at a temperature of at least about 170° C. and typically at a temperature up to 320° C., such as at least about 180° C. or about 190° C., such as at about 200° C. or 210° C. Higher temperatures may be required depending on the halogen, in the starting compound, for example when the halogen is Cl, higher temperatures are typically required than for the corresponding reaction where the Halogen is F. The halogen may be selected from the group consisting of Br, Cl, I, and F, and more typically selected from the group consisting of F and Cl.
Preferably, if X is SO 2 or CO, the Halogen will be F, so as to avoid the higher temperatures required for other values of Halogen, especially Cl. In the case where X is SO 2 or CO, and the halogen is Cl, the reaction is typically carried out at a temperature of 250° C. to 320° C., in diphenylsulphone or benzophenone as solvent.
The process is suitably carried out in the presence of a base, such as K 2 CO 3 and further typically comprises the use of a solvent such as sulfolane or other aprotic dipolar solvents, or diphenylsulphone or benzophenone. The size of the polymer synthesized, as known to the skilled person, may vary depending on stoichiometries and concentration. Suitably, under the process of this aspect of the invention,
(m+n) can range from 1 to 10,000 wherein m must be at least 1, preferably 1 to 1000, and more preferably m is 30 to 500, and n can vary from 1 to 9999, preferably 1 to 999, and more preferably 1 to 500.
In general the properties of the copolymer depend on the total chain length and in particular the end to end distance. The terminal groups of the polymer will typically be NH groups of the benzimidazole, or cyclics may form.
Advantageously, the polymers and copolymers of the present invention have very high Tgs and they are very thermally stable. The T d-5% (5% weight loss in N 2 ) for the copolymer of example 7 below is 539° C., similar to the properties of polymers prepared by Hergenrother et al.
The molecule 4-(1H-benzo[d]imidazol-2-yl)phenol has been used as an end-cap in the synthesis of poly(arylene ether benzimidazole)s and poly(N-arylenebenzimidazole)s to control the molecular weight of the polymers. 17 In this reaction it is reported that it acts as a monofunctional compound, i.e. with only the OH group entering the reaction. In the present invention it has been found, surprisingly, that 4-(1H-benzo[d]imidazol-2-yl)phenol can behave as a bifunctional compound and that high molecular weight polymers (n=0) can be prepared by reaction with activated dihalides, as shown below. Copolymers can also be synthesized by copolymerization with bisphenols as shown below with 4,4′-biphenol.
Accordingly a further aspect of the invention relates to copolymers of the formula
where Ar 2 , in and n are as defined above.
High molecular weight copolymers are produced by copolymerizing the bisbenzimidazoles with bisphenols as shown in the example below with 4,4′-biphenol.
Copolymers with 2,6-bisbenzimidazolylpyridine are synthesized as follows:
Accordingly, a further aspect of the invention relates to copolymers of the formula
where Ar, Ar 2 , m and n are as defined supra.
A further aspect of the invention relates to compounds obtainable by a process of the invention. In particular, an interesting aspect of the invention relates to polymers are of the formula I
wherein in and n are as defined above and Ar, Ar 2 , Ar 3 , and X are defined as follows:
Ar is a divalent radical selected from the group consisting of:
Ar 2 is a fused ring selected from the group consisting of:
Ar 3 is a divalent radical selected from the group consisting of:
X is a divalent radical selected from the group consisting of:
EXAMPLES
Characterization
Matrix assisted laser desorption ionization time-of-flight (MALDI-TOF) mass spectra were recorded on a Kratos Kompact MALDI-III TOF mass spectrometer with the instrument set in positive reflection mode to get higher resolution. The melting points were taken on a Fisher-Johns melting point apparatus. Ultraviolet-visible (UV-vis) absorption spectra were recorded on a CARY 50 spectrophotometer. Fluorescent spectra were taken on a Fluoro Max-2 spectrophotometer. Monitoring the progress of the reaction and purity of the isolated monomers was done by high performance liquid chromatography (HPLC, Milton Roy, CM 4000) with methanol as an eluent and a UV detector at 254 nm. The T g s of the polymers were obtained using a Seiko 220 DSC at a heating rate of 20° C./min. The T g was taken from the midpoint of the change in slope of the baseline, while melting temperature were taken from the onset of the change in slope to a minimum of the endotherm of peak. The weight loss data were obtained from a Seiko 220 TGA/DTA instrument at a heating rate of 20° C./min in nitrogen. Inherent viscosity data were obtained with a calibrated Ostwald viscometer. A water bath with a Julabo (Model type PC) heater was employed to control the temperature.
Homopolymers
Example 1
Polymerization of 1,3-dibenzimidazolylbenzene with bis(4-fluorophenyl)sulfone
The following procedure is typical for the preparation of homopolymers.
A 25 mL three-necked round-bottom flask was equipped with an argon inlet, magnetic stirrer, a Dean-Stark trap and condenser. The flask was flushed with argon, and then charged with 1, 3-dibenzimidazolylbenzene (0.62 g, 2.0 mmol), bis(4-fluorophenyl)sulfone (0.51 g, 2.0 mmol), cesium carbonate (0.65 g, 2.0 mmol), calcium carbonate (0.20 g, 2.0 mmol), sulfolane (2.5 g), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with chlorobenzene. After chlorobenzene was removed, the reaction mixture was brought up to 210° C. for 2 h. Additional 1 mL of sulfolane was then added to dilute the solution and the reaction was kept at 210° C. for 6 h. When the color of the reaction system changed and the viscosity increased significantly, the reaction mixture was cooled down and diluted with 2 mL of solvent. The resulting solution was poured into 200 mL of methanol and 2 mL of acetic acid to precipitate out the polymer. The resulting polymer was partially soluble in chloroform or dichloromethane and was redissolved. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the resulting polymer was precipitated out by pouring into methanol. The polymer was collected and dried in vacuo at 80° C. for 24 h. Yield 90%.
Co-Bisbenzimidazoles
Example 2
Copolymer of 1,3-dibenzimidazolylbenzene and 1,4-dibenzimidazolylbenzene 50/50
The polymer was prepared in a manner similar to Example 1. The resulting polymer was not very soluble in chloroform and gave a brittle film by casting from its DMSO-solution.
Example 3
Copolymer of 1,3-dibenzimidazolylbenzene and 2,6-bisbenzimidazolylpyridine 50/50
A 25 mL three-necked round-bottom flask was equipped with an argon inlet, magnetic stirrer, a Dean-Stark trap and condenser. The flask was flushed with argon, and then charged with 1, 3-dibenzimidazolylbenzene (0.20 g, 0.64 mmol), 2,6-bisbenzimidazolylpyridine (0.20 g, 0.64 mmol), bis(4-fluorophenyl)sulfone (0.33 g, 1.3 mmol), calcium carbonate (0.13 g, 1.3 mmol), anhydrous potassium carbonate (0.20 g, 1.4 mmol), sulfolane (2 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with chlorobenzene. The chlorobenzene was then removed, and the reaction mixture was brought up to 180-190° C. for 2 h, and then at 210° C. for 2 h additional. 1 mL of sulfolane was added to dilute the solution that was kept at 210° C. for 4 h. When the viscosity significantly increased the reaction mixture was cooled down and diluted. The resulting solution was poured into 200 mL of methanol and 2 mL of acetic acid to precipitate out the polymer. The resulting polymer was redissolved in DMSO. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the polymer was precipitated out by pouring into methanol. The polymer was redissolved in chloroform, and reverse precipitated in methanol. The polymer was collected and dried in vacuo at 80° C. for 24 h. Yield 90%.
Copolymerization Reactions with Bisphenols
General Procedure
The synthesis of most of the copolymers were carried out in sulfolane. The polymerization was conducted initially at 160-170° C. for 1.5-2 h to remove the water with chlorobenzene and then at 180-200° C. to effect the polymerization reaction.
Examples 4-6
Copolymerization of 1,3-dibenzimidazolylbenzene with 4,4′-biphenol
Example 4 is typical of the procedure used.
To a 25 mL three-necked round-bottom flask equipped with a Dean-stark trap, a water condenser, a magnetic stirrer and a nitrogen inlet were added 4,4′-biphenol (0.056 g 0.30 mmol), 1,3-dibenzimidazolylbenzene (0.22 g, 0.70 mmol), bis(4-fluorophenyl)sulfone (0.25 g, 1.0 mmol), calcium carbonate (0.15 g, 1.5 mmol), anhydrous potassium carbonate (0.28 g, 2.0 mmol), sulfolane (2 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with the chlorobenzene. The chlorobenzene was then removed, and the reaction mixture was brought up to 180-190° C. for 1-2 h. When the reaction mixture became too viscous to be stirred, an additional 2 mL of sulfolane was added to dilute the solution and it was kept at that temperature for 20 min. When the viscosity increased, the reaction mixture was cooled down, and diluted with dichloromethane. The solution was poured into 200 mL of methanol and 2 mL of acetic acid to precipitate out the polymer. The resulting polymer was redissolved in chloroform. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the polymer was precipitated out by pouring into methanol. The polymer was collected by filtration and dried in vacuo at 80° C. for 24 h. Yield 97%.
The property data for the copolymers is shown in the table.
Examples
Tg (° C.)
TGA-5% (° C.)
ξ inh (dL/g)
1
100%
295
530
0.22
4
70%
30%
274
519
0.44
5
50%
50%
260
533
0.34
6
30%
70%
248
521
0.75
Examples 7-10
Copolymerization of 1,3-dibenzimidazolylbenzene with 4,4′-dihydroxybenzophenone
Example 7 is typical of the reaction conditions used.
To a 25 mL three-necked round-bottom flask equipped with a Dean-stark trap, a water condenser, a magnetic stirrer and a nitrogen inlet were added 4,4′-dihydroxybenzophenone (0.13 g, 0.60 mmol), 1,3-dibenzimidazolylbenzene (0.43 g, 1.4 mmol), bis(4-fluorophenyl)sulfone (0.51 g, 2.0 mmol), calcium carbonate (0.22 g, 2.2 mmol), anhydrous
potassium carbonate (0.28 g, 2.0 mmol), sulfolane (2 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with chlorobenzene. The chlorobenzene was then removed, and the reaction mixture was brought up to 180-190° C. for 1-2 h. When the reaction mixture became too viscous to be stirred, an additional 2 mL of sulfolane was added to dilute the solution that was kept at that temperature for 20 min. When the viscosity was increased, the reaction mixture was cooled down and diluted with dichloromethane and then the solution was poured into 200 mL of methanol and 2 mL of acetic acid to precipitate out the polymer. The resulting polymer was redissolved in chloroform. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the polymer was precipitated out by pouring into methanol. The polymer was collected by filtration and dried in vacuo at 80° C. for 24 h. Yield 95%.
The property data for the copolymers are shown in the table.
Examples
Tg (□C)
TGA-5% (□C)
ηinh (dL/g)
7
70%
30%
265
539
0.28
8
50%
50%
247
540
0.32
9
40%
60%
240
537
0.44
10
30%
70%
230
536
0.43
Examples 11-12
Copolymer of 4,4′-bisbenzimidazolyldiphenyl ether with 4,4′-biphenol
The copolymers were prepared as in Example 4.
Examples
Tg (□C)
TGA-5% (□C)
η inh (dL/g)
11
70%
30%
255
524
0.43
12
50%
50%
268
535
0.60
Example 13
Copolymer of 1,2-dibenzimidazolylbenzene with 4,4′-biphenol
The copolymer was prepared as in Example 4.
Example 14
Copolymer of 1,4-dibenzimidazolylbenzene with 4,4′-dihydroxybenzophenone
The copolymer was prepared as in Example 4.
Example
Tg (□C)
TGA-5% (□C)
η inh (dL/g)
14
30%
70%
260
440
ND
Examples 15-17
Copolymers from 2,6-bisbenzimidazolylpyridine
The polymers were prepared as in example 4.
Ex- amples
Tg (□C)
TGA (□C)
η inh (dL/g)
15
30%
70%
ND
521
0.68
16
50%
50%
242
524
0.33
17
70%
30%
253
536
0.23
Polymers from 2-(4-hydroxyphenyl)benzimidazole
Example 18
Copolymerization of 2-(4-hydroxyphenyl)benzimidazole with 4,4′-biphenol
To a 25 mL three-necked round-bottom flask were added 2-(4-hydroxyphenyl)benzimidazole (0.15 g, 0.71 mmol), bis(4-fluorophenyl)sulfone (0.36 g, 1.4 mmol), calcium carbonate (0.22 g, 2.2 mmol), anhydrous potassium carbonate (0.28 g, 2.0 mmol), sulfolane (1.5 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with chlorobenzene. The chlorobenzene was then removed, and the reaction mixture was brought up to 180-190° C. for 1-2 h. The resulting mixture was analyzed by HPLC and MALDI-TOF mass spectrometry. The MALDI-TOF-MS spectrum showed the product was oligomeric with all the OH & NH groups reacted. 4,4′-biphenol (0.13 g, 0.71 mmol) and cesium carbonate (0.19 g, 0.58 mmol) were added and the reaction mixture was brought up to 180-190° C. for 1 h. When the reaction system became too viscous to be stirred, an additional 2 mL of sulfolane was added to dilute the solution and it was maintained at 180° C. for 0.5 h. When the viscosity increased, the resulting mixture was cooled down and diluted with dichloromethane and the solution was poured into 200 mL of methanol and 2 mL of acetic acid to precipitate out the polymer. The resulting polymer was redissolved in chloroform. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the polymer was precipitated out by pouring into methanol. The polymer was collected and dried in vacuo at 80° C. for 24 h. Yield 95%. A flexible thin film was cast from its chloroform-solution. Tg 251° C., TGA-5% weight loss at 532° C.
Example 19
Copolymerization of 2-(4-hydroxyphenyl)benzimidazole with bisphenol A (BPA)
To a 25 mL three-necked round-bottom flask equipped with a Dean-Stark trap, a water condenser, a magnetic stirrer and a nitrogen inlet were added BPA (0.16 g, 0.71 mmol), 2-(4-hydroxyphenyl)benzimidazole (0.15 g, 0.71 mmol), bis(4-fluorophenyl)sulfone (0.36 g, 1.4 mmol), calcium carbonate (0.22 g, 2.2 mmol), anhydrous potassium carbonate (0.28 g, 2.0 mmol), cesium carbonate (0.19 g, 0.58 mmol), sulfolane (1.5 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with chlorobenzene. The chlorobenzene was then removed. The reaction mixture was brought up to 180-190° C. for 1 h. When the reaction mixture became too viscous to be stirred, an additional 2 mL of sulfolane was added to dilute the solution and it was kept at that temperature for 30 min. When the viscosity increased, the reaction mixture was cooled down and diluted with dichloromethane and the solution was poured into 200 mL of methanol and 2 mL of acetic acid to precipitate out the polymer. The resulting polymer was redissolved in chloroform. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the polymer was precipitated out by pouring into methanol. The fibrous polymer was collected and dried in vacuo at 80° C. for 24 h. Yield 97%. A good film was cast from its chloroform-solution. Tg 230° C., TGA −5% weight loss 489° C.
Example 20
Copolymer of 1,3-dibenzimidazolylbenzene with BPA: polyetherketone
To a 25 mL three-necked round-bottom flask equipped with a Dean-stark trap, a water condenser, a magnetic stirrer and a nitrogen inlet there were added BPA (0.22 g, 0.97 mmol), 1,3-dibenzimidazolylbenzene (0.30 g, 0.97 mmol), 4,4′-difluorobenzophenone (0.42 g, 1.9 mmol), anhydrous potassium carbonate (0.28 g, 2.0 mmol), cesium carbonate (0.19 g, 0.58 mmol), sulfolane (1.5 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with the chlorobenzene. The chlorobenzene was then removed. The reaction mixture was brought up to 180-190° C. After heating for 3 h, the reaction mixture became too viscous to be stirred. An additional 2 mL of sulfolane was then added to dilute the solution, and the resulting mixture was kept at this temperature for an additional 30 min. The viscous solution was cooled down and diluted with dichloromethane and the solution was poured into a mixture composed of methanol (100 mL)/water (100 mL)/acetic acid (2 mL) to precipitate out the polymer. The resulting polymer was redissolved in chloroform. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials, and the polymer was precipitated out by pouring into methanol. The fibrous polymer was collected and dried in vacuo at 80° C. for 24 h. Yield 98%. A good film was cast from its chloroform-solution.
The polymer was soluble in THF. Tg 119° C., TGA −5% weight loss 545° C., Mn 18000, Mw 49000, MWD 2.8, η inh 0.38 dL/g.
Example 21
Copolymer of 2,6-bisbenzimidazolylpyridine with 4,4′-(perfluoropropane-2,2-diyl)diphenol: polyethersulfone
To a 25 mL three-necked round-bottom flask equipped with a Dean-stark trap, a water condenser, a magnetic stirrer and a nitrogen inlet were added 4,4′-(perfluoropropane-2,2-diyl)diphenol (0.32 g, 0.96 mmol), 2,6-bisbenzimidazoylpyridine (0.30 g, 0.96 mmol), bis(4-fluorophenyl)sulfone (0.49 g, 1.9 mmol), anhydrous potassium carbonate (0.28 g, 2.0 mmol), sulfolane (1.5 mL), and chlorobenzene (3 mL). The mixture was heated to azeotrope off the resulting water with chlorobenzene. The chlorobenzene was then removed, and the orange colored reaction mixture was brought up to 180-190° C. After heating for 2 h, the reaction mixture became reddish, and too viscous to be stirred. An additional 2 ml of sulfolane was then added to dilute the mixture, and the resulting mixture was kept at this temperature for an additional 30 min. When the reaction mixture changed into dark red and the viscosity increased significantly, the resulting mixture was cooled down, and diluted with dichloromethane. The resulting mixture was poured into a mixture composed of methanol (100 mL)/water (100 mL)/acetic acid (2 mL) to precipitate out the polymer. The precipitated polymer was redissolved in chloroform. The polymer solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials. The polymer was precipitated out by pouring the chloroform solution into methanol. The polymer was collected by filtration, and dried in vacuo at 80° C. for 24 h. Strong cast films were obtained from its chloroform-solution. The polymer was soluble in THF. Tg 245° C., TGA −5% weight loss 534° C., Mn 35000, Mw 79000, MWD 2.2, η inh 0.29 dL/g.
UV Absorption and Fluorescence
All of the Homopolymers and Copolymers Containing the Benzimidazole Groups Strongly Absorb UV Light and are Fluorescent as Shown in Table 1.
TABLE 1
UV absorption and fluorescence properties of polymers
Examples
λ abs, nm a
λ ex, nm b
λ em, nm c
4
282
327
387
5
282
278
379
6
278-281
319
378
7
288
331
387
8
285
327
382
9
285-287
319
381
10
285-290
314
380
12
283
300
408
13
279
314
401
14
282
328
375, 395, 417
15
281
315, 329
378
16
286
314
376
17
286-287
341
379
a Maximum absorption wavenumber in UV-vis spectra
b Excitation wavenumber.
c Emission wavenumber.
Copolymers from bis(4-chlorophenyl)sulfone with 4,4′-biphenol
Examples 22-26
Example 22 is typical of the reaction conditions used. 1,3-Dibenzimidazolylbenzene g, 1.0 mmol), 4,4′-biphenol (0.19 g, 1.0 mmol), cesium carbonate (0.20 g, 0.60 mmol), potassium carbonate (0.21 g, 1.5 mmol), diphenylsulfone (1.5 g), and chlorobenzene (3 mL) were charged into a 25 mL three-necked round-bottom flask equipped with a magnetic stirrer, an Ar inlet, and a Dean-Stark trap with a condenser under Ar atmosphere. The mixture was heated and stirred at 170° C. for 1 h to azeotrope off water. After the removal of chlorobenzene, the reaction mixture was cooled. To the cooled reaction mixture was added bis(4-chlorophenyl)sulfone (0.59 g, 2.0 mmol). The mixture was heated and stirred at 280° C. for 0.5 h, and then was heated to 300° C. for 15 h with the frequent addition of another 1 g of diphenyl sulfone, each time the reaction system became too viscous to be stirred. The resulting mixture was cooled, quenched by addition of acetic acid, and then poured into methanol. The precipitated polymer was collected by filtration and washed with boiling methanol. The crude polymer was redissolved in chloroform. The chloroform solution was filtered through a thin layer of Celite (trademark) to remove inorganic materials. The polymer was further purified by reprecipitation from chloroform solution into methanol. The polymer collected by filtration was washed thoroughly with boiling methanol, and dried in vacuo at 40° C. overnight. Yield 90%. The resulting polymer was soluble in various organic solvents such as chloroform. Flexible, and transparent films were obtained by casting from its chloroform solution.
Example 23
The copolymer was prepared in the same manner to Example 22, except that potassium hydroxide (3.6 mmol) and cesium carbonate (0.40 mmol) were used as base instead of potassium carbonate (1.5 mmol) and cesium carbonate (0.60 mmol). The polymerization was completed by heating at 250° C. for 7 h. Yield 84%. The resulting polymer was soluble in various organic solvents such as chloroform. Creasable, colorless and transparent films were obtained by casting from its chloroform solution.
Example 24
The copolymer was prepared in the same manner to Example 22, except that potassium hydroxide (3.6 mmol) and potassium carbonate (0.40 mmol) were used as base instead of potassium carbonate (1.5 mmol) and cesium carbonate (0.60 mmol). The polymerization was completed by heating at 256-258° C. for 20 h. Yield 91%. The resulting polymer was soluble in various organic solvents such as chloroform. Creasable, colorless and transparent films were obtained by casting from its chloroform solution.
Example 25
The copolymer was prepared in the same manner as Example 24, except that benzophenone was used as solvent instead of diphenylsulfone. The polymerization was completed by heating at 260° C. for 66 h. Yield 99%. The resulting polymer was soluble in various organic solvents such as chloroform. Yellow, and slightly brittle films were obtained by casting from its chloroform solution.
Example 26
The copolymer was prepared in the same manner as Example 22, except that sulfolane was used as solvent instead of diphenyl sulfone, and that potassium hydroxide (3.6 mmol), cesium carbonate (0.20 mmol), and potassium carbonate (4.0 mmol) were used as base instead of potassium carbonate (1.5 mmol) and cesium carbonate (0.60 mmol). The polymerization was completed by heating at 170-180° C. for 3.5 d. Yield 93%. The resulting polymer was soluble in polar organic solvents such as NMP. Yellow, and slightly brittle films were obtained by casting from its DMAc solution.
Examples Solvent
22 Diphenyl 50% 50% sulphone 23 Diphenyl 30% 70% sulphone 24 Diphenyl 30% 70% sulfone 25 Benzophenone 30% 70% 26 Sulfolane 30% 70% Examples Tg (° C.) TGA-5% (° C.) η inh (dL/g) 22 100% 254 543 0.35 23 100% 242 541 0.34 24 100% 242 548 0.36 25 100% 235 548 0.29 26 100% 241 517 0.36
Homopolymers from 4,4′-difluorobenzophenone
Example 27
1,3-Dibenzimidazolylbenzene (0.62 g, 2.0 mmol), cesium carbonate (0.098 g, 0.30 mmol), potassium carbonate (0.25 g, 1.8 mmol), sulfolane (1 g), and chlorobenzene (3 mL) were charged into a 25 mL three-necked round-bottom flask equipped with a magnetic stirrer, an Ar inlet, and a Dean-Stark trap with a condenser under Ar atmosphere. The mixture was heated and stirred at 170° C. for 1 h to azeotrope off water. After the removal of chlorobenzene, the reaction mixture was cooled. To the cooled reaction mixture was added 4,4′-difluorobenzophenone (0.44 g, 2.0 mmol) and calcium carbonate (0.21 g, 2.1 mmol). The mixture was heated and stirred at 215° C. for 2.5 h with the frequent addition of another 1 g of sulfolane each time the reaction system became too viscous to be stirred. The resulting mixture was cooled, quenched by addition of acetic acid, and then poured into methanol to precipitate a light yellow fiber. The precipitated polymer was collected by filtration and washed with boiling methanol. The crude polymer was purified by extraction with boiling distilled water to remove any salt. The polymer collected by filtration was washed with boiling methanol, and dried in vacuo at 40° C. overnight. Yield 93%. The resulting polymer was soluble in polar organic solvents such as NMP or DMAc. Flexible, and light yellow films were obtained by casting from its NMP solution.
Copolymers from 4,4′-difluorobenzophenone and bis(4-chlorophenyl)sulfone with 4,4′-biphenol
General Procedure
All the polymerizations of bisbenzimidazoles with 4,4′-difluorobenzophenone were carried out in sulfolane. The copolymerization was conducted by one-pot two-step procedures: (1) reaction of bisbenzimidazole and 4,4′-difluorobenzophenone; (2) the reaction of bis(4-chlorophenyl)sulfone and 4,4′-biphenol.
Example 28-29
Example 28 is typical of the reaction conditions used. 1,3-Dibenzimidazolylbenzene (0.43 g, 1.4 mmol), cesium carbonate (0.068 g, 0.21 mmol), potassium carbonate (0.17 g, 1.3 mmol), sulfolane (1 g), and chlorobenzene (3 mL) were charged into a 25 mL three-necked round-bottom flask equipped with a magnetic stirrer, an Ar inlet, and a Dean-Stark trap with a condenser under Ar atmosphere. The mixture was heated and stirred at 180° C. for 1 h to azeotrope off water. After the removal of chlorobenzene, the reaction mixture was cooled. To the cooled reaction mixture was added 4,4′-difluorobenzophenone (0.32 g, 1.5 mmol) and calcium carbonate (0.15 g, 1.5 mmol). The mixture was heated and stirred at 220° C. for 3.5 h with the frequent addition of another 1 g of sulfolane each time the reaction system became too viscous to be stirred. The resulting mixture was cooled. To the cooled resulting mixture was added 4,4′-biphenol (0.11 g, 0.60 mmol), cesium carbonate (0.029 g, 0.090 mmol), potassium carbonate (0.075 g, 0.54 mmol), sulfolane (0.5 g), and chlorobenzene (2 mL). The mixture was heated and stirred at 180° C. for 1 h to azeotrope off water. After the removal of chlorobenzene, the reaction mixture was cooled. To the cooled reaction mixture was added bis(4-chlorophenyl)sulfone (0.16 g, 0.54 mmol). The mixture was heated and stirred at 215° C. for 3 h with the frequent addition of another 1 g of sulfolane each time the reaction system became too viscous to be stirred. The resulting mixture was cooled, quenched by addition of acetic acid, and then poured into methanol to precipitate a light yellow fiber. The precipitated polymer was collected by filtration and washed with boiling methanol. The crude polymer was purified by extraction with boiling distilled water to remove any salt. The polymer collected by filtration was washed with boiling methanol, and dried in vacuo at 40° C. overnight. Yield 95%. The resulting polymer was mostly soluble in chloroform, and completely soluble in polar organic solvents such as DMAc. Creasable and light yellow cast films were obtained by casting from either its chloroform-solution or DMAc solution.
Examples
27
100%
100%
28
70%
73%
30%
29
50%
51%
50%
Examples
Tg (° C.)
TGA-5% (° C.)
η inh (dL/g)
27
269
565
0.21
28
27%
258
545
0.33
29
49%
250
543
0.56
Example 30
The polymer was prepared in a manner similar to Example 28. Yield 92%. The resulting polymer was soluble in polar organic solvents such as DMAc. Creasable and light yellow cast films were obtained by casting from either its chloroform solution or DMAc solution.
Examples
30 10% 60% 73% Examples
Tg (° C.) TGA-5% (° C.) ηinh (dL/g) 30 30% 27% 259 554 0.28
Poly(Arylene Ether Ketone)s Copolymers Containing Hydroquinone (HQ) Moieties
Examples 31-36
The procedure for the copolymer from 1,3-dibenzimidazolylbenzene (Example 32: 20 mole %) is typical.
To a three-necked round-bottom flask equipped with a magnetic stirrer, a Dean-Stark trap, a condenser, and a nitrogen inlet were added 4,4′-difluorobenzophenone (0.44 g, 2.0 mmol), HQ (0.18 g, 1.6 mmol), 1,3-dibenzimidazolylbenzene (0.12 g, 0.40 mmol), potassium carbonate (0.25 g, 1.8 mmol), cesium carbonate (0.098 g, 0.30 mmol), calcium carbonate (0.21 g, 2.1 mmol), diphenyl sulfone (2 g), and chlorobenzene (3 mL). The mixture was heated and stirred at 170° C. for 1 h to azeotrope off water under nitrogen atmosphere. After the removal of chlorobenzene, the mixture was carefully brought up to 180-200° C. for 1 h, then heated at 230-250° C. for 0.5 h, and finally heated at 300-313° C. for 1 h, with the frequent addition of another 1 g of diphenyl sulfone, each time the reaction system became too viscous to be stirred. The viscous reaction mixture was cooled, and quenched by addition of acetic acid. The reaction mixture was ground into fine powder in a blender with methanol. The fine powder was boiled in a mixture of methanol/water (3/1 v/v) for 1 h. The powder collected by filtration was boiled in acetone for 1 h. These extraction procedures were repeated twice. The resulting powdery polymer was washed with 5% HCl aqueous solution, with distilled water, and finally with acetone. The polymer was dried in vacuo at 40° C. for 24 h. Yields 94-98%. Flexible films were obtained with heating the powdery polymer sandwiched by glass plates at 300° C.
Copolymer
Ex-
(mole % of
Tg
Tm
Tc
TGA-5%
amples
dibenzimidazolylbenzene)
(° C.)
(° C.)
(° C.)
(° C.)
31
1,3-dibenzimidazolylbenzene
156
308
196
501
(10%)
32
1,3-dibenzimidazolylbenzene
180
295
182
475
(20%)
33
1,3-dibenzimidazolylbenzene
173
—
—
456
(30%)
34
1,4-dibenzimidazolylbenzene
150
297
180
520
(10%)
35
1,4-dibenzimidazolylbenzene
173
302
233
495
(20%)
36
1,4-dibenzimidazolylbenzene
188
—
—
539
(30%)
Tg, Tm, and Tc were taken from the second heating scan.
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13. Wang, S. J., et al., Synthesis and characterization of phthalazinone containing poly ( arylene ether ) s via a novel N—C coupling reaction . J. Pol. Sci., Part A, 2003. 41: p. 2481-90.
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17. Smith, J. G., et al., Controlled molecular weight poly ( arylene ether benzimidazole ) s end capped with benzimidazole and ethynyl groups . High Perf. Polym., 1995. 7(1): p. 41-53.
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23. Smith, J. G., Jr., J. W. Connell, and P. M. Hergenrother, Synthesis and properties of poly[arylene ether ( N - arylene benzimidazoles )]. Pol. Prep. (Am. Chem. Soc., Div. Pol. Chem.), 1992. 33(1): p. 1098-100.
24. Hergenrother, P. M., J. W. Connell, and J. G. Smith, Chemistry and properties of poly ( arylene ether benzimidazole ) s . Mat. Res. Soc. Symp. Proc., 1993. 305: p. 21-32.
25. Connell, J. W., P. M. Hergenrother, and J. G. Smith, Properties of poly ( N - arylenebenzimidazoles ) and their preparation by aromatic nucleophilic displacement , U.S. Pat. No. 5,410,012, 1995
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27. Hartwig, J. F., et al., Room - temperature palladium - catalyzed amination of aryl bromides and chlorides and extended scope of aromatic C—N bond formation with a commercial ligand . J. Org. Chem., 1999. 64: p. 5575-5580.
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31. Hay, A. S., Polymers derived from phenolphthaleins , U.S. Pat. No. 5,254,663, 1993 | Polymers and copolymers of formula I:
in which m is typically 30 to 500 and n is 0 to 500; Ar is for example, 1,2-phenylene, 1,3-phenylene, 1,4-phenylene, or 2,6-pyridylene; Ar 2 and Ar 3 are selected from various bivalent aryl and heteroaryl groups; and X is for example, the bivalent SO 2 or CO. have high temperature properties which make them useful as films, matrices in carbon fiber reinforced composites and high performance adhesives; processes for preparing the polymers and copolymers employ a novel C—N coupling reaction. | 2 |
BACKGROUND OF THE INVENTION
The present invention is directed generally to a gas return railway car hydraulic cushioning device designed to maintain separation between the pressurized gas and hydraulic oil therein, and to a method of converting a hydraulic cushioning unit, adapted for connection to an external spring operated restoring mechanism, to a self-contained gas return unit.
The cushioned underframe of a railway car generally includes a pair of end-of-car cushioning devices or gears at opposite ends of the car for providing a resilient or hydraulically controlled connection between the center sill and coupler. Each gear includes a hydraulic system consisting of two chambers related by valves and ports. These include the high pressure inner cylinder having a piston reciprocal therein and the low pressure outer housing.
Impact energy from coupling, starting and stopping forces is transmitted from the coupler through the outer housing and hydraulic cylinder system to the center sill of the car. As the cylinder closes on the piston through impact, oil is forced from the cylinder into the outer housing through metering ports appropriately sized and placed. The oil is instantly returned behind the piston so the hydraulic cushioning is continuously provided with the cylinder if movement of the unit is reversed.
When external forces are removed from the unit, the piston should be returned to a neutral position so the unit can effectively cushion the next impact. Restoring forces have conventionally been provided either by the repositioning springs of a separate restoring mechanism or by pressurized gas within the cushioning unit itself. Known gears including either restoring system have certain disadvantages.
Since the repositioning springs of mechanical restoring mechanisms are typically situated below the hydraulic cushioning unit, the restoring force is offset from the center line of the cylinder and thereby induces a canting of the unit's housing within the sill. Such off-center loading causes wear on the piston, shaft and other parts with most parts being particularly worn on one side. The purchase and maintenance of the compression spring restoring mechanism adds to the cost of the hydraulic cushioning unit. Breakage of the return springs or other failure of the restoring mechanism can furthermore disable the railway car for normal operation.
Gas return hydraulic cushioning units eliminate the off center forces and maintenance problems associated with mechanical restoring mechanisms but such units to date are either expensive to manufacture or provide an unpredictable spongy cushioning action. "Freight Saver" gas return gears afford predictable cushioning action by incorporating an extra piston to maintain separation between the hydraulic fluid and pressurized gas. The extra piston and associated structure, however increases the manufacturing cost of that gear. Other gas return gears simply allow foaming action between the hydraulic oil and pressurized gas but these generally produce a spongy unpredictable cushioning action due to the compressability of the oil and gas mixture.
Accordingly, a primary object of the invention is to provide an improved gas return hydraulic cushioning unit.
More specifically, an object of the invention is to provide such a unit wherein separation between the hydraulic oil and pressurized gas is maintained without an additional piston or other moving parts.
Another object is to provide such a unit of simple and economical construction.
Another object is to provide such a unit which eliminates the necessity for a separate mechanical restoring mechanism.
Another object is to provide such a unit wherein restoring forces are centrally directed so as to eliminate canting of the housing and one sided wear on many gear parts.
Another object is to provide a practical method of converting a railway car hydraulic cushioning unit adapted for connection to an external spring operated restoring mechanism to a self-contained gas return unit.
Another object is to provide such a method which requires minimum modification to the hydraulic cushioning unit.
Finally, another object is to provide a gas return railway car hydraulic cushion unit which is simple and rugged in construction, economical to manufacture and efficient in operation.
SUMMARY OF THE INVENTION
The present invention is directed to an improved gas return railway car hydraulic cushioning unit and to relatively simple method for converting a hydraulic cushioning unit adapted for use with an external spring operated restoring mechanism to a self-contained gas return unit.
The hydraulic cushioning unit of the invention includes a high pressure cylinder encased within an outer housing having opposite ends closed by cylinder heads defining the low pressure reservoir between the high pressure cylinder and outer housing. The high pressure cylinder is movable longitudinally of a piston having a piston rod extended through an opening at the rod end of the housing for securement to the railway car center sill. A series of metering or porting holes are formed through the wall of the high pressure cylinder so as to provide a hydraulically controlled cushioned transfer of forces between the coupler and center sill of the railway car. The main reservoir is only partially filled with hydraulic oil with the remaining space above the oil charged with a pressurized gas.
An important feature of the present invention is the strategic placement of the porting holes below the level of gas in the main reservoir thereby to minimize any mixing of the oil and gas and foaming action resulting therefrom. As a result, the unit affords a positive predictable cushioning effect free of the variances encountered with units wherein the oil and pressurized gas are turbulently mixed.
A hydraulic cushioning unit adapted for use with an external spring-biased restoring mechanism can be easily converted to a self-contained gas return unit by simply removing the high pressure cylinder, plugging any metering holes above the level of gas in the main reservoir, providing substitute metering holes through the cylinder below the level of gas in the main reservoir and then reassembling the unit, adding oil and charging the space above the oil with pressurized gas. As a result, the metering flow of hydraulic fluid between the high pressure cylinder and outer housing all occurs below the level of gas thereby virtually eliminating all turbulent mixing of the oil and gas.
The present invention thus affords a substantial advancement in the repair and maintenance of railway car end of car cushioning units. Conventional spring return gears can be made better than new by elimination of the compression spring restoring mechanism and by conversion to the simpler and more efficient gas return operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial exposed perspective view of the cushioned underframe at one end of a railway car;
FIG. 2 is a partial side sectional view of a railway car hydraulic cushioning unit of the prior art as installed in the cushioned underframe;
FIG. 3 is an end sectional view illustrating the various ports through the high pressure cylinder of an unmodified prior art gear;
FIG. 4 is an end sectional view, similar to FIG. 3, but incorporating the improvement of the invention;
FIG. 5 is an end view of the high pressure cylinder with circumferential positions of the metering holes illustrated thereon;
FIG. 6 is a plan view of the outer surface of the high pressure cylinder, with the cylinder wall "laid flat"; and
FIG. 7 is an enlarged partial sectional view through the high pressure cylinder wall showing a plugged metering hole therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-3 illustrate a known railway car hydraulic cushioning unit 10 which is a typical candidate for improvement according to the present invention.
FIG. 1 illustrates that the hydraulic cushioning unit 10 is adapted to be slidably supported within the sill 12 of railway car 14 by a sill base plate 16. A piston rod 18 extends from one end of the hydraulic cushioning unit 10 and carries a spherical bearing assembly 20 on its free end. The spherical bearing assembly 20 is secured against the longitudinal movement relative to the sill 12 by placement within an anchor housing 22 which, in turn, is secured within the sill 12 by welding or other suitable means.
Referring to FIG. 2, the opposite end of piston rod 18 carries a piston 24 received within a high pressure cylinder 26 that is carried within an cylinder housing 28, also shown in FIG. 1. "Draft" movement of the outer housing in a direction away from the center of the railway car is limited by engagement of abutment collar 30 on the end of the outer housing 28 with a coacting abutment collar 32 on the end of center sill 12. A conventional coupler 34 has its draw bar 36 extended through the abutment collars 32 and 30 for securement to the cylinder housing 28 by a coupler key 38 inserted through aligned slots 40 and 42 through draw bar 36 and cylinder housing 28 respectively. Accordingly, any longitudinal movement of the coupler 34 relative to the sill 12 produces a sliding movement of the cylinder housing 28 relative to piston 24 for hydraulic cushioning of both draft and buff forces on the coupler 34.
The cylinder housing 28 is biased toward abutment collar 32 on the end of sill 12 by a compression spring restoring mechanism 44 having one end secured to a bracket 46 (FIG. 2) on the underside of sill base plate 16 and an opposite end secured to a depending tongue 48 adjacent the head end of cylinder housing 28. Since the line of force 50 (FIG. 2) of restoring mechanism 44 is radially offset from the axis of piston rod 18, such force tends to induce an upward canting of the cylinder housing 28 which results in wear on the pistons 24, piston rod 18 and the various supporting apparatus, particularly on one side of those parts.
Referring to FIG. 2, the high pressure cylinder 26 is arranged within the cylinder housing 28 concentrically within a relatively thin-walled length referred to as outer housing 52. The head end of outer housing 52 is closed by a cylinder head portion 54 of cylinder housing 28, which head includes an interior annular shoulder 56 adapted for receiving and supporting the head end of high pressure cylinder 26 in press fit relation therein. The rod end of high pressure cylinder 26 is closed by an annular cylinder head 58 having a rod opening 60 therein with appropriate bearing and seal means 62 for engaging piston rod 18. Cylinder head 58 carries an annular flapper valve plate 64 which is biased by a series of springs 66 into engagement with cylinder head 58 for closing a series of high capacity apertures 68 for a valving action described below.
The rod end of outer housing 52 is likewise closed by a cylinder head 70 having a rod opening 72 therethrough for slidably supporting piston rod 18. A seal assembly 74 is secured to the cylinder head 70. An accordian like dust shield 76 extends from the seal assembly for engagement with the piston rod to cover and protect that portion of the piston rod 18 which reciprocates through cylinder head 70.
High pressure cylinder 26 defines an internal cavity 80 which is divided by piston 24 into cavities 80a and 80b on the head side and rod side of the piston respectively. A high capacity port 82 through the underside of high pressure cylinder 26 adjacent the head end is plugged to provide some resistance to free flow of fluid from the main reservoir 86 into cavity 80a. The main reservoir 86 is the space surrounding high pressure cylinder 26 including the gap between cylinder heads 58 and 70 at the rod end of cylinder 26 and outer housing 52. Another valved port 88 may be provided adjacent the rod end of the cylinder 26 for controlling impedance during "run-out" train action events wherein the piston moves rightward from the full buff position shown in FIG. 2.
Finally, high pressure cylinder 26 has a series of open metering ports 90 arranged in longitudinally and circumferentially spaced-apart relation thereon. The circumferential spacing of metering ports 90 is evident in FIG. 3 and the longitudinal spacing is diagrammatically illustrated in FIG. 2 wherein all ports are seen as though they were aligned with a median longitudinal plane through the cylinder wall. The longitudinal spacing of such ports 90-3 through 90-13 is more accurately disclosed in FIG. 6 wherein the cylinder is shown "laid flat" with the top end of the figure corresponding to rod end of the cylinder and the bottom of the figure corresponding to the head end of the cylinder. As most clearly evident in FIG. 2, the metering ports 90-3 through 90-13 are exponentially spaced apart longitudinally so as to be somewhat clustered adjacent the head end of high pressure cylinder 26 and more sparcely positioned toward the rod end. This longitudinal spacing of course effects the hydraulic cushioning action provided by the unit 10 as follows. It is understood that, in an unmodified prior art hydraulic cushioning unit, the high pressure cylinder cavity 80 and the main reservoir 86 are substantially filled with hydraulic fluid.
During buff movement of the cylinder housing 28 to the right, as seen in FIG. 2, relative to the stationary piston 24, hydraulic fluid is expelled from cavity 80a into the main reservoir 86. That fluid is returned to cavity 80b through the flapper valve apertures 68 and plate 64.
During draft movement of the cylinder housing 28 to the left relative to stationary piston 24, as seen in FIG. 2, fluid is expelled from the cavity 80b through the metering ports 90 and into the main reservoir 86. That fluid is returned to cavity 80a through the metering orifices or ports 90 at the opposite end of the cylinder.
Because of the exponential spacing of the metering ports 90 in the longitudinal direction, draft forces on the coupler initially produce significant longitudinal movement of the cylinder housing 28 relative to piston 24 but this same initial movement causes the piston to cover and close the cluster of metering ports adjacent the head end of high pressure cylinder 26 thereby increasing the impedance within cavity 80b, i.e. the resistance to flow of fluid outwardly of cavity 80b, which slows down relative movement between the cylinder housing 28 and piston 24. Continued draft movement of the cylinder housing 28 further increases impedance to the point where the piston covers the last ports 90-7 and 88 whereupon any further draft movement of cylinder housing 28 is very slow resulting from fluid leakage past the piston seals. The extremes of the gear stroke, in both buff and draft directions, are governed by mechanical stops that are part of the railway car installation.
The hydraulic cushioning unit 10 as above-described is converted to a self-contained gas return unit as described below. Once converted, the compression spring restoring mechanism 44 may be removed from the cushion underframe since the pressurized gas within the cushioning unit will be operative to restore the cylinder housing 28 to its neutral position upon removal of external forces from the coupler 34.
First, FIG. 4 illustrates a hydraulic cushioning unit 10 which has been converted according to the present invention. The dotted horizontal line 92 corresponds to the top surface of hydraulic fluid 94 in the main reservoir 86 with cross hatching designating the pressurized gas 96 above the hydraulic fluid 94. Note that each of the metering ports 90 which are situated above the level of hydraulic fluid in main reservoir 86 are closed by plugs 98, as shown in detail in FIG. 7. The outer end of each such port 90 is drilled and taper reamed for 1/8-27 NPTF type tap for receiving an internal wrenching (hex.) steel pipe plug which is installed flush to 0.060 inches below the external surface of high pressure cylinder 26 using Locktite 242 or its equivalent and torquing the plug to 300 in. lbs. The cylinder modifications for the preferred embodiment are more precisely illustrated in FIGS. 5 and 6 wherein it is seen that 7 of the metering ports 90 are plugged. These are all of the metering ports 90 situated above a horizontal plane 100 through the axis of the high pressure cylinder 26.
Specifically, the plugged holes include metering ports 90-4 through 90-8 and 90-12 and 90-13. So as not to alter the hydraulic cushioning effect produced by unit 10, substitute metering ports A-G are provided through the wall of the high pressure cylinder 26 at positions below the level of gas in the main reservoir and, in the preferred embodiment, below the plane 100 through the axis of the cylinder. Note that the longitudinal positions of substitute ports A-G correspond exactly to the longitudinal positions of the plugged metering ports 90-4 through 90-8 and 90-12 and 90-13.
Upon plugging the uppermost situated metering ports 90 and providing the substitute metering ports as described above, the high pressure cylinder is reassembled into the unit 10. The high pressure cylinder cavity 80 and main reservoir 86 are then filled with hydraulic fluid, after which approximately one quart is syphoned from the reservoir 86 so that space may be charged with a gas such as nitrogen to a pressure of approximately 450 psi. For this purpose, a gas inlet port is provided in communication with the upper most portion of main reservoir 86 The volume of gas charge in the gear fluid cavity is calculated to provide an adequate restoring force at both ends of the total piston stroke, i.e. too small a volume would result in unnecessarily high pressure when piston is in full buff position.
The gas charge pressure with the piston in "neutral" is a nominal valve which can easily absorb changes due to thermal expansion or contraction and still provide adequate restoration function.
The fluid pressure in the main reservoir 86 due to the gas 96 causes the high pressure cylinder cavity 80 to be completely filled with hydraulic fluid, preferably with no gas above the level of hydraulic fluid within the high pressure cylinder 26. All metering of hydraulic fluid through the metering ports 90 occurs well below the top surface of hydraulic fluid within the main reservoir so as to minimize any turbulence at that surface which may produce a mixing of the hydraulic fluid and gas in a foaming action as occurs in certain known hydraulic cushioning units. The plugged metering ports prevent any discharge of streams of fluid directly into the body of gas 96 and also prevent the discharge of fluid close to the interface between the hydraulic fluid and gas which could result in turbulent mixing at that interface.
Accordingly, in operation, the cushioning response of the converted hydraulic cushioning unit 10 is substantially identical to that afforded by the unit prior to conversion. The advantage is that the compression spring restoring mechanism 44 may be discarded so as to eliminate any future maintenance expenses and problems associated with that unit. Furthermore, the internal gas pressure return forces on the piston are substantially axially centered thereby avoiding the canting of the cylinder housing 28 by the spring restoring mechanism and the associated one sided wear on many of the gear parts. The improved gear according to the present invention is thus simpler in construction and more efficient in operation than the same unit prior to conversion to a self-contained gas return unit.
Whereas the invention has been shown and described in connection with a preferred embodiment thereof, it is understood that many modifications, additions and substitutions may be made which are within the intended broad scope of the appended claims. For example, the invention is in no way limited to the particular hydraulic cushioning unit illustrated in FIGS. 1 and 2. The present invention is applicable to various different models of hydraulic cushioning units made and sold by each of several manufacturers. Likewise, the structural efficiencies of the present invention may be incorporated into a newly manufactured gear without any necessity for plugging pre-existing metering ports.
Thus, there has been shown and described a hydraulic cushioning unit and method of converting the same to gas return operation which accomplish at least all of the stated objects. | A railway car hydraulic cushioning unit prevents the mixing of gas and hydraulic fluid in chambers interiorly and exteriorly of a high pressure cylinder unit by strategic placing of metering ports through the cylinder wall at positions below the level of gas in the exterior chamber. The invention is furthermore directed to a method for converting hydraulic cushioning units adapted for connection to an external spring operated restoring mechanism to a self-contained gas return unit. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a sewing machine which performs program control of sewing patterns, and more particularly to a movement control apparatus of a work holder of such sewing machines.
In some known sewing machines, sewing patterns are stored as coordinate values in memory medium, e.g., magnetic tape or magnetic card, and a work holder is moved in accordance with the sewing patterns information. In such sewing machines, a workpiece is moved to the next sewing point determined by the sewing patterns information while the needle is disengaged from the workpiece.
FIG. 1 illustrates a conventional movement control. So-called needle bar loci 1 and 2 are shown, in which needle bar locus 2 is twice the speed of the needle bar locus 1. Points A 1 and A 2 represent needle disengagement points and points B 1 and B 2 represent needle insertion points. Points C 1 and C 2 represent upper dead points which are highest points of the needle. In this stage, the movement period to move the work holder is determined between the needle disengagement point A 1 or A 2 and the needle insertion point B 1 or B 2 . In the needle bar locus 1 (hereinafter referred to as "locus 1"), the period 3 is the movement period. In the needle bar locus 2 (hereinafter to as "locus 2"), the period 5 is the movement period. To move the workpiece within the movement period, necessary pulse number based on the coordinate values information of the sewing patterns is moved to X coordinate pulse motor and Y coordinate pulse motor and the work holder is moved to predetermined distance.
The pulse motors have an inherent delay time α, so that when motor drive pulse is applied, the motor starts after the delay time α. Thus, in conventional movement control, movement pulse input timing is controlled previously by considering the delay time α of the pulse motor.
More particularly, in the known movement control, when the workpiece is to be sewn according to the sewing machine speed shown in the locus 1, a movement timing is set at a point 7 (hereinafter referred to as "movement point 7") having an upper shaft angle before the delay time α rather than the movement period 3 in order to move the workpiece within the movement period 3. Thus, when the upper shaft angle is reached at the movement point 7, a pulse generator applies a predetermined number of drive pulse train 8 synchronous with the sewing machine speed to the pulse motor. The pulse motor drives the work holder after the delay time α from receiving the drive pulse. Thus, drive period 9 of the work holder is within the movement period 3 as shown in FIG. 1, and the workpiece is moved accurately within the movement period 3.
In such known movement control, when the sewing machine speed is increased as shown in locus 2, a predetermined number of drive pulse train 8' is applied to the pulse motor synchronous with the sewing machine speed. The pulse initiates at the same movement point 7' of the upper shaft angle. As the upper shaft rotates twice in this case, time lapse from the point 7' to the needle disengagement point A 2 is not the delay time α. That means, the work holder is not started to move at the needle disengagement point A 2 , and the pulse motor drive period 9' does not coincide with the movement period 5. Consequently, as shown in FIG. 1, needle insert time B 2 may be within the drive period 9', so that stitch errror or needle breakage may result.
SUMMARY OF THE INVENTION
Accordingly, the primary object of the present invention is to eliminate the above-mentioned disadvantages of pitch error of stitch and needle breakage or bending, and to provide a movement control apparatus of a sewing machine to automatically control movement initiating timing corresponding to various sewing machine speeds.
According to the present invention, a movement control apparatus of a sewing machine which performs program control of sewing patterns, comprises a memory means storing movement control values to control input timing of driving pulse to the pulse motors corresponding to sewing machine speeds, a pulse generating means generating at least two speed pulses synchronous with the sewing machine speed and then generating drive pulse train to said pulse motors, a detecting means detecting sewing speed from said sewing machine speed pulses, and a control means reading said movement control value corresponding to output of the detecting means and utilizing a portion of said drive pulse corresponding to said movement control value as input timing regulating pulse.
According to the present invention, the memory circuit previously stores most suitable movement control values corresponding to various sewing speeds, and control means reads the movement control value corresponding to detected sewing machine speed. Base on the movement control value, pulse motor drive pulse input timing discriminated to move a work holder.
Consequently, a work holder is moved automatically and accurately corresponding to detected sewing machine speed, so that no stitch error occurs, no work holder movement occurs while needle insertion period so that needle breakage or bending do not occur.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a conventional movement control of sewing machine;
FIG. 2 is a simplified block diagram of a movement control apparatus according to the present invention;
FIG. 3 is a perspective view showing a mounting of the slit plate shown in FIG. 2;
FIG. 4 is a simplified plan view of the slit plate shown in FIG. 3;
FIG. 5 is an illustration of a movement control according to the present invention;
FIG. 6 is output of point (a) shown in FIG. 2; and
FIG. 7 is a conversion table between sewing machine speed and movement control value in the memory circuit shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows a block diagram of the control device and associated components of the sewing machine, according to the present invention. A photo interrupter 16 is formed by a photo diode 13 and a photo transistor 15 which are opposed each other and between which a slit plate 12 which is attached to a pulley (not shown) rotates. Output of the photo interruptor 16 is connected to an amplifier circuit 17 which in turn is connected with a central process unit (CPU) 18. A memory circuit 19 which stores movement control information is connected with CPU 18. Counters 21 and 22 and a drive circuit 23 are connected through an interface circuit 20 with the CPU 18. Output of the drive circuit 23 is connected with an x-coordinate pulse motor 24, a y-coordinate pulse motor 25 and a sewing machine drive motor 26 respectively. The outputs of the motors 24, 25 and 26 are applied to a sewing machine 27.
FIG. 3 shows the mounting of the slit plate 12. As shown, the slit plate 12 is mounted on a main pulley 28 of the sewing machine 27.
FIG. 4 shows arrangement of slits in the slit plate 12. 49 slits 30 1 -30 49 for drive pulse are formed at a uniform distance in the slit plate 12. Sewing machine speed detecting slits 33 and 34 are formed at a predetermined distances 31 and 32 respectively from the last slit 30 49 and the first slit 301.
Operation of the present invention will be described referring to FIG. 5 which shows a movement control according to the present invention. Same reference numeral shows same or similar part or portion described in FIG. 1. Position of the slit plate 12 is previously set relating movement information set position in the memory circuit 19.
A sewing pattern is selected as desired, and the sewing process is started. As the drive motor 26 drives the operating mechanism of the sewing machine 27, it drives the pulley 28 and also the slit plate 12. By rotation of the slit plate 12, the photo interruptor 16 detects the slits and it applies a pulse signal for each slit (hereinafter referred to as "slit pulse"). The pulse signal is amplified in the amplifier circuit 17 as shown in FIG. 6 and is supplied to the CPU 18. The CPU 18 discriminates a pulse after a predetermined space 31 as the speed detecting slit pulse 33'. When the pulse 33' is applied, the CPU 18 resets the counter 21. When the counter 21 is reset, a constant high speed clock pulse in the CPU 18 is counted from zero. When the next speed detecting slit pulse 34' is applied to the CPU 18, count β of the counter 21 is read by the CPU 18. Thus, sewing machine speed is detected. When the sewing machine speed is high, the distance between the speed detecting slit pulses 33' and 34' is detected as narrow, and when the sewing machine speed is low, the distance between the slit pulses 33' and 34' is detected as wide. The count β of the counter 21 is proportional to the sewing machine speed. The CPU 18 discriminates the sewing machine speed by the count β of the counter 21 and read out a movement control value corresponding to the sewing machine speed from the memory circuit 19.
The slit plate 12 is mounted on the pulley 28 such that a reference slit, e.g., the speed detecting slit 33 is detected by the photo interruptor 16 when the pulley 28 is reference upper shaft angle, e.g. 1/8 cycle before needle disengagement point. As shown in FIG. 7, in the memory circuit 19, various movement control values corresponding to various sewing machine speeds are stored such that when the sewing machine speed is reference value, e.g. β=100˜200, most suitable movement control value 1, e.g. first pulse from the slits 30 1 -30 49 is supplied. The movement control values are sorted in the memory circuit as number of the slit pulses.
Assume that, the sewing machine is operating describing needle bar locus 1' shown in FIG. 5 and the CPU 18 reads the count β=1600 from the counter 21. The CPU reads out a movement control value of 16 from the memory circuit corresponding to the count β=1600 as shown in FIG. 7.
The CPU 18 actuates the counter 22 such that slit pulses 30' 1 -30' 49 after the predetermined space 32 are sequentially counted by the counter 22. The count is compared with the movement control value 16. When the slit pulse 30' 16 is applied to the CPU 18, and the count of the counter 22 is 16, the CPU 18 applies the slit pulses 30' 16 and after in the number based on the coordinate information of the sewing pattern to the drive circuit 23 as the drive pulses 8. Thus, the pulse motors 24 and 25 are driven to move the work holder for a predetermined distance.
As described, 16 pulses corresponding to the slit pulses 30' 1 -30' 16 are utilized as delay pulses to select the movement point 7 (FIG. 5) and the slit pulse 30' 16 is applied to the pulse motors as the first drive pulse. The pulse motors actuate after a delay time α, however, the movement point 7 is automatically selected to a point of upper shaft angle corresponding to before the delay time α, so that driven period 9 is within movement period 3. Thus, a workpiece is accurately moved within the movement period 3.
When the sewing machine speed is doubled compared to the needle bar locus 1, and follows locus 2 in FIG. 5, the counter counts β=800 between the speed detecting slit pulses 33' and 34'. The CPU 18 reads the count value of and obtains movement control value of 8 from the memory circuit 19 as shown in FIG. 7. In this case, slit pulses 30' 1 -30' 8 are used as delay pulses to select the movement point, and the slit pulse 30' 8 is applied to the pulse motors as the first drive pulse. The slit pulse 30' 8 is half delay time compared with the above-described slit pulse 30' 16 . Consequently, when the sewing machine speed is doubled, the movement point 35 on the locus 2' is automatically selected at a point twice earlier upper shaft angle compared with the movement point 7 on the locus 1'. The pulse motors actuate after the delay time α. However, the movement point 35 is selected automatically as a point of the upper shaft angle before the delay time α. Thus, the drive period 9' of the work holder is within the movement period 5 shown in FIG. 5 and the workpiece is moved accurately within the movement period 5.
Although the 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 can be changed in the details of construction and the combination, and arrangement of parts may be restored to without departing from the spirit and the scope of the invention as hereinafter claimed. | A movement control apparatus for a sewing machine to automatically control movement initiating timing corresponding to various sewing machine speeds. | 3 |
FIELD OF THE INVENTION
The present invention relates to a method of manufacturing self-aligned transistors and more specifically to a method of manufacturing transistors which are designed for high frequency applications. In particular, a method is disclosed for manufacturing self-aligned transistors with increased base feeder conductivity.
Background of the Invention
In a device which uses the base feeder as a diffused conductor stripe it is desirable to obtain as high a conductivity as possible. Of course, this conductivity must be obtained within the constraints of the pitch (the distance between two repetitive parts, e.g. the emitter or the base) of the geometry. For self-aligned structures, this conductivity has generally been limited to the conductivity obtained from a very heavy dose implant (P + -B 11 at 1E16 dose). As a further complication, such a P + drive may result in a deeply driven base. Such a deeply driven base, in turn, adversely effects high frequency performance.
A top view of a typical self-aligned overlay geometry is shown in FIG. 20. FIG. 19 is a side cross sectional view of the device which is shown in FIG. 20 taken in the plane X--X'. As shown in FIG. 20, the device includes emitter stripe 41, P + light region 11 and P + heavy region 3.
The device which is shown in FIG. 19 and FIG. 20, which includes an implanted P + region, is typical of shallow geometry devices which are used for high frequency applications. However, for the device to exhibit desirable performance characteristics, a low sheet resistance has typically been required. If the sheet resistance is not sufficiently low, then the number of squares in the P + regions is often decreased in order to obtain an acceptable total resistance. However, decreasing the number of squares in the P + regions compresses the device which causes the figure of merit (emitter periphery/base area) to decrease. As is well known in the art, a reduction in the figure of merit of a device results in decreased power handling capabilities.
As explained above, a heavy P + drive may increase conductivity. However, such a P + drive (which creates a P + heavy region) after formation of a base region creates other problems. Specifically, formation of a P + heavy region is typically performed at very high temperatures. For example, a P + heavy region is typically performed at a temperature ranging from 1050° to 1100°. This is in contrast with base region formation which is typically performed using a driving step with a temperature between 900° and 950°. The difference between the temperature requirements for forming the base region and for forming the P + heavy region are particularly significant when one considers that there is a doubling of diffusion for every 25° increase in temperature. Thus, a base region is driven very deeply during formation of the P + heavy region.
A further consideration is the alignment of the P + heavy region with the emitter region. The edge of the P + heavy region is desirably well away from the edge of the P + light region because the P + heavy region is deeper than the P + region and the P + heavy region spreads out laterally during diffusion. In addition, it is not desirable for the P + heavy region to be offset with respect to the emitter region. If the P + heavy region was closer to one side of the emitter region than to another side of the emitter region, heavy injection on the closer side of the emitter region occurs, while no performance is obtained on the other side. Thus, the designer of such a device is always mindful of the fact that the P + heavy region is significantly narrower than the P + light region in order to align the P + heavy region well within the boundaries of the P + light region.
In order to resolve some of the problems set forth above, attempts have been made to form the P + heavy region before the base region is formed. This has involved the formation of a P + heavy region, stripping off of the P + heavy region to form an indentation in the silicon and then trying to form an emitter which is aligned with the indentation. Accurate alignment in this manner is difficult to obtain.
Summary of the Invention
A self-aligned overlay geometry is formed by creating a very deep P + heavy region prior to definition of a self-aligning P + light region and a self-aligning emitter region. Furthermore, a P + heavy region is formed which is narrow enough to ensure that a subsequent P + light formation step sufficiently overlaps the deeper P + heavy region.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1-19 are side cross-sectional views of a semiconductor device at various stages of manufacture in accordance with an exemplary embodiment of the method of the present invention.
FIG. 20 is a top view of a semiconductor device at the stage of manufacture illustrated by FIG. 19. FIG. 19 is a side cross-sectional view of a portion of FIG. 20 taken in the plane X--X'.
DETAILED DESCRIPTION
An exemplary embodiment of the present invention will now be described more fully with reference to FIGS. 1-19, in which a semiconductor device is shown during successive stages of manufacture. These figures are purely schematic and are not drawn to scale. In particular, the dimensions in the direction of thickness are comparatively strongly exaggerated for the sake of clarity.
As shown in FIG. 1, the starting material is a semiconductor wafer, in this example, epitaxial layer 15 of doped N-type silicon having a resistivity of, for example, 2 ohm cm. Epitaxial layer 15 is located above substrate 5. A base diffusion layer 18 is formed on the top surface of epitaxial layer 15. This base diffusion layer may have a depth of about 0.3 microns. Other depths are possible and will be chosen by those skilled in the art in accordance with existing conditions. Furthermore, P- regions 4 are formed by the implantation of boron ions (dose 5×10 12 atoms/cm 3 energy 100 keV) followed by well known diffusion techniques.
As shown in FIG. 2, the semiconductor device is subjected to a P- drive. This results in the growth of the previously deposited oxide layer, as well as the formation of oxide over the previously exposed portions of P- regions 4.
As shown in FIG. 3, portions of oxide layer 18 are removed to expose portions of P- regions 4 and epitaxial layer 15. The removal of portions of oxide layer 18 is accomplished using well known "mask and etch" technology. A further oxide layer 6 is then deposited on the wafer. Portions of this further oxide layer are then removed using mask and etch technology. P + regions 3 are then formed in epitaxial layer 15 at the top surface of the semiconductor device, as shown in FIG. 3, using well known diffusion techniques, such as a high concentration diffusion step at a high temperature range of approximately 1050 to 1100 degrees Celsius. Examples include a high concentration solid Boron Nitride diffusion step, a high dosage Boron Chloride gas diffusion step, or a high dosage Boron ion implantation drive step, including rapid thermal anneal, at the high temperature.
As shown in FIG. 4, oxide layer 6 is then removed. As shown in FIG. 5, a further oxide layer 7 is deposited on the wafer. Then, as shown at FIG. 6, a substantially large portion of oxide layer 7 is removed.
Next, as shown in FIG. 7, a shallow base region 25 is provided by implantation. This is accomplished using, for example, boron ions, dose 6E13, energy 25 keV.
As shown in FIG. 8, base implantation region 25 is then covered with nitride layer 9.
Then, as shown in FIG. 9, portions of nitride layer 9 are removed to create nitride islands 9'. The formation of nitride island 9' define emitter regions 41 as shown in FIG. 9. Emitter regions 41 are formed using well known ion implantation and activation steps; Arsenic ion implantation is commonly used. As shown, emitter regions 41 are formed at the surface of the semiconductor device and are separated from shallow P + region 11 by nitride spacers 9'.
As shown in FIG. 10, an oxide layer is deposited over nitride islands 9'. In FIG. 11, portions of oxide layer 10 are removed so that oxide islands 10' remain.
As shown in FIG. 12, P + implant regions 11 having a shallower depth than deep P + implant region 3, are formed. This may be accomplished using, for example, B 11 (5×10 15 atoms/cm 3 , 25 keV). A typical depth for P + implant regions 11 is, for example, 0.5 microns. This is compared to a typical depth for base region 25 of, for example, 0.3 microns. Thus, for purposes of clarity, base region 25 is not shown in FIG. 12. Formation of shallow P + implant regions 11 simultaneously isolates emitter regions 41 from the deep P + regions. Nitride islands 9' operate as spacers which isolate emitter regions 41 from the P + regions, as shown in FIG. 12.
As shown in FIG. 13, an oxide layer 12 is again deposited over the wafer. Portions of this oxide layer are then removed as shown in FIG. 14 so that oxide islands 12' remain.
As shown in FIG. 15, a layer of polysilicon 13 is then deposited over the wafer surface. Portions of this polysilicon layer 13 are removed in the step which is illustrated by FIG. 16.
As shown in FIG. 17, a nitride oxide layer 20 is then deposited over the wafer surface. Portions of nitride oxide layer 20 are then removed, as shown in FIG. 18, to form polycontacts. Metallization layer 21 is then provided as shown in FIG. 19 to form emitter metal 21 and base metal 22.
FIG. 20 provides a top view of the device which is shown in FIG. 19. FIG. 19 is a side cross-sectional view of a portion of the device which is shown in FIG. 20 taken in the plane X--X'. As shown by both FIG. 19 and FIG. 20, P + light region 11 extends beyond the upper surface of P + heavy region 3. Furthermore, P + heavy region 3 is aligned with respect to each emitter region 41.
By forming a very deep P + heavy region 3 prior to definition of emitter region 41 and P + light region 11, and by forming P + heavy region 3 with dimensions that are narrow enough to allow the subsequent P + light region 11 formation step to overlap the deeper P + heavy region 3 with sufficient dimensions, proper spacing is ensured. In other words, it is guaranteed that P + region will not be too close to either side of emitter region 41 because P + heavy region 3 has been completely covered with P + light region 11 through self-alignment. In this manner, a self-aligned overlay geometry is formed by the relative positioning of emitter region 41, shallow P + region 11, P + deep region 3, and base region 25 with respect to one another.
The overlap of P + light region 11 over P + heavy region 3 is important because if P + light region 11 does not extend past P + heavy region 3 laterally, automatic self-alignment is not obtained. In a typical case of an overlay geometry with a figure of merit between 5 and 6, the width of P + light region 11 is 3 to 4 microns. With allowances for misalignment and registration, a deep P + heavy region 3 of approximately 1.5 microns can be chosen and will still allow approximately 3/4 micron of overlap to ensure preservation of the self-alignment feature in order to guarantee that the P + heavy region does not get too close to a single emitter region. In this manner, a P + heavy region is obtained which is well within the P + light region without the injection nonuniformity which is obtained by using a P + heavy region within an aligned emitter.
Furthermore, the P + heavy region overcomes the disadvantages of the P + light region in terms of high conductivity because the P + heavy region can be as low as 3 ohms per square or less. This allows between a factor of two to three times reduction in resistivity of the P + region (i.e. the combination of the P + heavy region and the P + light region). This can improve the effective figure of merit for RF overlay transistors by 30 to 40 percent. In this manner, efficiency and RF power output may be enhanced by significant factors.
While the invention has been described in terms of an exemplary embodiment, it is contemplated that it may be practiced as outlined above with modifications within the spirit and scope of the following claims. | A very deep P + diffusion step is performed prior to the definition of a self-aligning emitter/P + region. Furthermore, the initial P + region is formed with dimensions sufficiently narrow to allow the subsequent emitter/P + formation step to overlap the deeper P + step by enough distance for the P + step to completely cover the deep P + region with its significant lateral diffusion. In this manner, a low sheet resistance in combination with proper alignment of the P + heavy region with the emitter region is obtained. | 7 |
BACKGROUND OF THE INVENTION
This invention pertains to novel fungicidal compounds.
As the world becomes more dependent for food on an ever-decreasing acreage of farmland, effective fungicides which protect crops from fungicidal destruction are becoming increasingly important.
EP-28-011 discloses N-aryl-N-acyl homoserine derivatives possessing microbiodal activity.
U.S. Pat. Nos. 4,034,108 and 4,032,657 disclose N-(1'-methyl-carbalkoxymethyl)acetanilides having fungicidal activity. U.S. Pat. No. 4,151,299 discloses N-(1'-methyl-carbalkoxy)-1-alkoxy-acetanilides having fungicidal activity.
SUMMARY OF THE INVENTION
The N-1-substituted cyclopropyl-N-acyl-2,6-dialkylanilines of this invention are represented by the formula ##STR2## wherein R and R 1 are independently hydrogen or lower alkyl; R 2 is lower alkenyl, lower alkynyl, or --CH 2 X wherein X is halogen, hydroxyl, lower alkoxy, lower alkylthio or a furyl group; Z is hydroxyl, lower alkoxy or --NR 3 R 4 wherein R 3 and R 4 are independently hydrogen or lower alkyl.
I have now found that N-1-substituted cyclopropyl-N-acyl-2,6-dialkylanilines are surprisingly effective fungicides. Moreover, some of the compounds of this invention also possess herbicidal activity.
Preferred R and R 1 lower alkyl groups include for instance methyl, ethyl, isopropyl and the like. Due to their superior fungicidal activity, particularly preferred compounds of this invention are those where R and R 1 are methyl.
Preferred R 2 lower alkenyl includes the 1-allyl and 2-allyl groups.
Preferred Z groups are hydroxy, methoxy, and dimethylamino. Due to its superior fungicidal activity, a particularly preferred Z group is methoxy.
DEFINITIONS
As used herein, the following terms have the following meanings, unless expressly stated to the contrary.
The term "alkyl" refers to both straight- and branched-chain alkyl groups. The term "lower alkyl" refers to both straight- and branched-chain alkyl groups having a total of from 1 to 6 carbon atoms and includes primary, secondary and tertiary alkyl groups. Typical lower alkyls include, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, n-hexyl, and the like.
The term "alkenyl" refers to unsaturated alkyl groups having a double bond [e.g., CH 3 CH═CH(CH 2 ) 2 --] and includes both straight- and branched-chain alkenyl groups. "Lower alkenyl" refers to groups having a total of from 2 to 6 carbon atoms. Typical lower alkenyl groups include, for example, ethylene, but-3-enyl, hex-4-enyl, 2-methylpent-4-enyl, and the like.
The term "halo" or "halogen" refers to the groups fluoro, chloro, bromo and iodo.
The term "alkoxy" refers to the group R 7 O-- wherein R 7 is alkyl. The term "lower alkoxy" refers to alkoxy groups having from 1 to 6 carbon atoms; examples include methoxy, ethoxy, hexoxy, and the like.
The term "alkynyl" refers to unsaturated alkyl groups having a triple bond [e.g. CH 3 C.tbd.C(CH 2 ) 2 --] and includes both straight- and branched-chain alkynyl groups.
The term "lower alkynyl" refers to alkynyl groups having from 2 through 6 carbon atoms and includes, for example, but-3-ynyl; hex-4-ynyl; 4-methylpent-2-ynyl and the like.
The term "alkylthio" refers to the group R 6 S-- where R 6 is alkyl. The term "lower alkylthio" refers to the group R 6 S-- where R 6 is lower alkyl.
The term "furanyl group" refers to the ring ##STR3## where substitution may be either at the 2 or 3 position ##STR4##
The term "carbonyl" refers to the group >C═O.
The term "hydroxycarbonyl" refers to the group
HO.sup.>C═O.
The term "alkoxycarbonyl" refers to the group
R.sup.8 O.sup.>C═O
wherein R 8 is lower alkyl.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the present invention are preferably prepared according to the following scheme: ##STR5## where R, R 1 , R 2 and Z are as defined above, X is a halogen and b represents either an organic or an inorganic base. The synthesis of the starting 1-(2'-haloalkyl)-carbalkoxymethyl-substituted acetanilide (II) is reported in my copending United States application, Ser. No. 280,653, which is incorporated herein by reference.
The above reaction is conducted by adding an essentially equimolar amount of a base to the 1-(2'-haloalkyl)-carbalkoxymethyl-substituted-acetanilide (II) starting material. The base employed may either be an organic or an inorganic base. Suitable organic bases include for instance 1,5-diazabicyclo[4.3.0]-nonene-5(DBN), lithium diisopropyl amide (LDA), and the like. Suitable inorganic bases include for instance sodium alkoxides, sodium hydroxide, sodium hydride and the like. The reaction is conducted in the liquid phase employing an inert organic solvent such as dimethoxyethane, benzene, toluene, and the like. Preferably the reaction employs sodium hydride as the base and dimethoxyethane as the solvent. In order to facilitate reaction completion and to improve the overall yield, a catalytic amount of an organic alcohol such as methanol or ethanol is sometimes necessary. The reaction is generally conducted at from 0° to 100° C. although preferably at from 18° to 50° C. Reaction pressure is not critical and for convenience the reaction is generally conducted at atmospheric pressure. The reaction is generally complete within 1 to 120 hours. The product, IV, is then isolated and purified by conventional procedures such as extraction, filtration, chromatography, distillation and the like.
The esters of formula I are converted to the corresponding carboxylic acids of this invention by acid or base hydrolysis using conditions well known in the art.
The amido compounds of this invention (i.e. Z═--NR 3 R 4 ) are prepared by reacting an essentially equimolar amount of the carboxylic acid (i.e. Z═OH) with a reagent capable of converting a carboxylic acid to an acid halide. Suitable reagents include, for example, thionyl chloride, oxayl chloride and the like. The reaction is done in the liquid phase using an inert organic solvent such as diethyl ether, tetrahydrofuran and the like. Reaction pressure is not critical and for convenience the reaction is generally conducted at atmospheric pressure. The reaction is generally conducted at from 0° to 100° C. and is generally complete from within 1 to 24 hours.
The acid halide is then converted to the amido compounds of this invention by addition of 2 equivalents of the appropriate amine, HNR 3 R 4 where R 3 and R 4 are as defined above. The reaction is conducted in the liquid phase using an inert organic solvent such as chloroform, toluene and the like. Excess amine is employed to scavenge the acid generated in the reaction. Reaction pressure is not critical and for convenience the reaction is generally conducted at atmospheric pressure. The reaction is generally conducted at from 0° to 100° C. and is generally complete from within 1 to 24 hours. The product is then isolated and purified by conventional procedures such as extraction, filtration, distillation, chromatography and the like.
UTILITY
The compounds of the present invention are useful for controlling fungi. In particular, some of the compounds of this invention are useful for controlling leaf blights caused by organisms such as Phytophthora infestans conidia, alternaria solani conidia, septoria apii and downy mildew caused by organisms such as Plasmopara viticola.
However, some fungicidal compounds of the invention may be more fungicidally active than others against particular fungi. Table II lists a summary of activity against some particular fungi for several compounds of this invention.
When used as fungicides, the compounds of the invention are applied in fungicidally effective amounts to fungi and/or their habitats, such as vegetative hosts and non-vegetative hosts, e.g., animal products. The amount used will, of course, depend on several factors such as the host, the type of fungus and the particular compound of the invention. As with most pesticidal compounds, the fungicides of the invention are not usually applied full strength, but are generally incorporated with conventional, biologically inert extenders or carriers normally employed for facilitating dispersion of active fungicidal compounds, recognizing that the formulation and mode of application may affect the activity of the fungicide. Thus, the fungicides of the invention may be formulated and applied as granules, as powdery dusts, as wettable powders, as emulsifiable concentrates, as solutions, or as any several other known types of formulations, depending on the desired mode of application.
Wettable powders are in the form of finely divided particles which disperse readily in water or other dispersant. These compositions normally contain from about 5% to 80% fungicide, and the rest inert material, which includes dispersing agents, emulsifying agents and wetting agents. The powder may be applied to the soil as a dry dust, or preferably as a suspension in water. Typical carriers include fuller's earth, kaolin clays, silicas, and other highly absorbent, readily wettable, organic diluents. Typical wetting, dispersing or emulsifying agents include, for example: the aryl and alkylaryl sulfonates and their sodium salts; alkylamide sulfonates, including fatty methyl taurides; alkylaryl polyether alcohols, sulfated higher alcohols, and polyvinyl alcohols; polyethylene oxides, sulfonated animal and vegetable oils; sulfonated petroleum oils, fatty acid esters of polyhydric alcohols and the ethylene oxide addition products of such esters; and the addition products of long-chain mercaptans and ethylene oxide. Many other types of useful surface-active agents are available in commerce. The surface-active agent, when used, normally comprises from 1% to 15% by weight of the fungicidal composition.
Dusts are freely flowing admixtures of the active fungicide with finely divided solids such as talc, natural clays, kieselguhr, pyrophyllite, chalk, diatmaceous earths, calcium phosphates, calcium and magnesium carbonates, sulfur, lime, flours, and other organic and inorganic solids which act as dispersants and carriers for the toxicant. These finely divided solids have an average particle size of less than about 50 microns. A typical dust formulation useful herein contains 75% silica and 25% of the toxicant.
Useful liquid concentrates include the emulsifiable concentrates, which are homogeneous liquid or paste compositions which are readily dispersed in water or other dispersant, and many consist entirely of the fungicide with a liquid or solid emulsifying agent, or may also contain a liquid carrier such as xylene, heavy aromatic naphthas, isophorone, and other nonvolatile organic solvents. For application, these concentrates are dispersed in water or other liquid carrier, and are normally applied as a spray to the area to be treated.
Other useful formulations for fungicidal applications include simple solutions of the active fungicide in a dispersant in which it is completely soluble at the desired concentration, such as acetone, alkylated naphthalenes, xylene, or other organic solvents. Granular formulations, wherein the fungicide is carried on relatively coarse particles, are of particular utility for aerial distribution or for penetration of cover-crop canopy. Pressurized sprays, typically aerosols wherein the active ingredient is dispersed in finely divided form as a result of vaporization of a low-boiling dispersant solvent carrier, such as the Freons, may also be used. All of those techniques for formulating and applying fungicides are well known in the art.
The percentages by weight of the fungicide may vary according to the manner in which the composition is to be applied and the particular type of formulation, but in general comprise 0.5% to 95% of the toxicant by weight of the fungicidal composition.
The fungicidal compositions may be formulated and applied with other active ingredients, including other fungicides, insecticides, nematocides, bacteriocides, plant growth regulators, fertilizers, etc.
Some of the compounds of this invention are useful as herbicides in both pre- and post-emergent applications.
A further understanding of the invention can be had in the following non-limiting Examples. Wherein, unless expressly stated to the contrary, all temperatures and temperature ranges refer to the centigrade system and the term "ambient" or "room temperature" refers to about 20° to 25° C. The term "percent" refers to weight percent and the term "mol" or "mols" refers to gram mols. The term "equivalent" refers to a reagent equal in mols, to the mols of the preceding or succeeding reactant recited in that example in terms of finite mols or finite weight or volume. Also, unless expressly stated to the contrary, geometric isomer and racemic mixtures are used as starting materials and correspondingly isomer mixtures are obtained as products.
EXAMPLE 1
Preparation of N-1-methoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline
11 gm of methyl 2-(N-methoxyacetyl-2,6-dimethylanilino)-4-chlorobutyrate 0.0335 moles, (the preparation of which is described in U.S. patent application Ser. No. 280,653 and incorporated herein by reference) was added to 125 ml of dimethoxyethane. 1.6 gm of sodium hydride (50% mixture in mineral oil), 0.0335 moles, was added to the system in portions. After addition, the system was stirred at room temperature for 72 hours. The system was then filtered through anhydrous magnesium sulfate. The dimethoxyethane was removed by stripping to give an oil. The oil was crystallized using petroleum ether/ethyl acetate to give 8.5 gm of N-1-methoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline as a white crystalline solid, m.p. 68° to 69° C., listed as compound number 5 in Table I.
EXAMPLE 2
Preparation of N-1-methoxycarbonylcyclopropyl-N-prop-2-enylcarbonyl-2,6-dimethylaniline
6.9 gm methyl 2-(N-crotonyl-2,6-dimethylanilino)-4-chlorobutyrate, 0.02 moles (the preparation of which is described in U.S. patent application Ser. No. 280,653 and which is incorporated herein by reference) was added to 150 ml of dimethoxyethane. 1 gm of sodium hydride (50% mixture in mineral oil), 0.02 moles, was added to the system in portions. After addition, the system was stirred at room temperature for 120 hours. The system was filtered through anhydrous magnesium sulfate. The dimethoxyethane was removed by stripping to give an oil. The product was purified by column chromatography using silica gel and a mixture of hexane, ethyl ether and petroleum ether as the eluant. 2.2 gm of N-1-methoxycarbonylcyclopropyl-N-prop-2-enylcarbonyl-2,6-dimethylaniline was recovered as a yellow oil listed as compound number 7 in Table I.
EXAMPLE 3
Preparation of N-1-hydroxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline
21 gm of N-1-ethoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline was dissolved in 125 ml of methanol. 3.5 gm of NaOH in 20 ml water was added to the system. The system was refluxed for 11 hours. Afterwards, the solution was stripped under vacuum. Dichloromethane was added to the residue. Gaseous HCl was bubbled in until a pH of 1 was obtained. At this time a white precipitate fell out of solution. The solution was filtered through magnesium sulfate and the methylene chloride removed by stripping to give the N-1-hydroxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline as a white solid, m.p. 179°-181° C. listed as compound number 4, Table I.
EXAMPLE 4
Preparation of N-(1-N',N'-dimethylaminocarbonyl-cyclopropyl)-N-methoxymethylcarbonyl-2,6-dimethylaniline
5.5 gm of N-1-hydroxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline is added to 100 ml of chloroform. The system is cooled to 0° to 5° C. and 2.60 gm of thionyl chloride in 10 ml of chloroform is then slowly added. After addition of the thionyl chloride, the system is stirred at room temperature for 2 hours and is then heated to reflux for an additional hour. The system is then cooled to room temperature and 2.0 gm of anhydrous dimethylamine is slowly added to the system. The system is stirred at room temperature for 2 hours and the reaction is then stopped. The solution is poured into 200 ml of an aqueous acidic solution (pH approximately 2). The product is extracted with chloroform. The chloroform solution is washed with saturated sodium bicarbonate solution and then is dried over magnesium sulfate. The solution is filtered and the chloroform removed by stripping to give the N-(1-N',N'-dimethylaminocarbonylcyclopropyl)-N-methoxymethylcarbonyl-2,6-dimethylaniline.
Other compounds which are prepared in a manner consistent with Examples 1 through 4 above include:
N-1-methoxycarbonylcyclopropyl-N-chloromethylcarbonyl-2,6-dimethylaniline;
N-1-ethoxycarbonylcyclopropyl-N-chloromethylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-allylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-prop-2-enylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-propargylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2-ethyl-6-methylaniline;
N-1-methoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2-ethylaniline;
N-1-methoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2-methylaniline;
N-1-ethoxycarbonylcyclopropyl-N-bromomethylcarbonyl-2,6-diethylaniline;
N-1-ethoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-diethylaniline;
N-1-ethoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-methoxymethylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-hydroxymethylcarbonyl-2,6-dimethylaniline;
N-1-methoxycarbonylcyclopropyl-N-hydroxymethylcarbonylaniline;
N-1-methoxycarbonylcyclopropyl-N-methylthiomethylcarbonyl-2,6-diethylaniline;
N-1-methoxycarbonylcyclopropyl-N-ethylthiomethylcarbonylaniline;
N-(1-N',N'-dimethylaminocarbonylcyclopropyl)-N-methoxymethylcarbonyl-2,6-dimethylaniline;
N-(1-N'-methylaminocarbonylcyclopropyl)-N-methoxymethylcarbonyl-2,6-dimethylaniline;
N-(1-N',N'-diethylaminocarbonylcyclopropyl)-N-chloromethylcarbonyl-2,6-dimethylaniline;
N-(1-N'-ethylaminocarbonylcyclopropyl)-N-methylthiomethylcarbonyl-2,6-diethylaniline;
N-1-hydroxycarbonylcyclopropyl-N-methoxymethyl-carbonyl-2,6-dimethylaniline;
N-1-hydroxycarbonylcyclopropyl-N-methylthiomethylcarbonyl-2,6-diethylaniline;
N-1-hydroxycarbonylcyclopropyl-N-chloromethylcarbonyl-2,6-diisopropylaniline;
N-1-hydroxycarbonylcyclopropyl-N-(2-furanylmethylcarbonyl)-2,6-dimethylaniline.
EXAMPLE 5
Tomato Late Blight
Compounds of the invention were tested for the preventative control of the Tomato Late Blight organism Phytophthora infestans. Five- to six-week old tomato (cultivar Bonny Best) seedlings were used. The tomato plants were sprayed with a 250 ppm suspension of the test compound in acetone, water and a small amount of a nonionic emulsifier. The sprayed plants were then inoculated one day later with the organism, placed in an environmental chamber and incubated at 66° to 68° F. and 100% relative humidity for at least 16 hours. Following the incubation, the plants were maintained in a greenhouse for approximately 7 days. The percent disease control provided by a given test compound was based on the percent disease reduction relative to untreated check plants. The results are tabulated in Table II. In Table II, the test concentration is 250 ppm unless otherwise indicated by the figures in parentheses.
EXAMPLE 6
Celery Late Blight
The celery late blight tests were conducted using celery (Utah) plants 11 weeks old. The celery late blight organism was Septoria apii. The celery plants were sprayed with 250 ppm solutions of the candidate toxicant mixed with acetone, water and a nonionic emulsifier. The plants were then inoculated with the organism and placed in an environmental chamber and incubated at 66° to 68° F. in 100% relative humidity for an extended period of time (approximately 48 hours). Following the incubation the plants were allowed to dry and then were maintained in a greenhouse for approximately 14 days. The percent disease control provided by a given candidate toxicant is based on the percent disease reduction relative to untreated check plants. The results are reported in Table II.
EXAMPLE 7
Grape Downy Mildew Control
The compounds of the invention were tested for the control of the grape downy mildew organism Plasmopara viticola. Detached leaves, between 70 and 85 mm in diameter, of 7-week old Vitis vinifera cultivar Emperor grape seedlings were used as hosts. The leaves were sprayed with a 250 ppm solution of the test compound in acetone. The sprayed leaves were dried, inoculated with a spore suspension of the organism, placed in a humid environmental chamber and incubated at 66° to 68° F. and about 100% relative humidity. After incubation for two days, the plants were then held in a greenhouse seven to nine days; then the amount of disease control was determined. The percent disease control provided by a given test compound was based on the percent disease reduction relative to untreated check plants. The results are tabulated in Table II.
EXAMPLE 8
Tomato Early Blight
Compounds of the invention were tested for the control of the tomato Early Blight organism, Alternaria solani conidia. Tomato (variety Bonny Best) seedlings of 6 to 7 weeks old were used. The tomato plants were sprayed with a 250 ppm solution of the test compound in an acetone-and-water solution containing a small amount of a nonionic emulsifier. The sprayed plants were inoculated one day later with the organism, placed in the environmental chamber and incubated at 66° to 68° F. and 100% relative humidity for 24 hours. Following the incubation, the plants were maintained in a greenhouse for about 12 days. Percent diseases control was based on the percent disease development on untreated check plants. The compounds tested and the results are tabulated in Table II.
TABLE I__________________________________________________________________________Compounds of the Formula ##STR6## ANALYSISCompound Carbon Hydrogen NitrogenNumber R Z Calc. Found Calc. Found Calc. Found Form m.p.__________________________________________________________________________1 CH.sub.2 OCH.sub.3 OC.sub.2 H.sub.5 66.88 64.34 7.57 7.84 4.59 4.60 yellow oil ##STR7## OCH.sub.3 69.00 67.71 6.11 6.68 4.47 4.08 white solid 130-137° C.3 CH.sub.2 Cl OCH.sub.3 60.91 63.86 6.13 6.57 4.78 4.93 white 94-97° C. solid4 CH.sub.2 OCH.sub.3 OH 64.97 63.75 6.91 7.02 5.05 4.93 white 179-181° C. solid5 CH.sub.2 OCH.sub.3 OCH.sub.3 65.96 69.23 7.27 7.51 4.81 5.08 white 68-69° C. solid6 CH.sub.2 CHCH.sub.2 OCH.sub.3 71.05 64.59 7.37 6.60 4.88 4.60 yellow oil7 CHCHCH.sub.3 OCH.sub.3 71.05 68.76 7.37 7.29 4.87 4.41 yellow oil__________________________________________________________________________
TABLE II______________________________________FUNGICIDAL ACTIVITY% CONTROLCompoundNumber Grape D.M. Tom. L.B. Cel. L.B. Tom. E.B.______________________________________1 42 29 0 712 37 11 -- 03 17 0 0 04 8 14 68 115 100 88 0 06 23 18 0 297 11 0 -- 0______________________________________ Grape D.M. Grape Downy Mildew Tom. L.B. Tomato Late Blight Cel. L.B. Celery Late Blight Tom. E.B. Tomato Early Blight | Compounds represented by the formula ##STR1## wherein R and R 1 are independently hydrogen or lower alkyl; R 2 is lower alkenyl, lower alkynyl or --CH 2 X wherein X is halogen, hydroxyl, lower alkoxy, lower alkylthio or a furanyl ring; and Z is hydroxyl, lower alkoxy or --NR 3 R 4 wherein R 3 and R 4 are independently hydrogen or lower alkyl possess fungicidal activity. Moreover, some of the compounds of this invention also possess herbicidal activity. | 0 |
This application is a division of application Ser. No. 939,823 filed on Dec. 9, 1986 now U.S. Pat. No. 4,470,291 which is a divisional application of prior application Ser. No. 695,435 filed on Jan. 10, 1985 now U.S. Pat. No. 4,682,488.
BACKGROUND OF THE INVENTION
Spined or slit fins are formed from flat stock with cuts made uniformly along each side and with the central portion left intact. The slit flat stock is then bent into a U-shaped configuration with the central un-cut portion serving as the bight or base. The U-shaped slit stock is spirally wrapped about the tubing and is glued or otherwise suitably secured to the tubing with the base or bight in metal-to-metal contact with the tubing. This results in the tubing being covered with radiating spines or tines to produce slit fin tubing stock suitable for use as heat exchange coils.
Conventionally, the slit fin tubing stock has been wrapped around a forming drum with the wraps in a parallel abutting relation to each other to form a plurality of helically wound circuits which, in turn, make up the coil. Terminal leads are provided at each end of the circuits. The forming drum is then removed. Terminal leads at each end of the circuits of the coil are bent, disposed one inwardly of the other so that they are positioned tangent to the same plane, which is perpendicular to the center longitudinal axis of the coil, and then a portion of each terminal lead is cut off and joined to a header. Due to the fragility of the individual spines or tines, any subsequent forming of the coil has been precluded.
SUMMARY OF THE INVENTION
Slit fin tubing stock is wound about two mandrels respectively attached to two rotating arms of a coil wrapping machine to form a flat coiled, two row, slit fin heat exchanger. The mandrels are spaced to provide enough material to form the desired coil shape and the distance may be variable to accommodate different coils. The flat coiled heat exchanger can be made up of a number of circuits having their ends strapped or otherwise suitably secured to make the flat coil with a pair of leads extending from the coil for each circuit. The flat coil is removed from the coil wrapping machine and placed upon corresponding mandrels of a coil forming machine. This flat coil can then be formed into a wide range of desired coil configurations according to the teachings of the present invention. Specifically, the flat coil coacts with a fixed platen due to the movement of the two arms of the coil forming machine. The two rows of the coil are brought into a nesting contact in their center portion with the fixed platen providing support. Because a considerable number of spines or tines initially contact the platen, their collective resistance to columnar buckling provides enough stiffness to prevent any significant deformation of the tines in the central area. As the arms move, the nexting contact between the two rows proceeds from the central section towards the ends. The nesting contact progresses with the bending of the two rows in accordance with the shape of the platen. As the axes of rotation of the arms are in a different plane than the upper surface of the platen, the arms become effectively shorter relative to the coil as they move from a horizontal position. Because of the nesting action, together with the resistance to columnar buckling, the two rows can be bent by folding through at least 120° without significantly deforming the tines and with no more than a 10-20% reduction in the cross sectional area of the tubes. Since in a simple "L", "U" or "C" bend, the outer rows will be bent at a larger radius than the inner rows the difference in lengths of the two rows of coils is compensated at the ends by forming a knob at the end of each coil.
It is an object of this invention to provide a method and apparatus for making and forming slit fin coils.
It is another object of this invention to form a slit fin coil by folding a flat coil into a desired configuration.
It is a further object of this invention to provide a method and apparatus for forming slit fin coils having multiple bends. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
Basically, the slit fin tubing stock is wound around two spaced and horizontally extending mandrels of a coil wrapping machine with the slit fin tubing stock being cut to form the required number of circuits. The cut slit fin tubing stock is collectively wound for the required number of turns whereupon the flat coil is removed from the mandrels of the coil wrapping machine and placed on the corresponding mandrels of a coil forming machine. The platen may be in place on the coil wrapping machine or else it is moved into place under the resulting flat coiled, two row, slit fin heat exchanger. The arms carrying the mandrels of the coil forming machine are rotated such that the mandrels are moved through arcs in opposite directions such that the outer ends of the mandrels move downwardly and towards each other. The downward movement of the mandrels initially brings the central portion of the lower rows of coils into contact with the upper planar surface of the underlying platen and brings the tines of the upper rows of coils into nesting contact with the tines of the lower rows of coils with the initial nesting taking place for all portions of the coils overlying the platen. Continued movement of the arms brings the mandrels below the upper surface of the platen and causes the folding of the coils. The nesting contact continues to extend toward the mandrels as the mandrels move through their arcs and cause further forming of the coils. Because they bend through tighter radii, the lower rows of coils would extend further from the bend than the upper rows of coils. However, at the mandrel ends the platen deforms only the lower rows of coils to make a knob which additionally nests the upper and lower coils essentially all the way to the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a top view of the coil wrapping machine and the coil forming machine showing the coil in phantom on the coil wrapping machine.
FIG. 2 is a front view of the coil wrapping machine with a multi-circuit coil being wound thereon;
FIG. 2A is a pictorial view of an end of a coil wrap secured in place on the wrapping machine;
FIG. 3 is a partially cut away front view of the coil forming machine with a coil shown in phantom;
FIG. 4 is a back view of the coil forming machine with a coil shown in phantom;
FIG. 5 is a view corresponding to FIG. 3 but only showing the coil and structure of the coil forming machine and platen which contacts the coil during forming;
FIG. 6 is a view corresponding to FIG. 5 but with the mandrels moved to start forming the coil;
FIG. 6A is a sectional view showing the nesting of he coils;
FIG. 7 is a view corresponding to FIG. 6 but showing further forming;
FIG. 8 is a view corresponding to FIG. 7 but showing the final forming for a "C" or "U" coil; and
FIG. 9 is an end view of the coil of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2 the numeral 10 generally designates the coil winding machine or device. In FIGS. 1, 3 and 4 the numeral 40 generally designates the coil forming machine or device. In FIGS. 1-4 the structure for supporting the coil winding and coil forming devices has been omitted to simplify and clarify the drawings. The support structure can be any suitable support structure, as is well known in the art, which will permit movement of the members necessary for the winding and forming operations. During the winding operation, slit fin coil stock 12 is fed from a source thereof, such as a fin winding machine (not illustrated) as the coil support structure of the coil winding device 10 is rotated. The coil stock 12 is wrapped around parallel, spaced mandrels 14a and b which are suitably adjustably secured to the outer ends of bar or plate 20. For example, the threaded portions 15a and b, respectively, of mandrels 14a and b can be placed in suitable bores 18 and held in place by nuts 17a and b respectively. Shaft 30 is suitably fixedly secured to plate 20 for rotating mandrels 14a and b, and plate 20 as a unit and for winding coil stock 12 onto mandrels 14a and b as is best shown in FIG. 2. Shaft 30 effectively divides plate 20 into two arms and is rotated by motor 32 in a conventional fashion.
Mandrels 14a and b are preferably initially adjustably spaced a predetermined fixed distance apart on bar 20 to obtain the desired coil width. As best shown in FIG. 2A, an end 12a of the coil stock is suitably secured to either mandrel 14a or b. As illustrated, an expanded metal cylinder 22a is initially placed over mandrel 14a and end 12a is secured thereto by a spring clip 24, a wire, twist tie or any other suitable attachment means. An expanded metal cylinder is similarly preferably placed over mandrel 14b. Motor 32 is actuated to cause the rotation of shaft 30, mandrels 14a and b, and plate or bar 20 as a unit which causes the coil stock 12 to be wound about mandrels 14a and b in a flat two row coil 38. As a plurality of circuits are generally required in the coil 38, each time a sufficient number of turns are made for a circuit, the coil stock 12 is cut with each end 12a, 12b, . . . 12n-1, 12n being strapped or otherwise suitably secured, as by spring clips 24, twist ties, etc. in place on mandrel 14a or b or the expanded metal cylinders 22a and b placed on mandrels 14a or b. However, all of the ends 12a-12n will be on only one of the mandrels 14a or b since they must be connected to headers. After the desired number of turns and circuits have been made, the flat coil 38 is slid from mandrels 14a and b of coil winding machine 10 and placed onto the mandrels 44a and b of coil forming device 40. While mandrels 14a and b and 44a and b are shown as being coaxial, this is not necessary and, in addition, the spacing must be great enough to permit removal of the formed coil 138. If expanded metal cylinders such as 22a and b are placed on mandrels 14a and b, removal of the coil 38 is facilitated as the contact between the tines and the mandrels is greatly reduced. This results in a reduced holding force relative to the mandrels and reduced flexural distortion of the tines upon removal of the coil.
As is best shown in FIGS. 3 and 4, the mandrels 44a and b are fixed at or near the outer ends of arms 46a and b, respectively, which are fixedly secured to and pivoted about axles 48a and b, repectively. Axle 48a has a gear 50a fixedly secured to one end while the other end extends through slots 53a in frame 52 into bearing block 54a. Similarly, axle 48b has a gear 50b fixedly secured to one end while the other end extends through slot 53b in frame 52 into bearing block 54b. Bearing blocks 54a and b are supported on plates 56a and b which are adjustably movable relative to slots 53a and b, respectively, for adjusting the spacing and locations of mandrels 44a and b, respectively. Plates 56a and b are fixedly positioned at the selected position by bolts 57 which extend through plates 56a or b and are threaded into threaded bores 58 in frame 52. Referring now to FIG. 4, gear 50a is in meshing engagement with racks 60a and 62a which are adjustably positioned by hydraulic cylinders 61a and 63a, respectively. Gear 50b is in meshing engagement with racks 60b and 62b which are adjustably positioned by hydraulic cylinders 61b and 63b, respectively. The hydraulic cylinders 61a and b and 63a and b are conventional hydraulic cylinders which are moved in response to pressurized hydraulic fluid supplied by a pump (not illustrated) and are controlled in any suitable conventional manner. The racks 60a and b and 62a and b are guidably secured so that only reciprocating movement under the control of hydraulic cylinders 61a and b and 63a and b and in engagement with one of gears 50a and b is possible. This arrangement affords positive individual bidirectional control over the rotation of arms 46a and b.
Extending outwardly from frame 52, parallel to and in the direction of mandrels 44a and b, are supports 66a and b which are received in corresponding openings 70a and b in platen 68 when platen 68 is positioned on frame 52 of coil forming device 40. The platen 68 is made up of a number of tubular or cylindrical members 71-74 which, when platen 68 is in place on frame 52, are parallel to mandrels 44a and b. Cylindrical members 71-74 and planar member 75 are the only portions of platen 68 to contact the coil 38 during the forming operation and the upper surface of planar member 75 is in a plane essentially tangential with the cylindrical members 72 and 73. Cylindrical members 72 and 73 and planar member 75 are located between plate members 76 and 77. Cylindrical member 71 is connected to cylindrical member 72 via support member 78 and cylindrical member 74 is connected to cylindrical member 73 via support member 79. Braces 80 and 81 serve to support the cylindrical members against the forming forces. Cylindrical members 73 and 73 and planar member 75 must, however, be located in a plane spaced from the plane containing mandrels 44a and b and axles 48a and b to provide a clearance for placing the coil 38 or platen 68 in place for the forming operation.
In operation, the coil winding machine 10 and the coil forming machine 40 can be proximately or remotely spaced or can be relatively positioned as illustrated in FIG. 1. They must, however, be sufficiently spaced to remove the formed coil from coil forming machine 40. This permits the flat two row coil 38 to be wound on coil winding machine 1 and then slid or otherwise moved directly onto the mandrels 44a and b of coil forming machine 40 where flat two row coil 38 is formed into coil 138 having the desired configuration.
Referring now to FIGS. 1 and 2, mandrels 14a and b are adjustably positioned so as to be properly spaced to form a coil 38 to the proper width to form the desired coil. Mandrels 14a and b are positioned by placing threaded portions 15a and b through appropriate bores 18 in plate 20 then threading nuts 17a and b thereon. Mandrels 44a and b and corresponding arms 46a and b, are adjusted as units. Specifically, the bolts 57 securing plates 56a and b in place would be removed to permit axles 48a and b to be repositioned within slots 53a and b, respectively, in frame 52. Since gears 50a and b are fixed to axles 48a and b, respectively, it is necesary to either permit sliding movemen of the gear and rack assemblies without rotation of the gears 50a and b or else the gears must be rotated to place the arms 46a and b in their proper orientation. When the axles 48a and b are repositioned in their desired locations, the plates 56a and b are secured in place by threading bolts 57 into appropriate threaded bores 58. The separation of mandrels 44a and b would be the same as the separation of mandrels 14a and b. An end, 12a, of coil stock 12 is secured in place on either mandrel 14a or b or, the expanded metal cylinders 22a and b placed thereon by a spring clip 24 or any other suitable means for holding end 12a in place. Motor 32 is then caused to rotate shaft 30, plate 20 and mandrels 14a and b as a unit which causes coil stock 12 to be wrapped about mandrels 14a and b in a flat two row coil. When the desired number of turns have been made to form a circuit, the coil stock 12 is cut and the resultant ends 12b and 12c are each secured in place on the same mandrel end as 12a. Motor 32 is then again caused to rotate shaft 30, plate 20 and mandrels 14a and b as a unit until the desired number of turns are made to form a second circuit. The coil stock is cut and the resultant ends are secured in place on the appropriate mandrel. This procedure continues until the desired number of circuits have been made. The resultant flat two row coil 38 is then removed from coil winding machine 10. Subsequently, coil 38 is slid onto the mandrels 44a and b of coil forming machine 40. As the initial, unformed, position of coil 38 should be spaced from the platen 68 to avoid damaging the tines of the tubing when the coil 38 is set in place, platen 68 is normally located in place on frame 52 of coil forming machine 40 when coil 38 is placed on mandrels 44a and b but in a different plane so as to provide a clearance. The platen 68 is secured in place on frame 52 by supports 66a and b which are received in corresponding openings 70a and b in platen 68.
As best shown in FIG. 3, mandrels 44a and b, and axles 48a and b which are received in bearing blocks 54a and b respectively, are in the same plane prior to the forming of the coil. The upper portion of platen 68 is in a plane below that containing mandrels 44a and b axles 48a and b and is located generally coextensively with axles 48a and b. Specifically, tubular or cylindrical members 72 and 73 are generally spaced the same distances as axles 48a and b to promote nesting between the two rows 38a and b of the coil 38 and because their relative positions are factors in determining the length of the arms of the U or C-shaped coil being formed. As viewed in FIG. 3, arm 46a turns clockwise and arm 46b turns counterclockwise in forming coil 38. Because axles 48a and b, mandrels 44a and b and the coil 38 are all initially above platen 68 arms 46a and b must be rotated to lower the coil 38 until row 38a is in contact with platen 68. Continued rotation of arms 46a and b brings the center portion of rows 38a and b coil 38 into nesting contact and starts forming coil 38 by bending the tubing. The movement of arms 46a and b is controlled by gears 50a and b, respectively. Gear 50a is, in turn, controlled by the racks 60a and 62a through hydraulic cylinders 61a and 63a, respectively. Similarly, gear 50b is, in turn, controlled by racks 60b and 62b through hydraulic cylinders 61b and 63b, respectively. The use of hydraulic cylinders to position members is well known in the art and takes place in conventional fashion in the present invention so that further explanation is unnecesary.
The forming of the coil 38 into coil 138 will now be described in terms of just the coil 38 and the structure in contact with the coil during the forming operation. FIG. 5 which corresponds to a simplified version of FIG. 3 illustrates the coil 38 in place on mandrels 44a and b prior to any forming action. A piece of expanded metal 90 may be placed between the rows 38a and b of coil 38. In FIG. 6, the rotation of arms 46a and b has lowered the spaced rows 38a and b of the coil such that the bottom row 38a is in contact with the tubular members 72 and 73 and planar member 75 of the platen 68 and the central portion of the rows 38a and b have been brought into nesting contact with the expanded metal 90 and each other to effectively lock the two rows together as is best shows in FIG. 6A. The portions of the coil 38 extending past tubular members 72 and 73 have started to be bent downward. The nesting action of the spines affords a stiffening action which resists lateral movement of the spines or tines and holds them such that columnar buckling is the deforming force and the resistance of the spines is greatest with respect to columnar buckling. It will also be noted that mandrels 44a and b have started to move closer together and that a gap, G, is starting to form between each of the mandrels 44a and b and the ends of the coil 38.
In FIG. 7, the nesting contact between the spaced coils has advanced further toward mandrels 44a and b locking more of the rows 38a and b together. Because mandrels 44a and b are rotating in arcs with axles 48a and b as their centers, while row 38a is being formed about tubular members 72 and 73 and row 38b is being formed about the resulting bends in rows 38a, the length of arms 46a and b is effectively reduced thereby effectively bringing the mandrels closer together due to the shifting of the plane of the coil 38 from the FIG. 5 position, and enlarging gaps G. The effective shortening of the arms 46a and b due to the shifting of the plane of the coil 38 allows the tubing to be formed without being subjected to tension from the mandrels 46a and b and the rows 38a and b are in a nested relationship at the bend which permits row 38 a of a 3/8 inch diameter tube to be bent on a one inch radius with a flattening or cross-sectional area reduction of only about 10%. It should be noted that in contacting tubular members 72 and 73 on the inside of the bend, the tines of row 38a are moved closer together to have greater resistance to lateral movement and, therefore, greater resistance to columnar buckling.
Since rows 38a and b start out at the same length, the longer distance taken by row 38b in bending around tubular members 72 and 73 is compensated for by placing a knob at each end of the coil as best shown in FIG. 8. Tubular members 71 and 74 contact the corresponding portions of row 38a to complete the nesting action and to form a knob at each mandrel and thereby compensate for the different lengths of the bends of the rows about tubular members 72 and 73 and closes gaps G. The resultant formed coil 138 has a degree of resilience and so bounces back from the most extreme or closed position taken during the forming action which facilitates removal of the coil 138 from the coil forming machine 40. The formed coil 138 is illustrated in FIG. 9. The ends 12a-n would then be attached to headers in a conventional manner to complete the coil. If the piece of expanded metal 90 was placed between the rows 38a and b as illustrated in FIG. 5, the resulting locking action due to the nesting action between rows 38a and b and the piece of expanded metal 90 would provide sufficient rigidity to the coil 138 so that tube supports are not required to support the coil.
In the practice of the present invention, the coil stock is aluminum tubing with aluminum slit fins spirally wrapped thereon. The expanded metal cylinders 22a and b and plate 90 would be of aluminum. In each case, the expanded metal should be unflattened.
Although the present invention has been specifically described and illustrated, other changes will occur to those skilled in the art. For example, although the coil winding and coil forming machines have been described as having mandrels extending horizontally, they could be vertically disposed without changing the principles of the present invention. Also, the wrapping and forming can take place on the same apparatus. It is, therefore, intended that the scope of the present invention is to be limited only by the scope of the appended claims. | A slit fin heat exchanger is formed by wrapping slit fin tubing into a flat coil having two spaced rows of tubing. The flat coil is located on mandrels which are rotatable about spaced parallel axes with the mandrels and axes initially being in the same plane. The mandrels are rotated about their axes in opposite directions which shifts the plane in which the coil is located. The shifting of the plane of the coil moves a portion of a first row of the coil into contact with a planar portion of a platen and the second row of the coil into a nesting relationship with the portion of the first row which is in contact with the planar portion of the platen. Continued rotation of the mandrels causes folding of the portions of the coil which extends the area of nesting. The folding takes place through up to 120° and the ends of the first row of the coil contacts a portion of the platen causing the formation of a knob at the end of each coil. | 8 |
BACKGROUND
When electronic components operate, they produce heat. In some, low power, applications, this heat can be adequately removed using free convection cooling. However, in many applications, free convection cooling (the un-aided movement of air) does not provide sufficient cooling to prevent overheating (and possibly premature failure) of electronic components. In applications where free convection cooling does not offer sufficient cooling capacity, electric fans are often used as a low cost way of moving ambient air across the electronic components at a higher rate than that possible using free convection cooling. Accordingly, the use of cooling fans is often employed as a low cost solution for keeping electronic components operating within the acceptable temperature ranges specified by the electronic component manufacturers.
Cooling fans are often integrated with an enclosure which houses, amongst other components, the electronic components to be cooled by the fan. The cooling fan is often mounted to the enclosure using fasteners such as screws, dowel pins, rivets, or the like. Although this fastening technique is widely used, it significantly increases the cost of the product due to the labor and tools that are needed to install the fasteners and the handling costs associated with handling the fasteners.
Embodiments set forth herein disclose a system for eliminating fasteners traditionally used for securing cooling fans to an enclosure. The embodiments disclosed herein can be utilized in various applications including the automotive, computer, electronic instrumentation, or in any industry where the forced movement of air is used as a temperature controlling medium.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of an embodiment of the cooling fan mounting system of the present invention used in conjunction with a computer tower.
FIG. 2 is an exploded enlarged isometric view of encircled portion 2 of FIG. 1 from a different perspective.
FIG. 3 is a partial cross-sectional view taken substantially through lines 3 - 3 of FIG. 2 .
FIGS. 4A-4I are a series of grouped interior, exterior, and side views of the position of the fan enclosure (with respect to the panel on which it is mounted) at various stages of fan assembly installation.
DETAILED DESCRIPTION
Now referring to FIG. 1 , an embodiment of the cooling fan assembly 12 of the present invention is shown in use with a panel 14 of computer tower 10 . Although cooling fan assembly 12 can be used in any computer application where forced air cooling is necessary, it is not limited to those applications and one skilled in the art will readily recognize that the cooling fan assembly of the present invention is applicable in any application where forced air movement is relied upon for adequate cooling of any heat generating system (electrical, mechanical, chemical, or the like).
Now referring to FIG. 2 and FIG. 3 , panel 14 can comprise any stationary member to which cooling fan assembly 12 is to be mounted. However, typically cooling fans are mounted to sheet-like stationary members (typically sheet metal panels). Throughout this disclosure, the device to which assembly 12 is mounted will be primarily referred to as a panel or stationary member; however, structures other than panels are fully contemplated within the scope of this disclosure. Panel 14 provides the mounting interface for supporting cooling fan assembly 12 . Cooling fan assembly 12 includes a motor 16 which is used to rotate a fan blade 18 by way of a motor output shaft 20 . In one embodiment of the present invention, motor 16 is an electrical motor which receives its electrical power requirements via power conductors 22 . Although in many applications, the preferred embodiment of motor 16 is an electric motor, it is well within the scope of this invention to use non-electric motors as the primary mover for moving fan blade 18 . Other primary movers that might be appropriate in various applications, include hydraulic motors, pneumatic motors, and the like. In some embodiments, depending on the type of electric motor that may be used, it may be convenient or cost effective to mount electronic motor control components 24 on, or about, motor 16 . In other applications, it may not be appropriate to mount motor control components on, or about, motor 16 and in such cases, motor control components 24 can be mounted separate from motor 16 .
In the majority of applications, it is most appropriate to establish the rotation of fan blade 18 such that it moves warm air, designated by arrows 26 , from the interior of an enclosure to the exterior of the enclosure through enclosure exhaust portals 28 . The enclosure is typically fitted with enclosure intake portals (intake portals not shown) which allow ambient air to enter into the enclosure interior to replace the air exhausted by cooling fan assembly 12 .
In one embodiment the motor 16 includes non-rotatable housing 30 which houses the operative components of motor 16 . The housing 30 is coupled to a motor carrier 32 . In one embodiment of the present invention, motor housing 30 is integrally formed (such as using plastic injection molding techniques) with motor carrier 32 to form an integrated unit.
Motor carrier 32 includes a plurality of mounting legs 34 . In one embodiment, each mounting leg 34 terminates into a pair of resilient leg portions 36 which are separated by a compression gap 38 . Each leg portion 36 may terminate into a turned-out portion 52 . Panel 14 may include a plurality of recess portions 40 which are convex with respect to the enclosure interior (i.e. are depressed into the enclosure interior and away from the enclosure exterior). In one embodiment, there is a recess portion 40 to correspond with each of the plurality of mounting legs 34 . Recess portion 40 includes an opening 42 which is shaped to include an enlarged opening region 44 and a residual opening region 46 (see FIG. 2 ). In one embodiment, the motor carrier 32 also includes a plurality of spring members 48 . Spring members 48 are designed to urge motor carrier 32 away from panel 14 once the plurality of mounting legs 34 are in their fully seated position. This urging function provided by spring members 48 prevents motor carrier 32 from moving (due to the vibrational forces imparted to it during normal operation of motor 16 ) and becoming disengaged from its seated position. This feature will be discussed more fully in conjunction with FIGS. 4A-4I .
In one embodiment, the height of turned-out portions 52 is less than or equal to the height of recessed portion 40 . By sizing turned-out portions 52 and recessed portions in this way, turned out portions 52 will not extend beyond the plane defined by the enclosure exterior thereby allowing one or more adjacent components (not shown) to directly abut the exterior of the enclosure.
Now referring to FIGS. 4A-4F , the steps for installing the cooling fan assembly 12 of the present invention are depicted.
The initial positioning of the cooling fan assembly 12 against panel 14 is shown in FIGS. 4A-4C and is hereinafter referred to as the load position.
In the load position, cooling fan assembly 12 is brought adjacent panel 14 such that the turned-out portions 52 of each mounting leg 34 are inserted into a respectively associated enlarged opening region 44 of opening 42 . Each turned-out portion 52 of the resilient legs 36 is sized in relation to its associated enlarged opening 44 such that the turned-out portions 52 freely pass into enlarged opening 44 without restriction. An interior view of the load position is shown in FIG. 4A and an exterior view (e.g. the view as seen from the exterior of enclosure 10 ) is shown in FIG. 4B . FIG. 4C shows a side view of the load position. It is important to note that in the load position, before any exertion force (designated by arrow 54 ) is applied to cooling fan assembly 12 , cooling fan assembly 12 rests against a surface of panel 14 by virtue of the contact between the bottom most bowed portion of spring member 48 and the panel 14 (see FIG. 4C ). It is also important to note that before any exertion force is applied against cooling fan assembly 12 toward panel 14 , the turned-out end portions 52 of each resilient leg 36 do not pass completely through enlarged opening 44 of opening 42 . In the load position, because enlarged opening 44 is sized larger than the turned-out portions 52 of resilient legs 36 , no compression forces are exerted against pairs of resilient leg portions 36 and the compression gap 38 is at its maximum size.
Now referring to FIGS. 4D-4F , in order to move the cooling fan assembly 12 from the load position ( FIGS. 4A-4C ) into the partially installed position ( FIGS. 4D-4F ), a combined compressive 54 and a rotating 56 force (arrows) must be imparted to at least one of the cooling fan assembly 12 or the panel 14 . The compressive force 54 acts to compress spring member 48 and move turned-out portions 52 fully into recess 40 , while the rotating force 56 repositions resilient legs 36 into an intermediate sized opening 58 of opening 42 . By comparing the length of dimension 50 between FIG. 4C and FIG. 4F , it is easily seen that dimension 50 in FIG. 4F is much smaller than it is in FIG. 4C . This is a depiction of the compression of spring 48 . Intermediate opening 58 is smaller than enlarged opening 44 which acts to bring together each pair of resilient leg portions 36 when rotating force 56 is exerted. Intermediate opening 58 is sized sufficiently small such that the turned-out portions 52 of each resilient leg 36 cannot pull through intermediate opening 58 under the urging of compressed spring member 48 .
Now referring to FIGS. 4G-4I , as cooling fan assembly 12 is further rotated 56 from the partially installed position (as shown in FIGS. 4D-4F ) into the fully installed position (shown in FIGS. 4G-4I ), resilient leg portions 36 of each mounting leg 34 enter into a third portion of opening 42 called the residual opening 60 . Residual opening 60 is sized smaller than enlarged opening 44 but not as small as intermediate opening 58 . Thus, when each pair of resilient leg portions 36 transition from the intermediate opening 58 into residual opening 60 , they spring outwardly. This outward movement captures each leg portion pair 36 within its respectively associated residual opening 60 . The relative compression experienced by each pair of resilient leg portions 36 at each stage of installation can be seen by comparing the size of the compression gap 38 as the installation progresses from the load position ( FIG. 4B ) through the partially installed position ( FIG. 4E ) and, finally into the fully installed position ( FIG. 4H ). In the fully installed position, spring member 48 remains in a compressed state thereby urging turned-out portions 52 of resilient leg portions against the exterior surface of panel 14 . This urging function performed by the spring member 48 assists in preventing vibrational noise from developing between the motor carrier 32 and the panel 14 and also serves to prevent vibrational forces from causing resilient leg portions 36 from “backing out” of their respectively associated residual opening 60 .
Having described various embodiments of the present invention, it will be understood that various modifications or additions may be made to the preferred embodiments chosen here to illustrate the present invention without departing from the spirit of the present invention. For example, the embodiment of spring member 48 shown in the drawings is generally depicted as a compressible “bowed” member; however, any device which is capable of exerting an urging force between cooling fan assembly and panel 14 is within the contemplation of this disclosure. Accordingly, it is to be understood that the subject matter sought to be afforded protection hereby shall be deemed to extend to the subject matter defined in the appended claims (including all fair equivalents thereof). | A mounting system for mounting a rotary member to a stationary member. The mounting system includes a carrier adapted to engage the rotary member, wherein the carrier includes a mounting leg portion which terminates into a pair of resilient leg portions. The carrier may also further include a spring member adapted to engage a first surface of the stationary member. At least one of the legs in the pair of resilient leg portions includes a turned-out portion adapted to engage a second surface of said stationary member. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Korean Patent Application No. 10-2009-0112236 filed on Nov. 19, 2009, the entire contents of which is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electric water pump. More particularly, the present invention relates to an electric water pump having improved performance and durability.
[0004] 2. Description of Related Art
[0005] Generally, a water pump circulates coolant to an engine and a heater in order to cool the engine and heat a cabin. The coolant flowing out from the water pump circulates through and exchanges heat with the engine, the heater, or the radiator, and flows back in the water pump. Such a water pump is largely divided into a mechanical water pump and an electric water pump.
[0006] The mechanical water pump is connected to a pulley fixed to a crankshaft of the engine and is driven according to rotation of the crankshaft (i.e., rotation of the engine). Therefore, the coolant amount flowing out from the mechanical water pump is determined according to rotation speed of the engine. However, the coolant amount required in the heater and the radiator is a specific value regardless of the rotation speed of the engine. Therefore, the heater and the radiator do not operate normally in a region where the engine speed is slow, and in order to operate the heater and the radiator normally, the engine speed must be increased. However, if the engine speed is increased, fuel consumption of a vehicle also increases.
[0007] On the contrary, the electric water pump is driven by a motor controlled by a control apparatus. Therefore, the electric water pump can determines the coolant amount regardless of the rotation speed of the engine. Since components used in the electric water pump, however, are electrically operated, it is important for electrically operated components to have sufficient waterproof performance. If the components have sufficient waterproof performance, performance and durability of the electric water pump may also improve.
[0008] Currently, the number of vehicles having an electric water pump is tending to increase. Accordingly, various technologies for improving performance and durability of the electric water pump are being developed.
[0009] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0010] Various aspects of the present invention are directed to provide an electric water pump having advantages of improved performance and durability and to provide an electric water pump which minimizes magnetic flux leakage of a permanent magnet by optimizing a shape of a rotor core.
[0011] In an aspect of the present invention, the electric water pump apparatus may include a body having a hollow cylindrical shape and including a stator chamber and a rotor chamber therein, a stator having a hollow cylindrical shape and being disposed in the stator chamber and generating a magnetic field according to a control signal, wherein the stator fluidly insulates the stator chamber and the rotor chamber, a rotor disposed in the rotor chamber and enclosed by the stator, wherein the rotor is rotated by the magnetic field generated at the stator, and a pump cover connected to the body and forming a volute chamber therein, wherein the volute chamber and the rotor chamber are fluidly-communicated through a connecting hole formed to the body and a coolant having flowed into the volute chamber is supplied to the rotor chamber through the connection hole, wherein the stator includes a stator groove formed in an inner circumference therein and the stator groove is fluid-connected to the rotor chamber and the volute chamber through the connection hole.
[0012] The rotor core having a hollow cylindrical shape may include a coupling groove formed along an inner circumference in a length direction therein and the rotor core is splined to the shaft through the coupling groove.
[0013] The stator may include a stator core having a hollow cylindrical shape to receive the rotor therein and provided with the stator groove at an inner circumference thereof along a length direction, and a stator case mounted at both distal ends of the stator core, wherein the stator case is made of a bulk mold compound including a potassium family that has a low coefficient of contraction.
[0014] The stator case may be provided with a fixing groove and a driver providing the control signal is slidably and detachably coupled thereto.
[0015] The rotor may include a rotor core having a hollow cylindrical shape to receive a shaft therein, and provided with a plurality of recesses formed by a plurality of guiding protrusions formed at an exterior circumference thereof along a length direction, a plurality of permanent magnets respectively mounted in the plurality of recesses of the rotor core, a rotor cover mounted at both distal ends of the rotor core and the plurality of permanent magnets so as to fix the rotor core and the plurality of permanent magnets each other, and a rotor case enclosing an exterior circumference of the rotor core and the plurality of permanent magnets so as to fix the rotor core and the plurality of permanent magnet each other in a state that the rotor core and the plurality of permanent magnets are mounted at the rotor cover, wherein the rotor case may be made of a bulk mold compound including a potassium family that has a low coefficient of contraction.
[0016] The plurality of permanent magnets may be mounted in such a manner that N pole and S pole are alternatively disposed.
[0017] The rotor cover may be provided with a plurality of balance holes and rotational balance of the rotor may be kept by changing positions of the balance holes.
[0018] In addition, the stator case may be provided with a plurality of balance holes and rotational balance of the stator may be kept by changing positions of the balance holes.
[0019] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of an exemplary electric water pump according to the present invention.
[0021] FIG. 2 is a cross-sectional view taken along the line A-A in FIG. 1 .
[0022] FIG. 3 is a perspective view showing a stator of an exemplary electric water pump according to the present invention.
[0023] FIG. 4 is a perspective view of a rotor cover used in an exemplary electric water pump according to the present invention.
[0024] FIG. 5 is a perspective view showing a shape of a rotor core used in an exemplary electric water pump according to the present invention.
[0025] FIG. 6 is a schematic diagram showing processes for mounting rotor covers to both ends of a rotor core and a permanent magnet in an exemplary electric water pump according to the present invention.
[0026] FIG. 7 is a schematic diagram showing processes for manufacturing a rotor used in an exemplary electric water pump according to the present invention.
[0027] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0028] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0030] An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
[0031] FIG. 1 is a perspective view of an electric water pump according to an exemplary embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along the line A-A in FIG. 1 .
[0032] As shown in FIG. 1 and FIG. 2 , an electric water pump 1 according to an exemplary embodiment of the present invention includes a pump cover 10 , a body 30 , a driver case 50 , and a driver cover 70 . The body 30 is engaged to a rear end of the pump cover 10 so as to form a volute chamber 16 , the driver case 50 is engaged to a rear end of the body 30 so as to form a rotor chamber 38 and a stator chamber 42 , and the driver cover 70 is engaged to a rear end of the driver case 50 so as to form a driver chamber 64 .
[0033] In addition, an impeller 22 is mounted in the volute chamber 16 , a rotor 200 (referring to FIG. 7 ) fixed to a shaft 82 is mounted in the rotor chamber 38 , a stator 101 is mounted in the stator chamber 42 , and a driver 80 is mounted in the driver chamber 64 . The shaft 82 has a central axis x, and the rotor 200 as well as the shaft 82 rotate about the central axis x. The stator 101 is disposed coaxially with the central axis x of the shaft 82 .
[0034] The pump cover 10 is provided with an inlet 12 at a front end portion thereof and an outlet 14 at a side portion thereof. Therefore, the coolant flows in the electric water pump 1 through the inlet 12 , and the pressurized coolant in the electric water pump 1 flows out through the outlet 14 . A slanted surface 18 is formed at a rear end portion of the inlet 12 of the pump cover 10 , and a rear end portion 20 of the pump cover 10 is extended rearward from the slanted surface 18 . The rear end portion 20 of the pump cover 10 is engaged to a cover mounting portion 44 of the body 30 by fixing means such as a bolt B. The slanted surface 18 is slanted with reference to the central axis x of the shaft 82 , and an intersecting point P of lines extended from the slanted surface 18 is located on the central axis x of the shaft 82 .
[0035] The volute chamber 16 for pressurizing the coolant is formed in the pump cover 10 , and the impeller 22 for pressurizing and discharging the coolant through the outlet 14 is mounted in the volute chamber 16 . The impeller 22 is fixed to a front end portion of the shaft 82 and rotates together with the shaft 82 . For this purpose, a bolt hole 29 is formed at a middle portion of the impeller 22 and a thread is formed at an interior circumference of the bolt hole 29 . Therefore, an impeller bolt 28 inserted in the bolt hole 29 is threaded to the front end portion of the shaft 82 such that the impeller 22 is fixed to the shaft 82 . A washer w may be interposed between the impeller 22 and the impeller bolt 28 .
[0036] The impeller 22 is provided with a confronting surface 26 corresponding to the slanted surface 18 at the front end portion thereof. Therefore, an intersecting point of lines extended from the confronting surface 26 is also positioned on the central axis x of the shaft 82 . The coolant having flowed into the water pump 1 may be smoothly guided and performance of the water pump 1 may be improved as a consequence of disposing centers of the impeller 22 and the rotor 200 that are rotating elements of the water pump 1 and a center of the stator 101 that is a fixed element of the water pump 1 on the central axis x.
[0037] In addition, the impeller 22 is divided into a plurality of regions by a plurality of blades 24 . The coolant having flowed into the plurality of regions is pressurized by rotation of the impeller 22 .
[0038] The body 30 has a hollow cylindrical shape that is opened rearward, and is engaged to the rear end of the pump cover 10 . The body 30 includes a front surface 32 forming the volute chamber 16 with the pump cover 10 , the stator chamber 42 that is formed at an exterior circumferential portion of the body 30 and in which the stator 101 is mounted, and the rotor chamber 38 that is formed at an interior circumferential portion of the stator chamber 42 and in which the rotor 200 is mounted.
[0039] The front surface 32 of the body 30 is provided with the cover mounting portion 44 , a first stator mounting surface 40 , a first bearing mounting surface 48 , and a penetration hole 34 formed sequentially from an exterior circumference to a center thereof.
[0040] The cover mounting portion 44 is engaged to the rear end portion 20 of the pump cover 10 . Sealing means such as an O-ring O may be interposed between the cover mounting portion 44 and the rear end portion 20 in order to prevent leakage of the coolant from the volute chamber 16 .
[0041] The first stator mounting surface 40 is protruded rearward from the front surface 32 , and defines a boundary between the stator chamber 42 and the rotor chamber 38 . In a state that the sealing means such as an O-ring O is mounted at the first stator mounting surface 40 , the front end of the stator 101 is mounted at the first stator mounting surface 40 .
[0042] The first bearing mounting surface 48 is protruded rearward from the front surface 32 . A first bearing 94 is interposed between the first bearing mounting surface 48 and the front end portion of the shaft 82 in order to make the shaft 82 smoothly rotate and to prevent the shaft 82 from being inclined.
[0043] The penetration hole 34 is formed at a middle portion of the front surface 32 such that the front end portion of the shaft 82 is protruded to the volute chamber 16 through the penetration hole 34 . The impeller 22 is fixed to the shaft 82 in the volute chamber 16 . It is exemplarily described in this specification that the impeller 22 is fixed to the shaft 82 by the impeller bolt 28 . However, the impeller 22 may be press-fitted to an exterior circumference of the shaft 82 .
[0044] Meanwhile, a connecting hole 36 is formed at the front surface 32 between the first stator mounting surface 40 and the first bearing mounting surface 48 . Therefore, the rotor chamber 38 is fluidly connected to the volute chamber 16 . Heat generated at the shaft 82 , the rotor 200 , and the stator 101 by operation of the water pump 1 is cooled by the coolant flowing in and out through the connecting hole 36 . Therefore, durability of the water pump 1 may improve. In addition, floating materials in the coolant are prevented from being accumulated in the rotor chamber 38 .
[0045] The rotor chamber 38 is formed at a middle portion in the body 30 . The shaft 82 and the rotor 200 are mounted in the rotor chamber 38 .
[0046] A stepped portion 83 , the diameter of which is larger than that of the other part, is formed at a middle portion of the shaft 82 . According to an exemplary embodiment of the present invention, a hollow shaft 82 may be used. A spline portion (not shown) may be formed at an exterior circumference of the stepped portion 83 along the central axis x.
[0047] The rotor 200 is fixed on the stepped portion 83 of the shaft 82 , and is formed in an unsymmetrical shape. Thrust is exerted on the shaft 82 toward the front surface 32 by the unsymmetrical shape of the rotor 200 and a pressure difference between the volute chamber 16 and the rotor chamber 38 . The thrust generated at the shaft 82 pushes the shaft 82 toward the front surface 32 . Thereby, the stepped portion 83 of the shaft 82 may be interfere and collide with the first bearing 94 and the first bearing 94 may be damaged, accordingly. In order to prevent interference and collision of the stepped portion 83 of the shaft 82 and the first bearing 94 , a cup 100 is mounted between the stepped portion 83 of the shaft 82 and the first bearing 94 . Such a cup 100 is made of an elastic rubber material, and relieves the thrust of the shaft 82 exerted to the first bearing 94 .
[0048] Meanwhile, in a case that the cup 100 directly contacts the first bearing 94 , the thrust of the shaft 82 exerted to the first bearing 94 can be relieved. However, rotation friction may be generated between the first bearing 94 and the cup 100 of a rubber material, and thereby performance of the water pump 1 may be deteriorated. Therefore, a thrust ring 98 is mounted between the cup 100 and the first bearing 94 in order to reduce the rotation friction between the first bearing 94 and the cup 100 . That is, the cup 100 reduces the thrust of the shaft 82 and the thrust ring 98 reduces the rotation friction of the shaft 82 . It is exemplarily described in this specification that a groove is formed at an exterior circumference of the cup 100 and the thrust ring 98 is mounted in the groove. However, a method for installing the thrust ring 98 to the cup 100 is not limited to the exemplary embodiment of the present invention. For example, a groove may be formed at a middle portion of the cup 100 and the thrust ring 98 may be mounted in this groove. Further, it is to be understood that any thrust ring 98 interposed between the cup 100 and the first bearing 94 may be included in the spirit of the present invention.
[0049] The rotor 200 includes a rotor core 86 , a permanent magnet 88 , a rotor cover 84 , and a rotor case 90 .
[0050] As shown in FIG. 2 and FIG. 5 , the rotor core 86 has a hollow cylindrical shape and is fixed to the stepped portion 83 of the shaft 82 by press-fitting or welding, or is splined to the stepped portion 83 of the shaft 82 . It is exemplarily described in this specification that the rotor core 86 is splined to the stepped portion 83 of the shaft 82 . For this purpose, a coupling groove 204 is formed at an interior circumference of the rotor core 86 along the central axis x and is splined to the stepped portion 83 .
[0051] A plurality of guiding protrusions 202 is formed at the exterior circumference of the rotor core 86 along the central axis x, and a plurality of recesses 203 is formed between the guiding protrusions 202 along the central axis x. In addition, the permanent magnets 88 are insertedly mounted in each recess 203 . Therefore, the plurality of guiding protrusions 202 prevents the permanent magnet 88 from rotating. In addition, the plurality of guiding protrusions 202 does not cover both ends of the permanent magnet 88 so as to limit axial movement of the permanent magnet 88 . If the guiding protrusion 202 covers both ends of the permanent magnet 88 , magnetic flux generated by the permanent magnet 88 may leak. Such a leakage of the magnetic flux causes that the more and the larger permanent magnet 88 should be used. Therefore, size of the water pump 1 may increase. According to an exemplary embodiment of the present invention, the guiding protrusion 202 , however, does not cover both ends of the permanent magnet 88 , and thus leakage of the magnetic flux may be reduced. Therefore, sufficient capacity of the water pump 1 may be achieved without increasing the size of the water pump 1 .
[0052] The permanent magnet 88 is mounted in the recess 203 formed at the exterior circumference of the rotor core 86 . The permanent magnet 88 includes N pole and S pole and is mounted in such a manner that the N pole and the S pole are alternately disposed.
[0053] As shown in FIG. 2 and FIG. 4 , a pair of rotor covers 84 is mounted at both ends of the rotor core 86 and the permanent magnet 88 . A permanent magnet guider 201 is formed at an interior circumference of the rotor cover 84 such that movement of the permanent magnet 88 mounted at the rotor core 86 along the central axis x is restricted. Therefore, the rotor cover 84 primarily fixes the rotor core 86 and the permanent magnet 88 , and is made of copper or stainless steel that has high specific gravity. In addition, the rotor cover 84 , as shown in FIG. 7 , is formed of a plurality of balance holes 205 . If the rotor 200 is manufactured, it is checked whether the rotor 200 is rotationally balanced. If the rotor 200 is not rotationally balanced, noise or vibration may occur when the water pump 1 operates. Thereby, performance of the water pump 1 may be deteriorated. Therefore, positions of the balance holes 205 are changed such that the rotor 200 is rotationally balanced.
[0054] In a state in which the rotor core 86 and the permanent magnet 88 are mounted to the rotor cover 84 , the rotor case 90 wraps exterior circumferences of the rotor core 86 and the permanent magnet 88 so as to secondarily fix them. The rotor case 90 is made of a bulk mold compound (BMC) including a potassium family that has a low coefficient of contraction. A method for manufacturing the rotor case 90 will be briefly described.
[0055] The rotor core 86 and the permanent magnet 88 are mounted to the rotor cover 84 , and the rotor cover 84 to which the rotor core 86 and the permanent magnet 88 are mounted is inserted in a mold (not shown). After that, the bulk mold compound including the potassium family is melted and high temperature (e.g., 150° C.) and high pressure BMC is flowed into the mold. Then, the BMC is cooled in the mold. As described above, if the rotor case 90 is made of BMC having the low coefficient of contraction, the rotor case 90 can be precisely manufactured. In general, the coefficient of contraction of a resin is 4/1000-5/1000, but the coefficient of contraction of the BMC is about 5/10,000. If the rotor case 90 is manufactured by flowing the high temperature resin into the mold, the rotor case 90 is contracted and does not have a target shape. Therefore, if the rotor case 90 is manufactured by the BMC including the potassium family that has the low coefficient of contraction, contraction of the rotor case 90 by cooling may be reduced and the rotor case 90 may be precisely manufactured. In addition, since BMC including the potassium family has good heat-radiating performance, the rotor can be cooled independently. Therefore, the water pump 1 may be prevented from being heat damaged.
[0056] In addition, according to a conventional method for manufacturing the rotor, the permanent magnet is fixed to the exterior circumference of the rotor core with glue. However, as the rotor rotates, high temperature and high pressure are generated near the rotor. Thereby, the glue may be melted or the permanent magnet may be disengaged from the rotor core. The permanent magnet 88 mounted to the rotor core 86 , on the contrary, is fixed primarily by the rotor cover 84 and secondarily by the rotor case 90 according to an exemplary embodiment of the present invention. Thus, the permanent magnet 88 may not be disengaged from the rotor core 86 .
[0057] The stator chamber 42 is formed in the body 30 at a radially outer portion of the rotor chamber 38 . The stator 101 is mounted in the stator chamber 42 .
[0058] The stator 101 is fixed to the body 30 directly or indirectly, and includes a stator core 102 , an insulator 104 , a coil 108 , and a stator case 109 .
[0059] The stator core 102 is formed by stacking a plurality of pieces made of a magnetic material. That is, the plurality of thin pieces is stacked up such that the stator core 102 has a target thickness.
[0060] The insulator 104 connects the pieces making up the stator core 102 to each other, and is formed by molding a resin. That is, the stator core 102 formed by stacking the plurality of pieces is inserted in a mold (not shown), and then molten resin is injected into the mold. Thereby, the stator core 102 at which the insulator 104 is mounted is manufactured. At this time, coil mounting recesses 106 are formed at front and rear end portions of the stator core 102 and the insulator 104 .
[0061] The coil 108 is coiled at an exterior circumference of the stator core 102 so as to form a magnetic path.
[0062] The stator case 109 wraps and seals the stator core 102 , the insulator 104 , and the coil 108 . The stator case 109 , the same as the rotor case 90 , is manufactured by insert molding the BMC including the potassium family.
[0063] In addition, when the stator case 109 is insert molded, a Hall sensor 112 and a Hall sensor board 110 may also be insert molded. That is, the stator 101 , the Hall sensor 112 , and the Hall sensor board 110 may be integrally manufactured as one component.
[0064] The Hall sensor 112 detects the position of the rotor 200 . A mark (not shown) for representing the position thereof is formed at the rotor 200 , and the Hall sensor 112 detects the mark in order to detect the position of the rotor 200 .
[0065] The Hall sensor board 110 controls a control signal delivered to the stator 101 according to the position of the rotor 200 detected by the Hall sensor. That is, the Hall sensor board 110 makes a strong magnetic field be generated at one part of the stator 101 and a weak magnetic field be generated at the other part of the stator 101 according to the position of the rotor 200 . Thereby, initial mobility of the water pump 1 may be improved.
[0066] A case mounting portion 46 is formed at an exterior surface of the rear end of the body 30 .
[0067] The driver case 50 is engaged to the rear end of the body 30 , and is formed of a case surface 52 at a front end portion thereof. The rotor chamber 38 and the stator chamber 42 are formed in the body 30 by engaging the driver case 50 to the rear end portion of the body 30 . A body mounting portion 60 is formed at an external circumference of the front end portion of the driver case 50 and is engaged to the case mounting portion 46 by fixing means such as a bolt B.
[0068] The case surface 52 is provided with an insert portion 54 , a second stator mounting surface 56 , and a second bearing mounting surface 58 formed sequentially from an exterior circumference to a center thereof.
[0069] The insert portion 54 is formed at an external circumferential portion of the case surface 52 and is protruded forward. The insert portion 54 is inserted in and closely contacted to the rear end portion of the body 30 . Sealing means such as an O-ring O is interposed between the insert portion 54 and the rear end portion of the body 30 so as to close and seal the stator chamber 42 .
[0070] The second stator mounting surface 56 is protruded forward from the case surface 52 so as to define the boundary between the stator chamber 42 and the rotor chamber 38 . The rear end of the stator 101 is mounted at the second stator mounting surface 56 with a sealing means such as an O-ring O being interposed. The stator chamber 42 is not fluidly connected to the rotor chamber 38 by the O-ring O interposed between the first stator mounting surface 40 and the front end of the stator 101 and the O-ring O interposed between the second stator mounting surface 56 and the rear end of the stator 101 . Therefore, the coolant having flowed in the rotor chamber 38 does not flow to the stator chamber 42 .
[0071] The second bearing mounting surface 58 is protruded forwardly from the case surface 52 . A second bearing 96 is interposed between the second bearing mounting surface 58 and the rear end portion of the shaft 82 so as to make the shaft 82 smoothly rotate and to prevent the shaft 82 from being inclined.
[0072] The rear end of the driver case 50 is open. The driver chamber 64 is formed between the driver case 50 and the driver cover 70 by engaging the driver cover 70 of a disk shape to the rear end of the driver 50 by fixing means such as a bolt B. For this purpose, a protruding portion 72 is protruded forward from an exterior circumference of the driver cover 70 , and this protruding portion 72 is inserted in and closely contacted to an exterior circumference 62 of the rear end of the driver case 50 . Sealing means such as an O-ring O is interposed between the protruding portion 72 and the exterior circumference 62 so as to prevent foreign substances such as dust from entering the driver chamber 64 .
[0073] The driver 80 controlling operation of the water pump 1 is mounted in the driver chamber 64 . The driver 80 includes microprocessors and a printed circuit board (PCB). The driver 80 is electrically connected to a controller (not shown) disposed at an exterior of the electric water pump 1 through a connector 74 and receives a control signal of the controller. In addition, the driver 80 is electrically connected to the Hall sensor board 110 so as to transmit the control signal received from the controller to the Hall sensor board 110 .
[0074] Meanwhile, the driver chamber 64 is isolated from the rotor chamber 38 by the case surface 52 . Therefore, the coolant in the rotor chamber 38 does not flow into the driver chamber 64 .
[0075] Hereinafter, the stator 101 of the electric water pump 1 according to an exemplary embodiment of the present invention will be described in further detail with reference to FIG. 3 .
[0076] FIG. 3 is a perspective view showing a stator of an electric water pump according to an exemplary embodiment of the present invention.
[0077] As shown in FIG. 3 , a plurality of fixing grooves 105 are formed at the external circumference of the rear end of the stator case 109 . The insert portion 54 is inserted in the fixing groove 105 so as to limit rotational and axial movements of the stator 101 according to the rotation of the rotor 200 . Such a fixing groove 105 can be formed together with the stator case 109 when the stator case 109 is insert molded, and an additional process or an additional device is not required for forming the fixing groove 105 . Therefore, processes for manufacturing the stator 101 do not increase. In addition, since the stator 101 is fixed to the body 30 neither with glue nor by press-fitting, the stator 101 can be easily disassembled from the body 30 . Therefore, if the stator 101 is out of order, the stator 101 can be easily replaced.
[0078] In addition, as shown in FIG. 2 , the interior circumference of the stator case 109 forms a part of the rotor chamber 38 . As described above, the coolant flows into the rotor chamber 38 and moves in the rotor chamber 38 by rotation of the shaft 82 and the rotor 200 . Since a stator groove 122 is formed at the interior circumference of the stator case 109 along the length direction thereof, the coolant in the rotor chamber 38 flows along the stator groove 122 and removes floating materials attached to the interior circumference of the stator case 109 . The shape of the stator groove 122 can be easily determined by a person of ordinary skill in the art considering the flow of the coolant in the rotor chamber 38 .
[0079] Further, in order to reduce vibration and noise according to the rotation of the rotor 200 and to reduce vibration generated when a vehicle drives, a plurality of damping holes 120 are formed at the stator case 109 . Vibration and noise according to the rotation of the rotor 200 and vibration generated when the vehicle drives are absorbed by movement of gas in the stator chamber 42 through the damping hole 120 . The position and shape of the damping hole 120 can be easily determined by a person of ordinary skill in the art according to vibration frequency and pressure frequency of the stator 101 . In addition, a frothing resin or sound absorbing material may be filled in the damping hole 120 so as to further reduce vibration and noise.
[0080] Meanwhile, the stator groove 122 and the damping hole 120 may be formed at the rotor 200 . That is, grooves (not shown) may be formed at the exterior circumference of the rotor case 90 such that the coolant in the rotor chamber 38 flows along the grooves and removes the floating materials attached to the exterior circumference of the rotor case 90 . In addition, vibration and noise according to the rotation of the rotor ( 84 , 86 , 88 , and 90 ) and vibration when the vehicle drives may be absorbed by forming holes (not shown) at the rotor case 90 .
[0081] FIG. 7 is a schematic diagram showing processes for manufacturing a rotor used in an electric water pump according to an exemplary embodiment of the present invention.
[0082] If the rotor core 86 provided with the plurality of recesses 203 at the exterior circumference thereof is provided as shown in FIG. 7A , the permanent magnets 88 are inserted in each recess 203 as shown in FIG. 7B . At this time, the permanent magnets 88 are mounted in such the manner that the N pole and the S pole are alternately disposed.
[0083] After that, the rotor covers 84 are mounted at both ends of the rotor core 86 and the permanent magnet 88 as shown in FIG. 7C . Thereby, the permanent magnets 88 are primarily fixed to the rotor core 86 .
[0084] After that, the rotor case 90 is molded to the exterior circumference of the rotor core 86 and the permanent magnet 88 as shown in FIG. 7D .
[0085] When the rotor 200 is manufactured as described above, it is checked whether the rotor 200 is rotationally balanced. If the rotor 200 is not rotationally balanced, the positions of the balance holes 205 are determined in order to keep the rotational balance of the rotor 200 . Then, the balance holes 205 are formed at the rotor cover 84 .
[0086] Since a stator and a rotor that are electrically operated are wrapped by a resin case having waterproof performance according to an exemplary embodiment of the present invention, performance and durability of an electric water pump may improve.
[0087] In addition, since a Hall sensor and a Hall sensor board are mounted in the stator and a control signal is changed according to an initial position of the rotor, initial mobility of the electric water pump may improve.
[0088] Further, the shape of the rotor core may be optimized so as to minimize leakage of magnetic flux of the permanent magnet. Therefore, sufficient capacity of the water pump may be achieved without increasing the size of the water pump.
[0089] For convenience in explanation and accurate definition in the appended claims, the terms “interior”, “exterior”, “inner”, and “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0090] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | An electric water pump apparatus may include a body having a stator chamber and a rotor chamber therein, a stator having a hollow cylindrical shape and being disposed in the stator chamber and generating a magnetic field, wherein the stator fluidly insulates the stator chamber and the rotor chamber, a rotor disposed in the rotor chamber and enclosed by the stator, wherein the rotor is rotated by the magnetic field, and a pump cover connected to the body and forming a volute chamber therein, wherein the volute chamber and the rotor chamber are fluidly-communicated through a connecting hole formed to the body and a coolant is supplied to the rotor chamber through the connection hole, wherein the stator includes a stator groove formed in an inner circumference therein and the stator groove is fluid-connected to the rotor chamber and the volute chamber through the connection hole. | 7 |
RELATED APPLICATION DATA
This application claims the benefit of and priority under 35 U.S.C. §119(e) to U.S. Provisional Application. No. 60/609,261, entitled “GPS Coordinate Transformer,” filed Sep. 14, 2004, which is incorporated herein by reference in its entirety.
BACKGROUND
1. Field of the Invention
This invention relates generally to navigation. In particular, an exemplary aspect of this invention relates to coordinating Global Positioning System (GPS), or other system, provided coordinates with a physical map. Another exemplary aspect of this invention relates to a device for use in conjunction with a GPS receiver that allows one to pinpoint an exact location on a map.
2. Description of Related Art
Various devices have been developed since the 1800s to aid in maritime navigation by adjusting sliding devices along scales made parallel to the edges of the maritime charts to determine intermediate latitudes and longitudes. From this, a location coordinate on the map could be determined. Most of these devices assume a flat surface such as a table, or some other near horizontal surface upon which to place the chart and device. Some devices have also been developed for aeronautical navigation and some have anticipated land navigation but assume use in a land vehicle where support would be available.
The GPS is a constellation of satellites which orbit the Earth. This system was developed by the U.S. military, however became publicly available to assist the public with global navigation. With advent of the GPS satellite system and the current state of GPS receivers, an ambulatory person can see their location on a map displayed by the GPS receiver. GPS receivers provide accurate location information but their display size compromise the amount of topographic information that can be displayed in context, to a user.
A user can connect the GPS receiver to a portable computer with a large screen which would then display the necessary topographic detail in context with a large enough map area for navigation and planning purposes, but for many ambulatory persons this is not a practical solution because of weight, battery life, cost and operational difficulties. It is still useful for ambulatory persons to use a handheld map and transform the GPS provided map coordinates onto the map for their en-route navigation and planning.
A simple device exists to aid in the transformation of the GPS provided coordinates by providing small orthogonal scales on a transparent base that are held against the map at the appropriate intersection of two coordinate lines. The device is then moved horizontally and vertically on the map parallel to the map coordinate lines, to arrive at the actual position on the map between lines that the GPS provided coordinates represent. This is a simple method but it is prone to interpretation and operator error in field conditions utilizing hand-held maps.
SUMMARY
Whereas the use of latitude and longitude are preferred by maritime navigators, the slightly less accurate Universal Transverse Mercator (UTM) and the military equivalent Military Grid Reference System (MGRS) coordinate systems, have great advantages for on-foot persons who are not concerned with the small errors, because one scale fits all maps of a group, independent of latitude. However this advantage is coupled with a small angle coordinate line orientation error relative to Truth North, and therefore a UTM/MGRS based system must accommodate those errors which vary in positive and negative directions depending on the longitude within the UTM/MGRS zone. Most of the prior art systems are oriented to True North and do not accommodate the UTM/GPRS coordinates.
An exemplary aspect of the invention overcomes the aforenoted deficiencies and in addition provides a quick, accurate and convenient method of transforming coordinates, including those utilizing the UTM/MGRS system, to a position on a map by a person on foot with the map and device hand-held, and this can be arranged to be suspended on the front of the body for quick use and temporary stowing, and in addition this is coupled with a folding scheme for longer term stowing, that provides dimensions that allow easy insertion and recovery of the folded device and rolled map into, for example, a body mounted holster which can be fitted to eliminate interference with other gear carried on the operators body, and also fitted so as not to interfere with the operator taking evasive action or with walking, running, riding, crawling or the like.
An aspect of the invention provides a mechanism for an operator on foot that can be fitted to a folded map that may be placed in a transparent map holder, and caused to indicate the position on the map of various given coordinates, while holding the mechanism, fitted holder and map by hand, without other support.
Another exemplary aspect of the invention provides a means for adapting the mechanism and map/holder to a size no greater than that which can be affixed to the operator's person in a way that does not interfere with use of a backpack or items carried on the operator's belt, while allowing full freedom of movement to accommodate evasive action and the mobility of crawling, walking and running.
Another exemplary aspect of the invention provides operation of a mechanism with coordinate transformation and the means for adapting for mobility, as simple, quick and self explanatory operations.
Another exemplary aspect of the invention is directed toward a mechanism with fully manual operation without need for battery power, and to provide various levels of automation to the mechanism with the addition of battery power.
Another exemplary aspect of the invention provides a protractor that can be placed on the “you are here” point so that compass direction to another point can be easily read by extending a retractable cord over the “you are here” point, to a point of interest. The protractor can then be folded up along the vertical arm for storage by using only one 100° straight scale on an offset arm that rotates in four 90° steps with four sets of numbers placed alongside the 100° scale. When the partial protractor is rotated so the positioned retractable cord crosses over the 100 degree segment, the set of numbers that are right side up are the ones used for reading the heading to the desired point, and a compensation for magnetic declination can be included.
These exemplary aspects and their attendant advantages are accomplished by an exemplary embodiment of the present invention by a near vertical, in the plane of the map, arm with a front and back slide-base separated by a slot that allows a map or map holder to slide through it and be locked to it at skewed angles to accommodate map misalignment and UTM/MGRS angle errors. On either side of the vertical slide base is a lockable slide upon which a foldable horizontal arm may be placed that is perpendicular to, and in the plane of the vertical arm and map holder. Upon the horizontal arm slide base is a lockable slide upon which is a projection that indicates the location on the map referred to by the input coordinates, after the operator holding the mechanism and map holder by hand and without other support, adjusts the mechanism to fit the coordinate information. The size of the vertical arm with the horizontal arm folded to the vertical position and the map and map holder rolled around it, is such that it can fit into a body mounted holster that secures it to an average adult person without interfering with the person's backpack or belt mounted equipment, but allowing the person full mobility of crawling, walking, riding and running while accommodating any map, such as maps typical of the USGS topographic type at 1:24,000 to 1:100,000 scales.
In accordance with one exemplary feature of the invention, the vertical arm has a slide-base fitted to the front and another slide-base fitted to the back, with a space between them to allow the map holder to slide through the opening horizontally, with an upper and lower thumb screw to lock the arm to the map holder which has been manually aligned with a vertical coordinate line (East Line) on the map and which may be skewed by up to a few degrees relative to the vertical edge of the map holder. The length of the vertical arm is made to accommodate a map holder for a typical topographic map folded in half horizontally, such that the vertical arm can be locked in a skewed position to the upper and lower edges of the map holder. The halves of the map may be viewed by choosing the desired side of the map holder, and the mechanism can be duplicated in each side's slide base or one mechanism can be transferred to the desired side slide base. Other sizes may be used, however increasing the length of the vertical arm may require additional folding to be accommodated by the design to keep it within the capability to be stowed on a mobile person.
In accordance with another exemplary feature of the present invention, a lockable slide that slides within the vertical slide-base, has attached a horizontal arm which has an easting attachment housed above and a northing attachment housed below the horizontal arm, relative to the map plane. Upon the horizontal arm the easting attachment is fastened in such a manner that it is allowed to slide along the horizontal arm and be locked at intervals to the horizontal arm. An east step slide is mounted in the easting attachment above the horizontal arm. The easting attachment is moved by the operator until its index-line lines up with the Easting line coordinate given by the GPS. The easting step slide is then moved to align its scale with an index line on the easting attachment, using the East Step coordinate number provided by the GPS. The east step slide has a projection that extends below the horizontal arm through a slot in the horizontal arm placing it in contact with the northing attachment that causes the northing attachment to slide east and west with the adjustment of the east step slide moving east and west. The northing attachment contains a Northing step slide and the attachment with slide can be rotated by the operator to place the northing step slide orthogonal to and either above or below the horizontal arm and in its plane, the orientation being chosen by the operator for clarity, based upon best readability for the portion of the map in use. The rotation of the northing attachment and slide can also be stopped midway by the operator, placing it parallel to the horizontal arm for stowing. The Northing step slide also slides through the northing attachment allowing it to be adjusted to the GPS provided North Step coordinate based on a scale affixed to it being moved relative to an index on the northing attachment. The northing attachment also has attached a Northing line index marker. In initial setup the slide in the vertical slide-base is adjusted by the operator to place the Northing line index marker on a convenient Northing Line chosen for clarity, and locked in preparation of subsequent use.
The Northing step slide extends for approximately the vertical length of the map and moves up or down one UTM segment width as the operator adjusts it. In addition there is a slide with a “bulls-eye” on it that slides up or down the Northing step slide that is lockable. To choose the correct Nothing line, before other adjustments the Northing slide is set to zero and the “bulls-eye” is slid to the Northing line corresponding to the given coordinate Northing Line and locked. Then when the other three adjustments have been made (Northing Step, Easting Line and Easting Step) the “bulls-eye” sits over the “you are here” spot.
In accordance with an additional exemplary feature of the present invention, a horizontal arm is affixed onto the pivot that extends from the slide on the vertical arm, so that the horizontal arm can be held in a direction perpendicular to the vertical arm on either side, and in a plane parallel to the map holder, for use, and can also be pivoted plus or minus 90 degrees relative to its “use” position to stow the horizontal arm in a vertical direction (in a plane parallel to the map holder) to prepare for extended period mobility. In accordance with a further exemplary feature of the present invention, there are two ways of stowing the device and map when the operator is moving.
There is a quick response stow method and a holstered stow method. The quick response stow method provide a means to fasten the side ends of the map holder together so that only the usable portion of the map is adjacent to the operator. The bottom of the vertical arm contains a device that holds it to one side of the operator's front belt line. The top of the vertical arm has an adjustable loop fastened that can go between the front and back portions of the map and fastens to the belt line on the other front side of the operator. To use, the operator adjusts the length of the adjustable loop to provide a loop that goes over the head and allows the map and mechanism to stow in front of the operator at chest level. When the map is needed, the operator raises the loop over the head and the map drops down for use, held near to the operator's waist. When the operator wishes to stow again the loop is returned over the head. This quick stow response stow method can be stand alone, or can be combined with the holstered stow method.
In the holster stow method, a holster is provided that fits the folded mechanism with map holder and map rolled around it, to be secured on a persons body for mobility including evasive action, crawling, walking, riding and running. The holster can be suspended from adjustable straps that are attached to the body. The bottom of the holster can attach, for example, to a horizontal seam of clothing around the waist such as a trouser top or belt. To use the holster, the horizontal arm of the mechanism is folded to the vertical position and the map holder, with map inside, are rolled around it so that a compact package is obtained. The package is placed in the holster and a fastener system emanates from the holster support strap to lock the top of mechanism to the holster and to pull it close to the upper body. The adjustable strap can be loosened for normal activity and tightened for running and crawling where the holster must stay very close to the body. The bottom of the holster can be adjusted so that the holster can be used above backpack belts and equipment on belts. The location of the holster can be the side of the carrier's chest and pointed slightly outward, but with enough room not to interfere with backpack straps. Other positions are also possible. The holster can sit above the belt line enough that when crawling on hands and knees, or mounted in a saddle, it does not interfere with the bent upper leg. In accordance with another exemplary feature of the present invention, methods of automating portions of the transformation operation are described. An exemplary intent of the automation is ease of use by decreasing chance for operator error, decreasing the level needed for operator training, and to speed up transformations. The map holder, map, a vertical arm that locks onto the map holder along a vertical coordinate line and the stowing methods are basic to both the manual and also to all the automated modes. In all automated modes, a power source such as a battery, solar cells and/or the like, are added to power an electronic controller and in the more automated versions, power electric motors.
The exemplary electronic controller provides: 1) an input-output communication device to acquire and return coordinate and other information; 2) a display for the operator; 3) an operator input means; and 4) mechanism position indications and output control signals used for directing the operator to adjust the transformer mechanism or cause the controlling-motors to adjust it. The input-output communication devices to acquire or return coordinate or other information can be: A) a manual input from the operator; or B) a wired or wireless transfer in communication with a local GPS or a remote site. The display for the operator can provide the entire coordinate information and can organize the information to make it more useful to the operator, such as allow the operator to insure that the correct map is being used, and to allow the operator to choose the correct side of the map to display, translate coordinate information to operator directives, and for general operator information. An operator input allows adding information for calibration that cannot be automatically read from the map and the operator can cause measured information of the coordinates from a point of interest on the map to be transferred to the local GPS or a remote site. The output control signals can go to audio and/or visual guides to the operator who moves the slides under such guidance until they represent the position on the map of the input coordinates, resulting in a low-power system. The output control signals may also go to motors which provide the movement but requiring somewhat higher power. All slide bases can have index marks that are read by distance measurer sensors and provide the feedback to the controller to use in calculations of output control signals. All of these automated modes may require a calibration step before use, after a new map has been inserted in the mechanism and it is also prudent to re-zero the distance measurers periodically during use.
At the start of operations on a newly inserted map, a calibration cycle is initiated. The controller displays the desired East and North line numbers for the input coordinates given. The operator may use the most significant digits, as in the manual mode, to confirm that the correct map is in place and the operator locks the vertical arm to a convenient vertical coordinate line on the map. A limit indicator is then moved towards the bottom of the Vertical arm to mark the position of the South-most horizontal coordinate line on the map, and locked. The vertical arm slide that positions the horizontal arm is then moved to that position, the mechanism on the horizontal slide is moved back to it the west-most limit and the distance measurers commanded to be zeroed. It is also necessary that the controller know what the calibration coordinate line numbers are. These digits can be entered through the operator input and can be entered serially with a rotary switch to eliminate necessity for a keyboard. To reduce complexity only the number that is the difference between the GPS supplied line coordinates and the limit line coordinates need be transferred. After the calibration, all new coordinates can be located automatically by the system until the map needs replacement, or map sides changed.
In the exemplary automated versions of coordinate transformation operation, the linear adjustments for the Northing and Easting steps can be made by the operator following visual or audible clues based on the desired position and measurement of the current position. The Easting line adjustment can be made by the operator by visual or audible clues indicating the correct detent along the horizontal arm. The Northing line adjustment is made automatically by the controller lighting a light at the correct selection on the northing arm, which is known after calibration. As an alternative the Northing and Easting steps and the Easting line can be adjusted by motors while the Northing line can still be selected by lighting a light at the proper location. These implementations may be accomplished while still maintaining the stow-ability mechanisms of the manual method. Another exemplary embodiment replaces the horizontal arm with a light-beam projecting from the correct position on the vertical arm and being intersected with another light-beam that is in correct position along a fixed horizontal arm, or mounted on the vertical and rotatable to intersect with the horizontal beam at the desired position. Other methods of mounting the two light beam sources can obtain the same results.
It is also possible to have both sides of the map with mechanisms that are both calibrated, in which case when the limit on one map is reached the controller would be able to move and provide the location on the other side while alerting the operator to the change. In this case the vertical arm locking mechanism on the end of the arm away from the map fold could have independent locks on each side.
The same techniques of transformation and location can be applied to full maps without folding, which may be useful in stationary situations. However, the unfolded maps are too large for use by mobile persons with hand held maps. Maps may also be made with coordinate lines able to be read electronically which would reduce chance for operator error and speed operations as well.
Additional exemplary embodiments include the device taking coordinates, such as might be supplied by a GPS receiver, and placing the position indicated by the coordinates on a map or chart contained in a transparent container. The device is particularly useful to a person on foot in the field, and does not require any additional support. The device is also usable in land, airborne and maritime vehicles, animal-borne and cycle-borne riders as well as on stationary tables in vehicles or buildings.
To aid in use by a person on foot, the device folds up for transport utilizing all captive parts, allowing the map/chart holder, the map/chart and the device to be rolled into a small diameter cylinder for ease of transport in a backpack or similar carrying container.
The exemplary coordinate transformer has room in the map container to provide complete operational instructions on use of the device, including a pictorial decomposition of the UTM digits or the MGRS alpha-numerics as they would appear on the GPS readout. The decomposition results in designation of an Easting Line and a Northing Line, and an Easting Step and a Northing Step, and information that insures one has the correct map.
The East Line is used to set and lock the mechanism on the horizontal arm. The North Line is used to set and lock the slide on the northing step slide. The Easting Step is used to adjust a horizontal slide against a scale where it is locked. The Northing Step is used to adjust a vertical slide against a scale where it is locked. At the end of those operations the result appears under a small aperture with “cross-hairs” around it, at a location that indicates “You are here.” The defined location can be marked on the map container through the “You are here” aperture with an appropriate pen.
The exemplary device can be of all manual operations, requiring no electrical power, except for the GPS needs. The device can also be made to include some electronic automation, if some source of power is provided. Various levels of automation are possible, and deriving information directly from a connection to the GPS is basic to most.
The exemplary general method of this invention starts with a calibration step that sets moveable arms to fixed positions on a map. This then is followed by conversion of given coordinate sets to directives that direct the arms to be moved to place an indicator-point anywhere on a map to indicate the position on the map corresponding to a given coordinate set. The directives are determined by knowing the scale of the map, the limits of the map and the equations describing arm movement. The calibration does not have to be repeated until a different portion of the map, or a different map is needed.
A non-limiting implementation utilizing the UTM coordinate system will be described in detail because the arm scales remain fixed for all latitudes within a full set of maps such as all the 7.5′ topographic maps of the 48 contiguous United States, and therefore do not need map dependent scale calculations to determine the directives. This provides a basic mechanism with fixed scales on the arms which may not need electronic calculation and therefore may not need a power supply such as a battery (although user utility can be enhanced by adding powered electronics).
In addition other coordinate systems that have scale changes over the range of maps require new scales to be substituted whenever a map scale changes. Another exemplary embodiment employs a controller that can calculate directives for using the fixed scale markings existing on the moveable arms but calculate the appropriate directive without changing scales on the arms. This could be particularly useful for, for instance, the latitude-longitude coordinate system in which the longitude scales change with latitude, but may require a power supply for the calculations.
Further, while the UTM implementation example uses arms related to rectangular coordinates, other arm arrangements can use other systems such as a polar coordinate implementation. Illustrating that the system is not limited to a particular arm arrangement, a system using a polar coordinate basis is also shown in which after calibrating the arm(s), an angle and a length can be used to move the indicator point over the position that represents the given coordinate set on the map.
For the system using UTM coordinates, the UTM coordinates can be converted to associated polar coordinates in a GPS or externally in a powered controller. And given a powered controller, latitude-longitude coordinates, and other coordinate systems that have scale changes on different maps can also be implemented in the rectangular coordinate based mechanism, the polar coordinate based mechanism and other similar mechanisms.
All of these implementations can have folding arms that stow in alignment with each other and allow the map/map-holder to be rolled up around the folded arms and placed in a holster fitted to the body of an average adult while allowing full mobility of walking, running and of riding.
These and other exemplary embodiments and aspects of the invention will be described in relation to the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates an exemplary environmental view of the GPS coordinate transformer according to this invention;
FIG. 2 is a flowchart outlining an exemplary method of setting-up the coordinate transformer for use according to this invention;
FIG. 3 is a flowchart outlining the exemplary method of using the coordinate transformer according to this invention;
FIG. 4 illustrates a first exemplary embodiment of the coordinate transformer according to this invention;
FIG. 5 illustrates a second exemplary embodiment of the coordinate transformer according to this invention;
FIG. 6 illustrates a third exemplary embodiment of the coordinate transformer according to this invention;
FIG. 7 is a cross-sectional view of the alignment arm taken along line A-A of FIG. 5 ;
FIG. 8 is a fourth exemplary embodiment of the coordinate transformer according to this invention;
FIG. 9 is a fifth exemplary embodiment of the coordinate transformer according to this invention;
FIG. 10 is a sixth exemplary embodiment of the coordinate transformer according to this invention;
FIG. 11 illustrates the exemplary coordinate transformer in a folded position;
FIG. 12 illustrates the coordinate transformer in an exemplary protective pouch according to this invention;
FIG. 13 illustrates basic map reading for use in conjunction with this invention;
FIG. 14 illustrates an exemplary method of transforming coordinates according to this invention; and
FIG. 15 illustrates an exemplary embodiment of a polar coordinate configuration.
DETAILED DESCRIPTION
The exemplary systems and methods of this invention will be described in relation to a coordinate transformer mechanism. However, to avoid unnecessarily obscuring the present invention, the following description omits well-known structures and devices. For the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It should be appreciated, however, that the present invention may be practiced in a variety of ways beyond those specifically set forth herein. For example, the various features illustrated in the differing embodiments can be combined into one or more additional embodiments that are not illustrated. For example, the linear scale feature of the invention could be combined with the display apparatus illustrated in conjunction with the embodiment shown in FIG. 6 and, for example, information from the linear scale used to assist with the placement of the “You Are Here” crosshairs as previously discussed.
FIG. 1 illustrates an exemplary embodiment of the coordinate transformer 10 . The coordinate transformer 10 comprises an alignment arm 20 , a traverse arm 30 , an orthogonal attachment 40 , a traverse attachment 50 , a traverse step slide 55 , an orthogonal step slide 48 and a You Are Here slide 60 .
As illustrated in the environmental view of FIG. 1 , the coordinate transformer 10 is secured to a map 5 . The coordinate transformer 10 comprises an alignment arm 20 and a traverse arm 30 . The alignment arm 20 has alignment arm alignment marks 25 . The traverse arm 30 is pivotably attached to the alignment arm 20 via the traverse arm-locking pivot 80 . Moving in increments relative to detents 70 in the traverse arm 30 is the traverse attachment 50 , which may be temporarily fixed to one of detents 70 by a pivot 57 , upon which the orthogonal attachment 40 moves in a transverse direction by attachment to the transverse step slide 55 . Within the traverse attachment 50 the traverse step slide 55 moves in a transverse direction and within the orthogonal attachment 40 the orthogonal step slide 48 moves in orthogonal direction. Slideably attached to the orthogonal step slide 48 is the You Are Here slide 60 .
While the coordinate transform is illustrated as being constructed of a transparent or partially transparent material, such as a clear plastic or a plastic-like material, it should be appreciated that the coordinate transformer or portions thereof can be made of differing types of materials that may or may not be transparent including, but not limited to, plastic or plastic like materials, metals, composite materials, wood, paper-based products, carbon fiber, fiberglass, metal alloys, or the like. Moreover, while the exemplary embodiments will be described in relation to a specific map type, it should be appreciated that the scales on the coordinate transformer can be adjusted, for example by replacing the various arms, or by maintaining the arm scale and using a controller to appropriately adjust the directives to accommodate different map scales.
It is assumed that the user has the appropriate maps to work with the coordinate transformer and these maps include perpendicular, equilateral coordinate lines such as the Universal Transverse Mercator (UTM) or its military equivalent GPRS and a source of coordinates to be plotted on the map such as from a GPS receiver. The UTM coordinates for a provided location are normally given as two sets of seven digits each with the first set of digits being the Easting set and the second set of digits being the Northing set. From these digits, a line number and step number can be determined for the Easting and the Northing coordinates. The Easting and Northing line numbers designate the lower left corner of the UTM box on a map at the desired location. The four sides of the box are defined by the Easting and Northing lines and the next line to the East and the next line to the North. The Easting step numbers show how far to the East the desired coordinate location is from the lower left hand corner of the box, and the Northing step number shows how far to the North the desired coordinate location is from the lower left-hand corner of the box (see FIG. 13 ).
As discussed above, the UTM coordinates for a provided location are normally given as two sets of seven digits each, with the first set the Easting set and the second set the Northing set. With reference to FIG. 14 , if the digits are designated as E 1 -E 7 for the Easting coordinate and N 1 -N 7 for the Northing coordinate, the digits can be coded as illustrated in the figure. The digits E 7 and N 7 add to the accuracy of the designated steps but can not be discerned on a map of scale equivalent to a 7.5 minute topographic map or maps of less resolution. If a higher resolution map were used, the E 7 and N 7 digits can be added into each step value, changing it from a two digit to a three digit number.
Typical 7.5 minute topographic maps printed by the U.S.G.S. are approximately 27 inches high and 22 to 23 inches wide. To facilitate ease of mobile use, these maps can be folded in half, although not limited thereto, for use with the coordinate transformer. The coordinate transformer device is affixed to the folded map, for example, by a friction fit between the two portions of the alignment arm, which can be slightly longer than the height of the map being affixed to (discussed hereinafter) and the alignment arm alignment marks aligned with a convenient coordinate line on the map. The alignment arm need not be limited to being longer than the map but could also be shorter than the map with, for example, an open end into which the map is slid. The alignment marks 25 are shown in the center of the alignment arm 20 however they can be placed other wise such as being placed on both sides of the alignment arm, with the right mark used when the transverse arm is chosen to project to the east, and the left mark used when the transverse arm is chosen to project to the west. Utilizing this alignment methodology, the coordinate transformer is able to accommodate any misalignment in placing the map in, for example, a map holder and can also accommodate the longitude-dependent skew that exists in the UTM coordinate system relative to the map border and the true North-South and East-West coordinate lines.
While the exemplary embodiment illustrated in FIG. 1 shows the alignment arm in the substantially vertical direction, it will be appreciated with reference to additional embodiments illustrated herein that the coordinate transformer can also be utilized with the traverse in various orientations relative to the alignment arm. The traverse arm can be attached via, for example, a friction fit, a locking pivot mechanism, nut and screw configuration, frictional fit with detents that allow the traverse arm to be held perpendicular to the alignment arm, or the like. The traverse arm is set along a coordinate line orthogonal to the coordinate line that the alignment arm is aligned to. This can be accomplished by allowing the traverse arm 30 to slide relative to the alignment arm and lock thereto. For example, the alignment arm 20 can contain a slot (not shown) along its length through which the traverse arm-locking pivot 80 slides.
The traverse attachment 50 slides on the traverse arm and is set to the various coordinate lines crossing the traverse arm, which are parallel to the alignment arm. The traverse step adjuster 35 moves the traverse step slide 55 relative to the traverse attachment 50 and can be set to a position between the coordinate lines parallel to the alignment arm 20 . The orthogonal attachment 40 is connected to the traverse step slide 55 and moves in the transverse direction together with the traverse step slide 55 along the traverse attachment 50 . The orthogonal step slide 48 moves relative to the orthogonal attachment 40 in the orthogonal direction. The orthogonal step adjuster 45 , in similar manner to the traverse step adjuster 35 can be used to adjust the position of the orthogonal step slide 48 relative to the orthogonal attachment 40 . Therefore, the orthogonal step adjuster 45 can be used to manipulate the position of the orthogonal step slide 48 between the coordinate lines orthogonal to the coordinate line that the alignment arm is aligned to.
There are at least two methods to utilize the coordinate transformer according to this invention. A first exemplary method moves the traverse arm 30 along the alignment arm and is locked in an appropriate position via the traverse arm-locking pivot 80 . The second exemplary method allows the traverse arm 30 to be aligned and locked along a convenient border coordinate line. The orthogonal step slide 48 is provided to slide within the orthogonal attachment 40 . The You Are Here slider 60 moves by increments on the orthogonal step slide 48 and is moved to the appropriate orthogonal line as discussed hereinafter.
In accordance with the first exemplary embodiment, the You Are Here slider 60 is provided at a proper offset along the orthogonal step slide 48 to indicate the position on the map indicated by a given coordinate after the coordinate transformer has been positioned to the correct two lines of the UTM box and the correct two steps.
With the second method outlined above, the orthogonal step adjuster 45 is temporarily set to zero and the You Are Here slider 60 moved on the orthogonal step 48 to the given orthogonal line coordinate. The orthogonal step adjuster 45 is then adjusted to the proper step adjustment, and this action together with the traverse line and step adjustment places the You Are Here marker at the correct coordinate position on the map. As discussed in more detail hereinafter, both the orthogonal step adjuster 45 and the traverse step adjuster 35 can include numbered increments that are calibrated to, for example, a specific type of map being used. Both of these adjusters are also envisioned as being interchangeable to accommodate different maps as appropriate.
FIGS. 2-3 outline an exemplary method of using the coordinate transformer according to an exemplary embodiment of this invention. FIG. 2 illustrates an exemplary method to set-up the coordinate transformer for use with an area of interest on the map. FIG. 3 provides the exemplary method for performing coordinate transformations within that area of interest. The set-up method shown in FIG. 2 will be performed again if the area of interest on the map is moved.
Control begins in step S 200 and continues to step S 210 . In step S 210 , the appropriate map is determined and selected. Next, in step S 220 , and if appropriate, the correct side of the map is chosen. Then, in step S 230 , the alignment arm of the coordinate transformer is placed in a usable position relative to the map. Control then continues to step S 240 .
In step S 240 , the traverse arm is attached to the alignment arm on the appropriate side of the map, if applicable. For convenience, the traverse arm can be attached to either side of the alignment arm by virtue of, for example, a slot (not shown) and traverse arm locking pivot as previously discussed or by unlocking the traverse arm locking pivot and rotating the attached traverse arm to the opposite side of the alignment arm. Next, in step 250 , the traverse arm is aligned with a convenient Northing line and control continues to step S 260 , which jumps to step S 300 .
Once the basic initialization and setup of the coordinate transformer has been performed, provided the user wants to locate various positions within the same general area the user only need perform the steps illustrated in exemplary FIG. 3 . More specifically, control begins in step S 300 and continues to step S 310 . In step S 310 , the GPS UTM, or equivalent, readings are obtained. Next, in step S 320 , the GPS UTM reading is translated into an East line number, an East step number, a North line number and a North step number. This can be done manually, for example in accordance with FIG. 14 , and/or automatically, for example, via the GPS receiver forwarding the information to the coordinate transformer, which may or may not be displayed thereon as discussed in relation to the embodiment illustrated in FIG. 6 . The orthogonal step adjuster is set to zero in step S 330 , and, in step S 340 , the You Are Here slider is aligned with the Northing line vw. Next, in step S 350 , the orthogonal step adjuster is adjusted to the xy position. For example, the orthogonal step adjuster can include a scale that corresponds to the step number. Additionally, the coordinate transformer can include, for example, a linear scale and can cooperate with a GPS receiver unit, local controller or the like, so that as the orthogonal step adjuster is moved, real-time location information about the step number can be provided and, for example, displayed to the user via a display device. Control then continues to step S 360 .
In step S 360 , the traverse attachment is moved to the provided Easting Line cd. Next, the traverse step adjuster moves the traverse step slide at the East step value ef, and as with the orthogonal step adjuster, can communicate with and display information associated with the GPS receiver, remote site, or the like. Control then continues to step S 380 , where the “You Are Here” crosshairs are located on the map and the position corresponding to the GPS coordinates revealed. Control then continues to step S 390 where the control sequence ends.
FIG. 4 illustrates another exemplary embodiment of the coordinate transformer 10 . In accordance with this exemplary embodiment, the orthogonal step adjuster 45 and traverse step adjuster 35 are provided with gear mechanisms, 47 and 37 , respectively. Each of these gear mechanisms respectively cooperates with racks 49 and 39 in a rack-and-pinion type configuration. However, it should be appreciated that the embodiment is not limited to this particular configuration but could also use a frictional, instead of rack-and-pinion system or in general, any mechanical and/or electromechanical mechanism(s) whereby the rotation of the step adjusters moves the orthogonal step slide and/or the traverse attachment.
FIG. 5 illustrates the exemplary embodiment of the coordinate transformer 10 that includes a linear scale that is associated with the traverse arm 30 and a linear scale associated with the orthogonal step slide 48 . Each linear scale comprises a scale ( 505 and 515 ) fixably disposed on each of the traverse arm 30 and/or orthogonal step slide 48 with a corresponding measuring circuit ( 510 and 500 ) that measure the location of the orthogonal step slide relative to the you are here slide 60 relative to the orthogonal attachment 40 , and the traverse attachment relative to the traverse arm and the traverse step slide 55 to the traverse arm 30 . Additionally, a linear scale could be associated with the alignment arm 20 or any other component of the coordinate transformer where the location of one element relative to another is desired. The linear scales can be one or more of inductive, capacitive, magnetic, or in general any type of linear scale that allows the position of one element to be determined relative to another element could be used with equal success with the systems and methods of this invention.
Thus, for example, the coordinate transformer can be equipped with a display unit (not shown in this embodiment) that can display the position of one or more of the orthogonal step slide and traverse attachment to assist with placement of the You Are Here crosshairs.
FIG. 6 illustrates another embodiment of the coordinate transformer that includes a plurality of displays 600 , each of which correspond to specific UTM coordinates. It should be appreciated that this embodiment could include features of other embodiments such that the coordinate transformer is capable of being in communication with a GPS receiver 650 or remote site and the UTM coordinates populated into the various displays 600 automatically and shown to assist with the placement of the You Are Here crosshairs or coordinate transformer measurements may be may be made and communicated to a GPS receiver or to a remote site, or the like. For example, visual and/or audio cues such as up or down arrows could be included in the appropriate display 600 to instruct the user regarding the direction of movement required of one or more of the orthogonal step slide and traverse attachment 50 and traverse step slide 55 to place the You Are Here slider 60 in the appropriate location on the map. Moreover, the location, size and color of the displays can be varied as appropriate.
FIG. 7 illustrates a cross-sectional view taken along line A-A of FIG. 5 . More specifically, the alignment arm 20 is illustrated with the map 5 frictionally engaged between the two portions of the alignment arm. The alignment arm 20 further includes set screws 705 and 710 , however is not limited thereto and can include any mechanism that allows for the alignment arm to be held in a fixed position relative to the map including, but not limited to, clips, snaps, elasticized members, or the like. Furthermore, the alignment arm could be made slightly flexible with a slot cut therein that the map 5 can be inserted into. By virtue of the construction of the alignment arm 20 , the map 5 would be held in place with sufficient space from the map ends to the fixing means to accommodate misalignment of the map and to accommodate the UTM angle errors prior to tightening the fixing means, such as set screws.
FIGS. 8-10 show various exemplary orientations of the coordinate transformer 10 . For example, as previously discussed, it may be advantageous to position the alignment arm and the traverse arm in different locations depending on the anticipated portion of the map that will be used.
An exemplary attribute of the transformer uses a traverse arm 30 that is rotatable around a pivot 80 , and uses an orthogonal step arm 48 , rotatable around a pivot 90 , which can slide along the length of a slot 92 in traverse arm 30 , so that the coordinate transformer can transform over a map area of interest in any of four orientations. Orientation one was shown previously in FIGS. 1 , 4 , 5 and 6 , and orientation two is shown in FIG. 8 , orientation three is shown in FIG. 9 , and orientation four is shown in FIG. 10 . These four orientations allow the operator to choose an orientation that covers the largest area of interest to the operator with the minimum amount of obscuration, and in addition allows the operator to choose the orientation that more easily allows the operator to move to an adjacent area of interest when that becomes necessary.
In addition the orientation choices allow the transformer to provide transformation on the partial map UTM areas that appear adjacent to the west and south map borders, which have missing portions of the UTM areas including missing easting or northing lines because they fall in the margin of the map. Orientations 2 and 3 allow transformation of the partial UTM section just east of the west map border and Orientations 3 and 4 allow transformation of the partial UTM section just north of the south map border. (There is no problem in the partial map sections at the east and north map borders because the UTM given line is always on the lower left of the UTM area, therefore these lines always appear on the map next to the partial UTM sections located adjacent to the east and north map borders.)
The pivoting arms that provide this multi-orientation capability can include two scales for each arm because of the reversal of the lettering/numbering and the direction of the scale, since the UTM lines are always on the lower left of the UTM area. In this design the two scales both appear to the operator, each with the correct scale for one of the orientations, but the operator's eye chooses the correct scale as the right-side-up scale relative to the operator who is observing the map annotation right-ride-up. Also instructional text can be made orientation unique by using the same method, allowing the operator's eye to choose the right-side-up text for the orientation in use.
FIG. 11 illustrates the coordinate transformer in a folded position. By virtue of the attaching mechanisms between the alignment arm, traverse arm, and orthogonal step slide, the coordinate transformer 10 is able to be folded upon itself, and thus easily stored. The coordinate transformer may be folded with the traverse arm 30 over the orthogonal step slide 48 and both over the alignment arm 20 as shown in FIG. 11 or an offset pivot from the traverse arm locking pivot point may be included which places the folded traverse arm 30 over the orthogonal step slide 48 next to the alignment arm 20 rather than on the top.
As illustrated in FIG. 12 , the folded coordinate transformer 10 , an optionally rolled map, can be placed in a satchel 1200 that includes a strap, clip, or the like 1205 which attaches a little above, for example, the front belt line of the operator and a strap arrangement 1210 that goes over the shoulder and attaches to the operator's body to secure the satchel. The length of coordinate transformer in the pouch can be such that it may be angled slightly in a direction towards the side of the body, and will not interfere with the bent leg when sitting or crawling, nor will it interfere with the person in other positions or actions or with backpack straps or belt. Other adjustable mechanisms may be included to provide fit for multiple operator sizes and to loosen or tighten based on the type of operator activity. However, it should be appreciated that most any type of containment mechanism can be made to work well including containment mechanisms that may be affixed by one or more of hook and loop fasteners, belts, straps, or the like and may be attached to one or more of the user, a backpack, a portion of the body such as an arm or leg, a piece of apparel such as a jacket or shirt, or the like.
The coordinate transformer also allows quick and easy set up such that a large area of interest on the map can be clearly displayed and, over that area, the coordinate transformer adjusted to transform various coordinates to indicate a position on the map. This can easily be accomplished by a single person without the need for additional supporting structures such as a table. Moreover, the area of interest can be easily modified and the coordinate transformer moved for use on another area of the map. While the exemplary system is described with a purely mechanical configuration without the need for electrical power, embodiments are also described that include display elements, linear scales, and the like. Additionally, the coordinate transformer can include motorized elements and can contain a GPS or cooperate with, for example, a GPS receiver or remote site to facilitate placement of the You Are Here crosshairs or to transfer the coordinates determined by operator placement of the transformer on the map to a GPS receiver or a remote site. Even with these enhanced embodiments, the device may still be used in a mechanical fashion as a fail-safe backup.
An enhancement that does not require adding electric power can provide the compass heading from the You Are Here to another position of interest, by utilization of a string that can be retrieved from a mounted container and moved through the You Are Here center to the position of interest. A protractor (not shown) or a portion of a protractor that can be rotated around the center position under the string can be made to read the desired compass heading, and can also compensate for the magnetic declination and the UTM grid error. When a portion of the protractor is used it can be made on a straight scale on an offset arm around the “you are here” point such that it can be easily folded up for stowing, and the various scales to cover 360 degrees can be printed in orientations such that the correct scale will appear right side up to the operator for each orientation of the partial protractor. The string could then be returned to its container, for example, by being spring loaded. Moreover, the string could be associated with the You Are Here slider and, for example, be tied to a spring-loaded mechanism so that the string is always readily available and associated with the coordinate transformer. Additional enhancements to the basic system further utilize communication mechanisms, local position sensors on the devices to provide operator directives for movement of the devices in a low power mode and could include motors to automatically move the devices in a higher power mode and readout devices that indicate the coordinate location by projection or by, for example, pixels in a field without physically having to move the components. Two-way communication between the GPS receiver and/or a remote site and the coordinate transformer can also be provided. Thus, the coordinate transformer could display received coordinates, and could supply new coordinates based on the operator indicating a position of interest while using the device. The amount of information to be transferred in either can be reduced after the first transfer of a coordinate is received since only the relative change to a prior point is needed for transmission. The coordinate transformer also gains the capability of coding coordinates provided by the operator positioning of the device because of the inclusion of position sensors in the device. The coordinate transformer can also use the position sensors to provide visual and/or audible cues to the operator as directives to move the device to the given coordinate location in a manner that uses less power than providing motion by motors.
It is therefore apparent that there has been provided, in accordance with the invention, systems and methods for navigation.
Another exemplary embodiment is illustrated in FIG. 15 . A polar coordinate type coordinate transformer 15 having a given arm arrangement is illustrated. Specifically, the coordinate transformer includes an alignment arm 1500 , a first pivot 1510 , a second pivot 1520 , a third pivot 1530 , folding protractor arms 1540 , a rotating arm 1550 and a you are here slide. In use the alignment arm 1500 is set on a vertical coordinate line on either side of the map area of interest. The pivot 1530 is slid on the alignment arm 1500 until the pivot 1530 it is on a horizontal coordinate line on the edge of the area of interest. The equal length protractor arms 1540 are unfolded around the area of interest (to make a U shape with the alignment arm). The 0° mark of the protractor arm 1540 is aligned with the pivot 1530 of the rotating arm 1550 (as illustrated, the pivot 1530 of the rotating arm 1550 and the 0° of the protractor arm could be on the same horizontal coordinate line). The rotating arm 1550 is rotated around the pivot and over the protractor arms 1540 (which can included scaled increments from 0° to 90°), to the directed angle. The you are here slide is moved to the directed length value. The you are here slide then is over the location on the map designated by the directives derived from the given coordinates. The rotating arm's length could also be collapsible so that the end signifies the you are here point, which would also make the arm easier to stow. While a specific configuration of the arms is shown, it should be appreciated that a number of modifications and alternative mechanical assemblies are possible provided they have an alignment arm to which a protractor type assembly is affixed and to which a you are here arm is used to locate the desired angle.
While this invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be or are apparent to those of ordinary skill in the applicable art. Accordingly, the invention is intended to embrace all such alternatives, modifications, equivalents, and variations that are within the spirit and scope of the invention. | A coordinate transformer that includes foldable horizontal and vertical members utilizes GPS provided map coordinates to assist with location determination on a handheld map. Typically, GPS receivers provide accurate location information but their display size, memory and battery life prohibit the amount of topographic information that can be displayed in context, to a user. Through the use of the coordinate transformer, an ambulatory user is provided with an accurate location indication displayed within the context of a large portion of an actual topographic map, and the user is also able to determine the coordinates of a location of interest on the map for transfer to an internal or external unit. | 6 |
This application is a division of Ser. No. 08/225,502 filed Apr. 11, 1994 which is a continuation of Ser. No. 07/940,495, filed Sep. 4, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a novel and useful exercise apparatus.
Many exercise apparatuses have been proposed to rehabilitate or develop different muscles of the body. In addition, exercise apparatuses have use resistance devices such as weights and springs against which the user pulls or pushes, using the arm and leg portions of the body.
Reference is made to U.S. Pat. No. 1,621,477 which describes a gymnastic apparatus using a set of weights connected to a wheeled platform which moves on a track. The user lies down on the platform and pushes against the frame with his feet by gaining support at the shoulders and hands by structures which extend upwardly from the platform. Unfortunately the apparatus shown in the U.S. Pat. No. 1,621,477 patent is not susceptible to use by persons of different heights or physical abilities.
An exercise apparatus using a slidable platform which is adjustable to accommodate persons of different heights would be a notable advance in the physical therapy field.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel and useful exercise apparatus is herein provided.
The exercise apparatus of the present invention utilizes a sliding platform which is movable on a frame against a resistance force. The frame may provide a pair of rails and the platform may include wheels to ride on such rails. The resistance force may be provided by weights, springs or other similar items. In any case, the resistance force element, such as a spring, is connected to the platform and may span the platform and frame member.
The frame includes a pair of stanchions connected by a standing rail system which may also serve as a sliding surface for the platform. One of the stanchions may be constructed with a pair of arms which extend upwardly from a base portion and are separated from one another by a gap or hiatus which is of sufficient size to permit passage or movement of the head of the user through the same. Cables fix to the platform and extend through a pulley system to hand or first straps which are gripped by the user. In addition, shoulder rests are constructed to extend outwardly from the platform.
The apparatus of the present invention also includes a foot support which is connected to the frame or, in certain embodiments, from a stanchion of the frame. The foot support includes foot contacting surface and a mounting member for supporting the same. The foot contacting surface may be embodied in a bar, a plate, a pair of plates individually positionable, and the like. First support means is also provided for adjustably holding the foot support along a first dimension. Likewise, second support means is also included for adjustably holding the foot support along the second dimension. The first and second support means dimensions may includes horizontal and vertical components.
It may be apparent that a novel and useful exercise apparatus has been described.
It is therefore an object of the present invention to provide an exercise apparatus which utilizes a sliding platform and requires the user to push the platform against a resistance force in the form of a spring member.
Another object of the present invention is to provide a exercise apparatus using a sliding platform movable against a resistance force which is adjustable to persons of different height and physical abilities, while using a foot support element capable of being multi-positioned relative to the user.
Yet another object of the present invention is to provide an exercise apparatus which is compact and easy to assemble and use.
A further object of the present invention is to provide an exercise apparatus which employs a sliding platform and a multiplicity of supports permiting the use of the exercise apparatus in various therapeutic situations.
The invention possesses other objects and advantages especially as concerns particular characteristics and features thereof which will become apparent as the specification continues
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top right, perspective view of an embodiment of the apparatus of the present invention.
FIG. 2 is a top right, perspective view of an embodiment of the apparatus of the present invention showing particular foot support.
FIG. 3 is a top, right, perspective view of an embodiment of the apparatus of the present invention showing another type of foot support.
FIG. 3A is a sectional view of a particular adjustment mechanism for the foot supports depicted in FIGS. 1-3.
FIG. 4 is a top right, perspective view of an embodiment of the exercise apparatus of the present invention showing yet another foot support.
FIG. 5 is a left end view of the exercise apparatus depicted in FIG. 4.
FIG. 5A is a left end view of the exercise apparatus depicted in FIG. 4 showing an extended foot support position.
FIG. 6 is a right end view of the exercise apparatus of FIG. 4.
For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be referenced to the hereinabove described drawings.
The apparatus as a whole is depicted in the drawings by reference character 10 and an upper case letter to denote multiple embodiments. Apparatus 10A utilizes a platform 12 which is intended to support a sitting, standing or reclining user. Platform 12 slides on rails 14 and 16 which are positioned within a frame 18. Platform 20 may slide directly on rails 14 and 16 or through the use of plurality of wheels 20 (shown in phantom FIGS. 1-3). Frame 18 is supported above the floor surface by legs 22. Frame 18 is also constructed with an end piece 24. Multiplicity of springs 26 connect to platform 12 and end piece 24 such that platform 12 moves away from end piece 24, against a resistance force provided by springs 26.
Platform 12 is also provided with a pair of shoulder rests 28 which extend upwardly from platform 12. A pair of end loops 30, shown encircling rests 28, are connected to a pair of lines 32. Lines 32 past through a pair of pulleys 34 which are connected to posts 36 and 38 affixed to frame 18. Lines 32 then extend into connection with platform 12. Thus, pulling of loops 30 by the user's hands or feet will tend to move platform against the resistance force afforded by plurality of springs 26.
The apparatuses 10A, 10B, and 10C are identically constructed in FIGS. 1-3 with the exception of particular adjustable foot supports. With respect to the foot support 40 of apparatus 10A, FIG. 1, a pair Of elongated elements 42 and 44 extend upwardly from horizontal bar 46 and another identical horizontal bar (not shown) which are affixed to side piece 48 of frame 18. Elongated element 42 is identically constructed to elongated element 44. Thus, the discussion hereinafter with respect to elongated element 42 would be applicable to the construction of a elongated element 42. Elongated element 42 terminates in a bushing 50 which slides over horizontal bar 46. Bushing 50 includes a set bolt 52 which fits into any number of a plurality of openings 54 through horizontal bar 46, FIG. 3A. Thus, elongated element 42 and 44 may be moved back and forth horizontally and fixed to a certain position by set bolt 52. In addition, a spanning bar 56 is adjustably fixed to elongated elements 42 and 44 by end bushings 58 and 60, which are fixed by set bolts in a manner similar to bushing 50, illustrated in Fig. 3A. Namely, spanning bar 56 may move along elongated elements 42 and 44, a movement which includes a vertical component. Plate 62 allows the user to rest his feet when spanning bar 56 is not employed as a foot support.
Turning now to FIG. 2, apparatus 10B includes a foot support mechanism 64, in addition to a foot support mechanism 66 which is identical to foot support mechanism 40 of apparatus 10A, FIG. 1. Foot support mechanism 64 includes a rod 68 which extends through flange 70 of end piece 24. Rod 68 connects to a cross piece 72 having a pair of foot plates 74 and 76 which fasten to rotatable blocks 78 and 80. Rotatable blocks, although permitted to rotate about cross piece 70 are held tightly thereto by a friction fit.
With reference now to apparatus 10C, FIG. 3, foot support 82 is depicted as being identical to foot support 40 found on embodiment 10A of FIG. 1. In addition, flattened member 84 is illustrated as being attached to spanning bar 86. Brace block 88 lies across flange 70 of end piece 24 to aid in the support of flattened member 84 when the same is contacted by the feet of the user of apparatus 10C. Flattened member 84 may be transparent to permit observation of the foot contact makes with flattened member 84.
FIG. 4 represents a further embodiment 10D of the apparatus of the present invention. Apparatus 10D includes a frame 90 formed of metallic tubing. Frame 90 is constructed with longitudinal members 92 and 94 which are welded or otherwise connected to end pieces 96 and 98. Platform 100 rides along longitudinal member 92 and 94 by the use of plurality of casters 102. Multiplicity of springs 104 fasten to platform 100 and cross bar 106 of end piece 96. Pairs of hand loops 108, lines 110 and pulleys 112 are similar to the loop, line, and pulley combination described in FIG. 2 with regard to embodiment 10B.
Now viewing FIGS. 5 and 5A, end piece 96 includes a base member 114 spanned by cross bar 106 of the upper portion thereof. Upper portion 116 is roughly U-shaped and includes a pair of bosses 118 and 120 which telescopically nest within the ends of hollow base 114. Base 114 rests on ground surface 121. Pair of locking bolts 122 pass through the hollow ends of base 114 and engage a plurality of openings 124 (shown schematically in FIG. 5 and 5A) to determine the height of bar 126 of upper piece 116. Bar 126 is shown at a higher level in FIG. 5A than in FIG. 5.
FIG. 6 depicts end piece 98 which includes a horizontal element 128 and a pair of arms 130 and 132 extending therefrom. Arms 130 and 132 do not meet, but form a gap 134 which is of sufficient dimension to allow the head of the user lying on platform 100 to pass through the same when the feet of the user contact bar 126.
In operation, the user lies down platform 12 of embodiments 10A, B, or C and engages loops 30 with the user's hands or feet while gaining support from shoulder rests 28. Loops 30 are then pulled to move platform 12 against the resistance force of springs 26. The user's feet are either placed on bar 56 of apparatus 10A, foot plates 74 and 76 of apparatus 10B, or flattened member 84 of embodiment 10C. In the latter case, flattened plate 84 may be constructed of transparent material such that an observer may ascertain the foot pressure placed on flattened member 84 by each foot of the user. The height of bar 56 and flattened member 84 may be adjusted by means typically illustrated in FIG. 3A. Thus, apparatus 10A, B or C may accommodate users of different heights. With reference to apparatus 10D depicted in FIGS. 4-6, the user again lies on platform 100, engages hand or foot loops 108, and pulls against plurality of springs 104. Platform 100 then travels along longitudinal members 92 and 94. The user's feet rest on bar 126 which is adjustable by the mechanism described in FIGS. 5 and 5A to accommodate users of different heights.
While in foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and principles of the invention. | An exercise apparatus utilizing a platform which is slidable on a frame. The platform moves on the frame against a resistance force provided by a spring connected to the platform and the frame. A foot support connects the frame and includes a contact surface which is adjustable along first and second dimensions. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to runged ladders generally and, more particularly, but not by way of limitation, to a novel positionable platform for a ladder upon which platform a user of the ladder may stand.
2. Description of the Related Art
Runged ladders have been employed for thousands of years to provide an elevated platform for various activities. A disadvantage with conventional runged ladders is that prolonged standing on a rung can be uncomfortable, at the least, and can cause foot trauma in some cases. This foot stress occurs because only a small area of the user's feet engage a rung, that area typically being under the arches of the foot. This area of the foot is not particularly strong, yet all of the user's weight is concentrated into this relatively small area. The situation is aggravated if the user is overweight. Often, the user will try to temporarily stand sideways on a rung for relief or place only the ball of his foot on a rung, but either practice is dangerous and can lead to falling off the ladder.
U.S. Pat. No. 2,827,336, issued Mar. 18, 1958, to Johnson, describes a ladder step platform which extends entirely rearwardly from a rung of a ladder. The platform extends from the rung which supports it and is relatively complex, having numerous parts that require loosening and tightening, e.g. screws and cams, for installation and adjustment.
U.S. Pat. No. 4,953,661, issued Sep. 4, 1990, to Hilton et al., describes a ladder attachment which can serve as either a tool support or a step. The attachment includes a frame and a platform hinged to the frame, the frame having brackets which are fitted over a rung that lies above the platform. The frame rests against the front face of the ladder. The angle of the platform relative to the ladder is selectively adjustable by means of saw-like racks which engage toothed brackets.
Accordingly, it is a principal object of the present invention to provide a ladder platform that is simple in construction and easily deployed.
It is a further object of the invention to provide such a ladder platform that is economically constructed.
It is an additional object of the invention to provide such a ladder platform that can be folded to a compact form, attached to the belt of the user, and easily carried up a ladder.
It is another object of the invention to provide such a ladder platform that is easily adjusted between open and closed positions.
Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or be apparent from, the following description and the accompanying drawing figures.
SUMMARY OF THE INVENTION
The present invention achieves the above objects, among others, by providing, in a preferred embodiment, a ladder platform, comprising: a frame which can be removably attached to a ladder; a planar platform fixedly mounted on a shaft rotatably disposed in said frame; and a position adjustment mechanism operatively connected to said shaft to selectively lock said platform in a desired angular position with respect to said ladder or to permit said platform and said shaft to rotate freely within said frame, said position adjustment mechanism including no threaded fasteners.
BRIEF DESCRIPTION OF THE DRAWINGS
Understanding of the present invention and the various aspects thereof will be facilitated by reference to the accompanying drawing figures, submitted for purposes of illustration only and not intended to define the scope of the invention, on which:
FIG. 1 is an isometric view of a ladder platform constructed according to the present invention and mounted on a ladder in an open and unlocked position.
FIG. 2 is a fragmentary side elevational view of the ladder platform of FIG. 1 illustrating the platform in fixed, horizontal position.
FIG. 3 is a fragmentary side elevational view of the ladder platform of FIG. 1 illustrating how the angle of the ladder platform with respect to the ladder is adjusted. The manual lock hereinafter described is not shown for purposes of clarity.
FIG. 4 is a fragmentary detail illustrating a manual lock for the present invention.
FIG. 5 is a fragmentary, bottom plan view, partially in cross-section, of the ladder platform of FIG. 1 taken along line "5--5" of FIG. 2.
FIG. 6 is a fragmentary detail illustrating an alternate embodiment of the manual lock for the ladder platform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference should now be made to the drawing figures, on which similar or identical elements are given consistent identifying numerals throughout the various figures thereof, and on which parenthetical references to figure numbers direct the reader to the view(s) on which the element(s) being described is (are) best seen, although the element(s) may be seen also on other views.
FIG. 1 illustrates a ladder platform according to the present invention, generally indicated by the reference numeral 10. Ladder platform 10 includes a rectilinear frame comprising channel shaped side members 12 and 14 fixedly attached together by horizontal brackets 16, at the upper ends of the side members, and horizontal brackets 18 and 20, at the lower ends thereof. A platform 30 is rotatably disposed between side members 12 and 14, the angular position of which platform with respect to a ladder 36 on which ladder platform 10 is disposed is adjustable by an position adjusting mechanism, generally indicated by the reference numeral 40, the operation of which position adjusting mechanism will be described later.
Side members 12 and 14 each include a substantially L-shaped upper slot 44 defined in the upper rear portions thereof for fitting over a rung 46 of ladder 36. A pair of vertical lower slots 48 (only one visible on FIG. 1) is defined in the lower portions thereof for fitting over a rung 50 of ladder 36 immediately below rung 46. It will be noted that slots 48 have a greater vertical depth than slots 44. This permits lower slots 48 to be initially positioned over rung 50 and then upper slots 44 may be more easily positioned over rung 46.
A counterweight 52 may be provided at the front of platform 30 to facilitate proper setting of the position of platform 30.
No further description of the elements of ladder platform 10 will be given with reference to FIG. 1, except to note that position adjusting mechanism 40 includes a substantially L-shaped manual locking rod 60 the distal end of which is selectively insertable in either of upper or lower L-shaped slots 62 and 64, respectively, defined in side member 14. When the distal end of locking rod 60 is inserted in slot 62, the locking rod is in its unlocked position and, when the distal end of the locking rod is inserted in slot 64, the locking rod is in its locked position.
Reference should now be made primarily to FIGS. 2 and 3 for an understanding of the operation of position adjustment mechanism 40. Mechanism 40 includes a circular ratchet wheel 70 fixedly keyed to a shaft 72 on which platform 30 is fixedly mounted. Ratchet pawls 74 and 76 rotatably mounted on shafts 78 and 80, respectively, engage ratchet wheel 70 and prevent counterclockwise rotation of platform 30 when the ratchet wheel 70 is so engaged. Ratchet pawls 74 and 76 are biased in the positions shown on FIG. 2 by means of coil springs 82 and 84, respectively, stretched between the ratchet pawls and side member 14.
Formed integrally or fixedly attached with ratchet wheel 70 is a square toothed wheel 88 between a pair of teeth of which the proximal end of manual locking rod 60 is inserted. Referring back to FIG. 1 momentarily, it will be recalled that, when locking rod 60 is in the position shown on FIG. 2, the distal end of the locking rod will be inserted into slot 64 in side member 14. Manual locking rod 60 is biased into the locking position shown on FIG. 2 by means of a coil spring 66. The action of the locking rod is also indicated by the toothed wheel 88 of FIG. 4 and by the notched wheel of the alternate embodiment shown in FIG. 6. The notched wheel is provided with at least two inwardly extending holes, and the manual locking rod 60 is selectively insertable into one of the holes.
A selective pawl releasing mechanism engages and disengages the ratchet pawls 74 and 76 in relation to the ratchet wheel 70. Rotatably mounted in the distal end of shaft 72 is a circular ratchet release plate 90 having an integral ratchet release lever 92. Integrally disposed on the inner surface of ratchet release plate 90 are two ratchet release bosses 96 and 98. A coil spring 100 stretched between ratchet release plate 90 and side member 14 biases the release plate to a counterclockwise position, the biasing being terminated by the engagement with a fixed stop 102 of an edge of a cut-out 104 defined in the periphery of the ratchet release plate 90.
When it is desired to unlock platform 30 to move the same to another angular position with respect to ladder 36 (FIG. 1), manual locking rod 60 is raised and the distal end thereof inserted into slot 62 in side member 14. Then, ratchet release lever 92 is rotated clockwise to the position shown in solid lines on FIG. 3. This causes bosses 96 and 98 to engage the inner surfaces of ratchet pawls 74 and 76, respectively, thereby lifting the ends of the pawls from ratchet wheel 70, permitting the ratchet wheel 70, shaft 72, square toothed wheel 88, and platform 30 to rotate freely either clockwise or counterclockwise, as is indicated in broken lines on FIG. 3. Clockwise rotation of ratchet release plate 90 is limited by the engagement of the other end of cut-out 104 with stop 102, as is shown on FIG. 3. When platform 30 is rotated to its desired new position, ratchet release lever 92 is released, coil spring 100 will cause ratchet release plate 90 to rotate counterclockwise, re-engaging ratchet pawls 74 and 76 with ratchet wheel 70 and preventing counterclockwise rotation of shaft 72 and platform 30. Manual locking rod 60 is then returned to its locked position (FIG. 2).
Referring now to FIG. 5, it will be seen that shaft 72 is journalled in a supporting bushing 110 pressed into side member 14. It will be understood that a similar bushing is provided in side member 12 at the other end of shaft 72. Platform 30 has a tubular reinforcing member 120 fixedly attached to shaft 72 and the platform, and the tubular reinforcing member 120 encircles the inner periphery of the forward portion of the platform 30.
The elements of ladder platform 10 may be economically constructed of any suitable materials properly selected for their purposes. The upper surface of platform 30 should be covered with an abrasive material for easy gripping and safety.
In use, ladder platform 10 with platform 30 folded into the frame thereof, with manual locking rod 60 in its unlocked position (FIG. 3) is carried up ladder 36 and placed over a selected pair of rungs thereof. Then, ratchet release lever 92 is moved to its release position (FIG. 3) and platform rotated to a horizontal working position (FIG. 1). Then, ratchet release lever 92 is released to return to the position shown on figure (2) and manual locking rod is moved to its locked position (FIG. 2). Ladder platform 10 can be quickly and easily repositioned on ladder 36.
Ladder platform 10 provides a comfortable and sturdy surface on which even a fairly heavy individual can stand for long periods of time.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only 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. | An adjustable platform for attachment to a ladder, including: a frame which can be removably attached to a ladder; a planar platform fixedly mounted on a shaft rotatably disposed in the frame; and a position adjustment mechanism operatively connected to the shaft to selectively lock the platform in a desired angular position with respect to the ladder or to permit the platform and the shaft to rotate freely within the frame, the position adjustment mechanism including no threaded fasteners. | 4 |
[0001] This application is a continuation-in-part of U.S. Utility patent Ser. No. 12/812,488, filed 12 Jul. 2010, which is a 371 National Stage Entry of International Application No. PCT/AU2008/001834 filed 12 Dec. 2008, which claims the priority to Australian Application No. 2007906771, filed on 12 Dec. 2007, wherein the specifications and contents of these applications are hereby incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the invention relate generally to nutraceutical compositions and methods of administering them for the treatment of inflammation or inflammation associated disorders.
[0004] Embodiments of the invention also relate to nutraceutical compositions extracts from a plant capable of treating inflammation or inflammation associated disorders.
[0005] 2. Description of the Related Art
[0006] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date: part of common general knowledge, or known to be relevant to an attempt to solve any problem with which this specification is concerned.
[0007] The use of non-steroidal anti-inflammatory drugs (NSAID), such as aspirin and ibuprofen, for the treatment of pain, inflammation and fever is well known. Adverse reactions from such drugs are widespread and increasingly prevalent resulting in over 100,000 hospitalisations in the US in 2001. Some of the newer NSAID's have been shown to increase a patients risk of myocardial infarction by 80%.
[0008] Moreover, there have been a number of increased adverse drug reactions (ADR), particularly when the NSAID was taken in combination with a COX-2 inhibitor.
[0009] Some common gastrointestinal ADR's observed include, nausea, vomiting, dyspepsia, gastric ulceration and diarrhoea, other more severe ADR's have also been observed to include hypertension, interstitial nephritis, acute renal failure and photosensitivity.
[0010] NSAID's work primarily as a COX inhibitor, and certain NSAID's were developed as specific COX-1 or COX-2 inhibitors.
[0011] In 2004, the US FDA issued a public health advisory on the safety of Vioxx™, a selective COX-2 inhibitor, on the basis that there was an increase in cardiovascular events observed in those taking the drug.
[0012] In 2005, the US FDA issued an alert for practitioners in relation to the safety of the NSAID Celebrex™ again on the basis of the observed increase in cardiovascular events in patients taking the drug.
[0013] As a result of the above there has been a general reluctance to prescribe known NSAID's in many situations, or to prescribe reduced dosages in an attempt to combat the adverse side effects currently being observed.
[0014] NSAID's have long been used in the treatment of joint inflammation as a form of pain relief.
[0015] Shark cartilage provides significant improvement in joint health in an experimental model of immune-mediated arthritis (Pivnenko et al., 2005), and may improve sulfate uptake into new proteoglycan molecules.
[0016] Similarly, there is clinical evidence for the efficacy of perna mussel as a treatment for degenerative joint disease in dogs (Pollard et al., 2006; Bui and Bierer 2003). Likewise abalone has potential benefits in alleviating and treating joint disease. It has a high concentration of n-3 polyunsaturated fatty acids (Su and Antonas 2004) which are known to reduce the formation of inflammatory eicosanoids (Mesa Garcia et al., 2006) and at least in part account for the inhibition of nitric oxide production (Pearson et al., 2007). The latter being linked with chondroprotective and analgesic properties (Pearson et al., 2007).
BRIEF SUMMARY OF THE INVENTION
[0017] It is an object of the invention to provide a nutraceutical composition for the treatment of inflammation or inflammation associated disorders.
[0018] It is an object of the present invention to overcome, or at least substantially ameliorate, the disadvantages and shortcomings of the prior art.
[0019] Other objects and advantages of the present invention will become apparent from the following description, taking in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0020] In a first aspect of the invention there is a method of treating joint inflammation in a mammal in need thereof, the method including obtaining hydrolysed Biota orientalis seed oil and administering to the mammal a composition including an effective amount of the hydrolysed Biota orientalis seed oil to said mammal.
[0021] In preference, the composition inhibits Cox expression in said mammal, wherein said inhibiting comprises administering to said mammal said non-aqueous extract of said seed of said Biota orientalis plant in an effective amount to inhibit Cox expression.
[0022] In preference, the composition includes an additional extract selected from the group consisting of mussel extract, abalone extract or powder, shark cartilage powder or combinations thereof.
[0023] In preference, the composition includes a pharmaceutical carrier.
[0024] A further aspect of the invention is a method for treating joint inflammation in a mammal in need thereof, the method including obtaining hydrolysed Biota orientalis seed oil and administering to the mammal a composition including an effective amount of the hydrolysed Biota orientalis seed oil to said mammal, wherein said obtaining said hydrolysed Biota orientalis seed oil comprises adding Biota orientalis seed oil to an alkaline solution of about 1:2.9:1.4 (w/w) KOH:EtOH:cold water; neutralising said alkaline solution to a pH of about 4.5; and separating a non-aqueous phase to yield the hydrolysed Biota orientalis seed oil.
[0025] In a further aspect of the invention, although this should not be seen as limiting the invention in any way, there is provided a method of modulating inflammation in an organism, the method including administering to an organism a composition including a therapeutic amount of an extract from the plant Biota orientalis.
[0026] In a typical method, administering a composition a composition including a therapeutic amount of an extract from the plant Biota orientalis to an organism decreases inflammation in the organism.
[0027] In one embodiment, a composition for modulating inflammation including a B. orientalis extract as described herein further includes an additional extract such as mussel extract, abalone extract or powder, shark cartilage powder or combinations thereof.
[0028] In one embodiment, the B. orientalis extract can be produced from a simulated digest mimicking gastrointestinal functioning/processing.
[0029] In a further aspect of the invention there is a provided a method of inhibiting cox expression in an organism, the method including administering to an organism a therapeutic or prophylactic amount of an extract from the plant Biota orientalis.
[0030] In preference, the cox is cox 1.
[0031] In preference, the cox is cox 2.
[0032] In preference, the cox expression is inhibited by greater than 70% “(e.g., 75, 80, 85, 90, 95%)”.
[0033] A further aspect of the invention resides in the provision of a method of inhibiting IL-1-induced iNOS expression in an organism, the method including administering to an organism a therapeutic or prophylactic amount of an extract from the plant Biota orientalis.
[0034] In yet a further form of the invention, there is a therapeutic composition including a synergistic combination of an extract from the plant Biota orientalis , with one or more of shark cartilage, perna mussel extract or powder and abalone extract or powder.
[0035] In a further embodiment, the composition comprises an extract from the plant Biota orientalis at a concentration of 5-30% by weight, shark cartilage at a concentration of 10-30% by weight, abalone extract at a concentration of 10-30% by weight, and mussel extract at a concentration of 40-60% by weight.
[0036] In yet a further form of the invention there is a use of a composition including at least one of the compounds selected from the group consisting of (9Z,13S,15Z)-12,13-epoxyoctadeca-9,11,15-trienoic acid, cis, cis, cis-9,12,15-octadecatrienoic acid (ALA), cis, cis, cis-6,9,12-octadecatrienoic acid (GLA), cis, cis-9,12-octadecadienoic acid and 9-Octadecenoic acid for the manufacture of a medicament for the therapeutic and/or prophylactic treatment of anti-inflammatory conditions.
[0037] In preference, the medicament includes an additional extract such as perna mussel extract, abalone extract or powder, shark cartilage powder or combinations thereof.
[0038] A further form of the invention resides in a method of treatment for anti-inflammatory conditions in a mammal, which includes administering to the mammal a therapeutically effective amount of a polyunsaturated fatty acid.
[0039] In preference, the polyunsaturated fatty acid is selected from the group of omega-3, omega-6, omega-9 and conjugated fatty acids or mixtures thereof.
[0040] In preference, the omega-3 fatty acid is selected from the group including: cis,cis,cis-7,10,13-hexadecatrienoic acid; cis,cis,cis-9,12,15-octadecatrienoic acid; cis,cis,cis,cis-6,9,12,15-octadecatetrae-noic acid; cis,cis,cis-11,14,17-eicosatrienoic acid; cis,cis,cis,cis-8,11,14,17-eicosatetraenoic acid; cis,cis,cis,cis,cis-5,8,11,14,17-eicosapentaenoic acid; cis,cis,cis,cis,cis-7,10,13,16,19-docosapentaenoic acid; cis,cis,cis,cis,cis,cis-4,7,10,13,16,19-docosahexaenoic acid; cis,cis,cis,cis-9,12,15, 18,21-tetracosapentaenoic acid; and cis,cis,cis,cis,cis,cis-6,9,12,15,18,21-tetracosahexaenoic acid or mixtures thereof.
[0041] In preference, the omega-6 fatty acid is selected from the group including: cis,cis-9,12-octadecadienoic acid; cis,cis,cis-6,9,12-octadecatrienoic acid; cis,cis-11,14-eicosadienoic acid; cis,cis,cis-8,11,14-eicosatrienoic acid; cis,cis,cis,cis-5,8,11,14-eicosatetraenoic acid; cis,cis-13,16-docosadienoic acid; cis,cis,cis,cis-7,10,13,16-docosatetraenoic acid; and cis,cis,cis,cis,cis-4,7,10,13,16-docosa-pentaenoic acid or mixtures thereof.
[0042] In preference, the omega-9 fatty acid is selected from the group including: cis-9-octadecenoic acid; cis-11-eicosenoic acid; cis,cis,cis-5,8,11-eicosatrienoic acid; cis-13-docosenoic acid; and cis-15-tetracosenoic acid or mixtures thereof.
[0043] In preference, the conjugated fatty acid is selected from the group including: 9Z,11E-octadeca-9,11-dienoic acid; 10E,12Z-octadeca-9,11-dienoic acid; 8E,10E,12Z-octadecatrienoic acid; 8E,10E,12E-octadecatrienoic acid; 8E,10Z,12E-octadecatrienoic acid; 9E,11E,13Z-octadeca-9,11,13-trienoic acid; 9E,11E,13E-octadeca-9,11,13-trienoic acid; 9Z,11Z,13E-octadeca-9,11,13-trienoic acid; 9Z,11E,13Z-octadeca-9,11,13-trienoic acid; 9E,11Z,15E-octadeca-9,11,15-trienoic acid; 9E,11Z,13Z,15E-octadeca-9,11,13,15-trienoic acid; trans,trans,trans,trans-octadeca-9,11,13,15-trienoic acid; (9Z,13S,15Z)-12,13-epoxyoctadeca-9,11,15-trienoic acid; and 5Z,8Z,10E,12E,14Z-eicosanoic acid or mixtures thereof.
[0044] In preference, the fatty acid(s) are/is in a form of a salt.
[0045] Another form of the invention resides in a pharmaceutical preparation anti-inflammatory conditions in a mammal, which includes a therapeutically effective amount of a polyunsaturated fatty acid.
[0046] The term “effective amount” as used herein refers to that amount of the extract that will contribute to the ability of the composition to treat joint inflammation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] The above and other aspects, features and advantages of the invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
[0048] FIG. 1 : Relative expression of cox 1 RNA in IL-1 stimulated (A) and unstimulated (B) cartilage explants.
[0049] FIG. 2 : Relative expression of cox 2 RNA in IL-1 stimulated (A) and unstimulated (B) cartilage explants.
[0050] FIG. 3 : Relative expression of iNOS RNA in IL-1 stimulated (A) and unstimulated (B) cartilage explants.
[0051] FIG. 4 : Relative expression of aggrecan RNA in IL-1 stimulated (A) and unstimulated (B) cartilage explants.
[0052] FIG. 5 : Prostaglandin E 2 (PGE 2 ) production by IL-1 stimulated (A) and unstimulated (B) cartilage explants.
[0000]
[0000] represents treatments significantly different from stimulated (A) or unstimulated (B) controls. Indo sim , SEQ sim (both doses) and BO sim (0.18 mg/mL) resulted in significantly lower PGE 2 in stimulated explants compared with stimulated controls. Indo sim and SEQ sim lowered PGE 2 production in unstimulated explants relative to unstimulated controls.
[0053] FIG. 6 : Timeline of injections and sample collection; Sample collection consisted of synovial fluid arthrocentesis from left and right intercarpal joints, and jugular venous blood. Dietary supplementation began on day 0 and continued for the duration of the experiment.
[0054] FIG. 7 : Synovial fluid [PGE 2 ] from intercarpal joints of control horses injected with IL-1 (10 ng on inj-1, 100 ng on inj-2) or saline in CON (A) and SEQ (B) horses. Healthy horses received a diet containing placebo (CON) or Sasha's EQ (SEQ) for 28 days. Intra-articular IL-1 (10 ng in 500 μL sterile saline) was injected into the intercarpal joint, and sterile saline (500 μL) was injected into the contralateral joint 14 days after commencement of supplementation (inj-1). A second intra-articular injection of IL-1 (100 ng in 500 μL sterile saline) or saline (500 μL) was injected the same joints 24 h later (inj-2). Approximately 1.5 mL synovial fluid was aspirated from the intercarpal joints on days pre (before commencement of supplementation), inj-1 and inj-2 (prior to injections), inj-2-2 (8 h after 2 nd IL-1 injection), and 1, 3, 7 and 14 days after 2 nd IL-1 injection. * denotes significant change from inj-1 within treatments. Letters denote significant differences between saline and IL-1 within treatments. Changes are significant when p≦0.05.
[0055] FIG. 8 : Synovial fluid [GAG] from intercarpal joints injected with IL-1 (10 ng on inj-1, 100 ng on inj-2) or saline in CON (A) and SEQ (B) horses. Healthy horses received a diet containing placebo (CON) or Sasha's EQ (SEQ) for 28 days. Intra-articular IL-1 (10 ng in 500 μL sterile saline) was injected into the intercarpal joint, and sterile saline (500 μL) was injected into the contralateral joint 14 days after commencement of supplementation (inj-1). A second intra-articular injection of IL-1 (100 ng in 500 μL sterile saline) or saline (500 μL) was injected the same joints 24 h later (inj-2). Approximately 1.5 mL synovial fluid was aspirated from the intercarpal joints on days pre (before commencement of supplementation), inj-1 and inj-2 (prior to injections), inj-2-2 (8 h after 2 nd IL-1 injection), and 1, 3, 7 and 14 days after 2 nd IL-1 injection. * denotes significant change from inj-1 within treatments. Letters denote significant difference between IL-1 and saline within treatments. SEQ horses had significantly higher synovial fluid [GAG] than CON horses. Differences were significant when p≦0.05.
[0056] FIG. 9 : Synovial fluid [protein] from intercarpal joints of control horses injected with IL-1 (10 ng on inj-1, 100 ng on inj-2) or saline in CON (A) and SEQ (B) horses. Healthy horses received a diet containing placebo (CON) or Sasha's EQ (SEQ) for 28 days. Intra-articular IL-1 (10 ng in 500 μL sterile saline) was injected into the intercarpal joint, and sterile saline (500 μL) was injected into the contralateral joint 14 days after commencement of supplementation (inj-1). A second intra-articular injection of IL-1 (100 ng in 500 μL sterile saline) or saline (500 μL) was injected the same joints 24 h later (inj-2). Approximately 1.5 mL synovial fluid was aspirated from the intercarpal joints on days pre (before commencement of supplementation), inj-1 and inj-2 (prior to injections), inj-2-2 (8 h after 2 nd IL-1 injection), and 1, 3, 7 and 14 days after 2 nd IL-1 injection. * denotes significant change from inj-1 within treatments. Letters denote significant differences between IL-1 and saline within treatments. Differences were significant when p≦0.05.
[0057] FIG. 10 : Circumference of intercarpal joints injected with IL-1 (10 ng on inj-1, 100 ng on inj-2) or saline in CON (A) and SEQ (B) horses. Healthy horses received a diet containing placebo (CON) or Sasha's EQ (SEQ) for 28 days. Intra-articular IL-1 (10 ng in 500 μL sterile saline) was injected into the intercarpal joint, and sterile saline (500 μL) was injected into the contralateral joint 14 days after commencement of supplementation (inj-1). A second intra-articular injection of IL-1 (100 ng in 500 μL sterile saline) or saline (500 μL) was injected the same joints 24 h later (inj-2). Approximately 1.5 mL synovial fluid was aspirated from the intercarpal joints on days pre (before commencement of supplementation), inj-1 and inj-2 (prior to injections), inj-2-2 (8 h after 2 nd IL-1 injection), and 1, 3, 7 and 14 days after 2 nd IL-1 injection. * denotes significant change from inj-1 within treatments. Letters denote significant differences between IL-1 and saline within treatments. Joint circumference of IL-1-injected joints was significantly lower in SEQ horses than CON horses (p<0.001). Differences were significant when p≦0.05.
[0058] FIG. 11 : Table 1 showing the primers for aggrecan and β-actin.
[0059] FIG. 12 : Table 2 showing the composition of Sasha's EQ powder prepared by combining Abalone (AB), New Zealand Green Lipped Mussel (NZGLM), Shark cartilage (SC) and BO (Interpath Pty Ltd, Australia).
[0060] FIG. 13 : Table 3 showing the nutrient composition of Sasha's EQ for feeding to horses.
[0061] FIG. 14 : Chromatographic spectrum of the extract of Biota orientalis oil.
[0062] FIG. 15 : Shows the concentration of NO of each of the isolated fractions in the cell culture assay.
[0063] FIG. 16 : Shows the induced PGE2 level of the isolated fractions Fr1 and FI.
[0064] FIG. 17 : Shows the induced PGE2 level of the isolated fractions FV and Vi
[0065] FIG. 18 : Shows the reduction of IL-1β induced PGF2α levels on fractions Frl and Fri.
[0066] FIG. 19 : Shows the reduction of IL-1β induced PGF2α levels on fractions FrV and FrVi.
DETAILED DESCRIPTION OF THE INVENTION
[0067] To facilitate an understanding of the invention various terms and abbreviations are used and defined below:
[0068] “SEQ” means a blend of New Zealand Green Lipped Mussel, abalone, shark cartilage powder and Biota oil.
[0069] “BO” means “ Biota oil” being a hydrolysed extract of the seeds of the plant Biota orientalis . The crude Biota oil is hydrolysed to provide the Biota oil in the free fatty acid form.
[0070] “NZGLM” means New Zealand Green Lipped Mussel.
[0071] “sim” means a simulated digest or simulated digestion.
[0072] “COX” or “cox” means the enzyme cyclooxygenase.
[0073] “iNOS” means inducible nitric oxide (NO) synthase.
[0074] Biota is an herb native to Western China and North Korea and is known by a number of other names, such as Thuja orientalis, Platycladus stricta , and Platycladus orientalis.
[0075] Preparation of Hydrolysed Biota orientalis (BO) Seed Extract (Ex
[0000]
Biota orientalis (BO) seed extract (oil)
60 kg
Ethanol
44.4 kg
Cold water
21 kg
Potassium hydroxide (KOH)
15 kg
[0076] Hydrolysis: KOH is dissolved in a mixture of cold water and ethanol (1:2.9:1.4 (w/w) KOH:EtOH:cold water), ensuring that the temperature of the solution is maintained at around 40° C. Once all the KOH is fully dissolved, check temperature to ensure that it is approximately 40° C. and slowly add the BO seed oil in 10 kg amounts taking care to monitor any increases in temperature and if required adding portions of cold water to ensure that the reaction solution temperature is maintained at around 40° C. under an inert atmosphere (N 2 ). Continue until all BO seed oil has been added. Continue stirring reaction mixture for 1.5 hrs adding whilst maintaining temperature of mixture at around 40° C.
[0077] Neutralisation: Prepare a solution of 36% sulphuric acid (49 kg) and ensuring the reaction mixture is approximately 40° C. slowly add 15 kg the 36% sulphuric acid solution and check pH. Continue adding portions of the 36% sulphuric acid solution and monitoring the pH until the pH is approximately 6. Continue mixing adding smaller portions (25-50 ml) of 36% sulphuric acid until the pH is approximately in the range of 4.5-4.6.
[0078] Extraction: drain the aqueous phase (water/ethanol) from the reaction mixture and wash the non-aqueous phase with warm (40° C. water), retain the non-aqueous phase and repeat washing step if required. Separate again the non-aqueous phase which is the hydrolysed BO seed oil.
[0079] An alternative hydrolysis process is as follows:
[0080] Enzyme hydrolysis: 80% by total weight of BO seed oil is mixed together with 20% by total weight of water. Lipozyme® RM IM (2% of the weight of BO seed oil) is then added. The mixture is stirred and heated until it reaches 45° C. The temperature of 45° C. and stirring are then maintained for 6 hours.
[0081] Separation and drying: After 6 hours the reaction mixture is filtered to remove any insoluble material and to recover the immobilised enzyme. The oil phase is separated either by gravity settling and decanting or by centrifugal separation. Optionally additional warm water can be mixed with the oil before separation to remove additional water soluble components from the oil. The separated oil phase is then evaporated under vacuum to remove remaining moisture.
[0082] Lipozyme® RM IM is a commercial immobilised lipase from Rhizomucor miehei . Other lipases are also suitable to act as the hydrolysis biocatalyst.
[0083] Simulated digests of shark cartilage, NZGLM and abalone have been previously reported to have anti-inflammatory effects in a cartilage explant model of arthritis by reducing PGE 2 , GAG and/or nitric oxide (Pearson et al., 2007).
[0084] The following data reports alterations in gene expression associated with conditioning cartilage explants with simulated digests of the combination of all four constituents (SEQ; SEQ sim ), and to characterize their effects on IL-1-induced PGE 2 , GAG, NO, cell viability, and genetic expression of cox 1, cox 2, iNOS and aggrecan.
[0085] Methods
[0086] Explant Cultures
[0087] Front legs of market weight pigs (5-7 months old, 200-250 lbs) were obtained from a local abattoir. Legs were chilled on crushed ice until dissection. Using aseptic technique, the intercarpal joint was opened and the cartilage surfaces exposed. A 4 mm dermal biopsy punch was used to take explants (˜0.5 mm thickness; 11-15 mg/explant) of healthy cartilage from the weight-bearing region of both articulating surfaces of the intercarpal joint. Cartilage pieces were washed 3 times in DMEM supplemented with NaHCO 3 . Two cartilage discs were placed into each well of 24-well tissue culture plates containing DMEM supplemented with amino acids, sodium selenite, manganese sulfate, NaHCO 3 and ascorbic acid (TCM—tissue culture medium). Plates were incubated at 37° C., 7% CO 2 in a humidified atmosphere for up to 144 h. Every 24 h media was completely aspirated into 1 mL microcentrifuge tubes and immediately replaced with control, conditioned and/or stimulated media (described below) before being returned to the incubator. The collected media was stored at −80° C. until analysis. Cartilage was harvested at the end of each experiment with one explant per well stained for cytotoxicity and the remaining cartilage immediately frozen at −80° C.
[0088] Simulated Digestion and Ultrafiltration
[0089] A simulated digestion procedure was developed to mimic the gastrointestinal processing of ingested dietary supplements. This type of approach has previously been used to improve the bio-assessment of putative nutraceuticals (Rininger et al., 2000; Pearson et al., 2007).
[0090] Simulated digests were prepared using SEQ (0.85 g), BO [2.5 mL (0.85 g)] and indo (0.074 g—a positive anti-inflammatory control). Each test substance was individually suspended in 35 mL of simulated gastric fluid (37 mM NaCl, 0.03N HCl, 3.2 mg/mL pepsin), and shaken at 37° C. for 2 h (Rininger et al., 2000). After this, solution acidity was neutralized by adding an equinormal volume of 2.2 N NaOH (1.15 mL). To this was added 36.15 mL of simulated intestinal fluid (Rininger et al., 2000-30 mM K 2 HPO 4 , 160 mM NaH 2 PO 4 ; 20 mg/mL pancreatin; pH adjusted to 7.4) and the resultant mixture shaken in a 37° C. incubator for a further 2 h. A “blank” was prepared using identical methodology but without including any test substance. Appropriate volumes of gastric and intestinal fluid were derived from those approximated in a human stomach (Marciani et al., 2005).
[0091] Upon completion of the 4-hour incubation, simulated digests of SEQ (SEQ sim ) BO (BO sim ) and indomethacin (indo sim ) were centrifuged at 3,000×g for 25 min at 4° C. The supernatant was decanted and centrifuged a second time at 3,000×g for 15 min at 4° C. The resulting supernatant was warmed to room temperature and filtered (0.22 μm) to remove particulates. This filtrate was further fractioned with an ultrafiltration centrifuge unit with a 50 kDa molecular weight cut-off, (AmiconUltra, Millipore, Mississauga ON), spinning at 3,000×g for 25 min (room temperature). Filtered simulated digest was stored at 4° C. until use for a maximum of 7 days.
[0092] Effect of SEQ sim and BO sim on IL-1-Induced Inflammation
[0093] SEQ sim was prepared as explained above. Explants from 12 pigs were prepared as previously described, and maintained in unconditioned media for the initial 24 h. At 24 hours post-culture, SEQ sim , BO sim (0, 0.06 or 0.18 mg/mL) or indo sim (0.02 mg/mL) was added to TCM (conditioned media). Conditioned media was refreshed every 24 hours for the duration of the experiment. At 72 hours post-culture, and every 24 hours thereafter, explants were stimulated with IL-1 (0 or 10 ng/mL; Medicorp, Montreal, Quebec; Cat. #PHC0813). Explants from each animal were exposed to each treatment in duplicate. Explants were cultured for a total of 120 h. Media was analyzed for [PGE 2 ], [GAG], [NO]. One explant per treatment was collected into sterile phosphate buffered saline (PBS) and immediately stained for cell viability (see below). The second explant was frozen at −80° C. for RNA extraction (see below).
[0094] PGE 2 Analysis:
[0095] PGE 2 concentration of TCM was determined using a commercially available PGE 2 ELISA kit (The kit has 7% cross-reactivity with PGE 1 ) (Amershan, Baie D'Urfé, Québec). Plates were read using a Victor 3 microplate reader (Perkin Elmer, Woodbridge ON) with absorbance set at 405 nm. PGE 2 standard curves were developed for each plate, and a best-fit 3 rd order polynomial equation with R 2 ≧0.99 was used to calculate PGE 2 concentrations for standards and samples from each plate.
[0096] NO Analysis:
[0097] NO concentration of tissue culture media was determined by the Griess Reaction (Shen et al., 2005). Plates were read using a Victor 3 microplate reader with absorbance set at 530 nm. Sodium nitrite standard curves were developed for each plate, and a best-fit linear regression equation with R 2 ≧0.99 was used to calculate NO concentrations, which were compared with the nitrite standard.
[0098] Isolation of Total RNA and Synthesis of cDNA
[0099] Total RNA was extracted from cartilage explants using a modified TRIzol procedure (Chan et al., 2005). Frozen cartilage from each animal was pooled according to conditioning and stimulation, and homogenized in Tri-Reagent (100 mg tissue/mL; Sigma, Mississauga ON). Chloroform was added to extract RNA followed by vigorous agitation and 2-min incubation at room temperature. Sample was then centrifuged (12,000×g, 15 min) and RNA was precipitated with an equal volume of 70% ethanol (DEPC). RNA precipitate was applied to an RNeasy mini column (Qiagen, Valencia Calif., USA) and RNA was purified according to manufacturer instructions.
[0100] For each pooled sample, 1 μg total RNA was converted to single stranded cDNA using Moloney Murine Leukemia Virus (MMLV) reverse transcriptase (Invitrogen, Burlington ON) according to manufacturer instructions. Single-strand cDNA was quantified by UV spectrophotometry and diluted with DEPC-H 2 O to a final concentration of 10 ng/μL.
[0101] Quantitative Real Time RT-PCR
[0102] Primers for porcine iNOS (Granja et al., 2006), Cox1/2 (Blitek et al., 2006), aggrecan (Fehrenbacher et al., 2003) and β-actin (housekeeping gene; Nishimoto et al., 2005) (Table 1) were prepared (Laboratory Services Division, University of Guelph) and stored at −20° C. until use. Cartilage samples from SEQ sim and BO sim were evaluated for changes in gene expression, together with cartilage cultured under identical conditions previously with the other 3 components of SEQ (see Pearson et al., 2007 for detailed culture conditions). Twenty five microliter PCR reactions were performed in triplicate using an ABI Prism 7000 sequence detection system (Perkin-Elmer). Amplification of 50 ng of each cDNA sample was detected using SYBR-Rox (Invitrogen, Burlington ON) and compared to a standard curve of pooled cDNA containing equal amounts of cDNA from each sample. A 1.5% agarose electrophoresis gel was used to confirm PCR products. Expression of each gene of interest (G) in each sample was compared to amplification of β-actin (β), and calibrated to unstimulated control explants (ie. fold change for calibrator=1). Fold change in expression (ΔG/Δβ) is presented in arbitrary units.
[0103] Cytotoxicity Staining
[0104] Cell viability was determined using a commercially available viability staining kit (Invitrogen; Burlington ON) (Pearson et al., 2007). Briefly, explants were washed in 500 uL PBS and placed into a 96-well microtitre plate (one explant per well), and were incubated in 200 uL of stock stain (4 μM C-AM; 8 μM EthD-1) for one hour at room temperature. The plate was read from the bottom of each well using 10 horizontal steps, 3 vertical steps, and a 0.1 mm displacement. C-AM and EthD-1 fluorescence in live and killed explants were obtained with excitation/emission filters of 485/530 nm and 530/685 nm, respectively.
[0105] Data Analysis
[0106] Data from analysis of tissue culture media and viability are presented as means±standard error. Means of replicates from each treatment/animal were analyzed using two-way repeated measures analysis of variance comparing each treatment with unconditioned controls and indomethacin-conditioned controls. Viability data were analyzed using the Student's t-test, individually comparing stimulated controls with all other treatments. When a significant F-ratio was obtained, the Holm-Sidak post-hoc test was used to identify significant differences between treatment and/or time. Significance was accepted if p≦0.05.
[0107] Due to low cellularity of cartilage explants, it was necessary to pool RNA from explants exposed to the same conditioning and stimulation in order to extract sufficient RNA for a reverse transcription reaction. Thus, PCR data are presented in the text as a mean change in gene expression (calibrated to controls) relative to β-actin±coefficient of variation for the assay. A calibrated fold expression change ≧2 is considered to be biologically relevant (Yang et al., 2002; Schena et al., 1995) and are discussed in the text as significant differences.
[0108] Results
[0109] PCR
[0110] Cox 1 ( FIG. 1 , A and B): IL-1 stimulation of control explants resulted in a 35% increase in cox 1 expression compared with unstimulated controls. Cox 1 expression was decreased by exposure to indo sim by 98 and 91.5% in unstimulated and stimulated explants, respectively.
[0111] All constituents of SEQ reduced cox 1 expression in unstimulated explants (range: 76-95% inhibition). Importantly, it was observed that BO sim (0.06 mg/mL) was the most effective cox 1 inhibitor, reducing cox 1 expression by 95% in both unstimulated and stimulated explants.
[0112] In addition, it was observed that SEQ sim (0.06 and 0.18 mg/mL) reduced cox 1 expression in unstimulated explants by 90 and 80%, respectively. In IL-1 stimulated explants, SEQ sim (0.06 and 0.18 mg/mL) inhibited cox 1 expression by 57 and 76%, respectively. The least effective cox 1 inhibitor in IL-1-stimulated explants was NZGLM (0.18 mg/mL), which increased cox 1 expression by 62%.
[0113] Fold change in cox 1 for all samples was >2 and therefore not considered significant.
[0114] Cox 2 ( FIG. 2 , A and B): Stimulation of control explants resulted in a significant 4.3-fold increase in cox 2 expression. Indo sim reduced expression of cox 2 by 44 and 47% in unstimulated and stimulated explants, respectively. Fold increase in cox 2 for indo sim -conditioned, IL-1-stimulated explants was significant (2.3).
[0115] Abalone (0.18 mg/mL) significantly increased cox 2 expression in unstimulated explants, showing similar effect on cox 2 (3.7-fold) as IL-1. All other constituents decreased Cox 2 expression in unstimulated explants (range: 56-90%).
[0116] IL-1-stimulation resulted in a significant increase in cox 2 expression in those explants conditioned with indo sim (2.3-fold), SEQ sim (0.06 mg/mL; 2.0-fold), NZGLM sim (0.18 mg/mL; 28.2-fold), and AB sim (0.18 mg/mL; 41.5-fold). All other constituents prevented a significant increase in IL-1-induced cox 2 expression; the most effective inhibitor was BO sim (0.06 mg/mL) which inhibited cox 2 expression by 92%.
[0117] iNOS ( FIG. 3 , A and B): Stimulation of control explants by IL-1 resulted in a 287-fold increase in iNOS expression. Indo sim conditioning had no effect on iNOS in unstimulated explants. In IL-1-stimulated explants, indo sim conditioning augmented the effect of IL-1 on iNOS expression (725-fold increase).
[0118] SEQ and all of its individual constituents significantly increased iNOS expression in unstimulated explants (range: 39-2486-fold increase). IL-1-stimulation resulted in a significant increase in iNOS expression in all conditioned explants. However, compared with IL-1-stimulated controls, iNOS was significantly inhibited by both doses of SEQ sim in a dose-dependent manner (60 and 89% inhibition for 0.06 and 0.18 mg/mL, respectively). BO sim (0.06 mg/mL) and AB sim (0.18 mg/mL) also significantly inhibited IL-1-induced iNOS expression by 55 and 12%, respectively.
[0119] Aggrecan ( FIG. 4 , A and B): Stimulation of control explants with IL-1 resulted in a slight, non-significant decline in aggrecan expression. Conditioning of unstimulated explants with indo sim resulted in 58-fold increase in aggrecan. This increase was completely abolished by stimulation of indo sim -conditioned explants with IL-1.
[0120] SEQ and all of its constituents significantly increase aggrecan expression in unstimulated explants. SEQ sim increased aggrecan expression in unstimulated explants in a dose-dependent manner (42.8 and 215.7-fold increase for 0.06 and 0.18 mg/mL, respectively).
[0121] Stimulation of conditioned explants with IL-1 resulted in significant increase in aggrecan expression in SEQ and all of its constituents, with the exception of SC sim (0.18 mg/mL; 1.4-fold increase).
[0122] Tissue Culture Experiments:
[0123] PGE 2 ( FIG. 5 , A and B): Stimulation of control explants with IL-1 (10 ng/mL) resulted in a significant increase in media [PGE 2 ] over the 48 h stimulation period, resulting in a significant difference between stimulated and unstimulated controls (p=0.03). Indo sim (0.02 mg/mL) significantly reduced media [PGE 2 ] in IL-1 stimulated and unstimulated explants compared with stimulated and unstimulated controls, respectively. There was no IL-1-induced increase in media [PGE 2 ] in explants conditioned with indo sim .
[0124] Stimulation with IL-1 of explants conditioned with SEQ sim (0.06 and 0.18 mg/mL) did not increase media [PGE 2 ]. Media [PGE 2 ] was significantly lower in these explants compared with stimulated and unstimulated control explants ( FIG. 5 , A). In unstimulated explants media [PGE 2 ] was significantly lower in explants conditioned with SEQ sim (0.06 and 0.18 mg/mL) than in unstimulated controls ( FIG. 5 , B). There was no significant difference in media [PGE 2 ] between SEQ sim (0.06 and 0.18 mg/mL) and indo sim in both IL-1-stimulated and unstimulated explants.
[0125] There was no increase in media [PGE 2 ] subsequent to IL-1 exposure in explants conditioned with BO sim (0.06 and 0.18 mg/mL) ( FIG. 5 , A). Conditioning of IL-1-stimulated explants with BO sim (0.18 mg/mL) resulted in a significantly lower media [PGE 2 ] than stimulated controls. There was no significant effect of BO sim on unstimulated explants ( FIG. 5 , B).
[0126] NO: There was no significant change in media [NO] in unstimulated control explants. Exposure of control explants to IL-1 (10 ng/mL) resulted in a significant elevation of media [NO] at 24 (1.21±0.1 μg/mL) and 48 h (1.06±0.1 μg/mL). There was no significant effect of indo sim on [NO] in stimulated or unstimulated explants ( FIG. 7 ).
[0127] Discussion
[0128] These experiments assist in describing effects of the simulated digest of SEQ on cox 1, cox 2, iNOS, and aggrecan gene expression. The gene expression data can then be used to make predictions about the mechanism of action of SEQ.
[0129] Alterations in gene expression observed in IL-1-stimulated control explants showed a pattern consistent with an inflammatory response. IL-1 stimulation resulted in a small, non-significant increase in cox 1 expression coupled with a significant increase in cox 2 expression, as has been reported by other authors (Kydd et al., 2007).
[0130] As shown, indo sim showed a cox 1:cox 2 inhibition profile of about 2:1, which is consistent with its classification as a cox 1/2 inhibitor (Gerstenfeld et al., 2003). We have also shown that indo sim does not inhibit IL-1-induced iNOS expression, consistent with reports by other authors (Palmer et al., 1993). Nor did it influence IL-1-mediated aggrecan expression in IL-1-stimulated explants, an effect that has been reported in mechanically stressed cartilage explants (Iimoto et al., 2005).
[0131] These data characterize indomethacin as an effective anti-inflammatory predominately through cox inhibition. Its inability to reduce IL-1-mediated aggrecan expression and its augmenting effect on IL-1-mediated iNOS expression, however, suggest that cartilage exposed to indomethacin would continue to degenerate through decline in matrix formation and would suffer from increased nitric oxide-mediated cell death. Indeed these adverse effects have been reported in arthritic dogs using prophylactic indomethacin (Hungin and Kean 2001), and indomethacin is associated with worsening of some pathophysiological indicators of arthritis in humans (Rashad et al., 1989; Huakinsson et al., 1995). When indo sim was applied to cartilage explants in the current study, there was an increase in IL-1-mediated NO production, but this was not coupled with a decrease in cell viability.
[0132] The relative inhibitory profile of SEQ sim on cox 1:cox 2 expression was approximately 1:1 at both doses. In the experiments described herein, SEQ sim at the lower dose was comparable to indo sim as a cox 2 inhibitor, whereas the higher dose was a more effective inhibitor of cox 2 than indo sim . It is therefore predicted that SEQ sim should effectively inhibit PGE 2 production by IL-1-stimulated explants.
[0133] This inhibition was observed in the tissue culture explant experiment. Inhibition of IL-1-mediated PGE 2 production by SEQ sim -conditioned cartilage explants was significant at both doses, and was not statistically different from PGE 2 inhibition by indo sim . This provides an explanation for the observed clinical benefit of SEQ in relieving pain in arthritic patients (Rukwied et al., 2007; Zhao et al., 2007).
[0134] Earlier publications have reported that SC sim and NZGLM sim inhibit PGE 2 production by IL-1-stimulated cartilage explants (Pearson et al., 2007), and the data in this application shows that BO sim also has this effect. However, it is of interest that, with the exception of SC sim (0.18 mg/mL), cox 2 inhibition by the most effective dose of SEQ sim is stronger than any single constituents alone. This points to a synergistic relationship between the constituents.
[0135] Given the effective PGE 2 -inhibiting, and related cox-inhibiting properties of SEQ sim , the effects of SEQ sim on iNOS were investigated. With a standard ‘NSAID-like’ mechanism it is predicted that SEQ would also augment iNOS expression in IL-1-stimulated explants. In fact, the opposite was true, and SEQ sim was found to significantly and strongly inhibit iNOS expression.
[0136] The effect of IL-1 on cellular expression of iNOS and cox 2 is differentially regulated through activation of at least 2 Mitogen Activated Protein Kinases (MAPKs) (LaPointe and Isenovi 1999). Net expression of iNOS and cox 2 are at least partially dependent on the relative amounts of pericellular NO and PGE 2 (Shin et al., 2007). Thus, products which increase pericellular NO can effectively downregulate expression of cox 2, and vice versa (Shin et al., 2007; Kim et al., 2005). This provides some explanation as to why SEQ sim showed a significant inhibitory effect on iNOS while many of the individual constituents, including shark cartilage, Biota and NZGLM sim (0.18 mg/mL), actually upregulated expression of iNOS.
[0137] Conclusions
[0138] SEQ is capable of effectively downregulating RNA for iNOS and cox 2. Its effect on iNOS and cox 2 appears to be due to synergy between its four constituents, but it may be related to post-translational inhibition of NO production (Pearson et al., 2007).
[0139] Models of cartilage inflammation in horses are widely reported, and include intra-articular challenges such as lipopolysaccharide (Jacobsen et al., 2006), Freunds Complete Adjuvant (Toutain and Cester 2004) or Na-monoiodoacetate (Welch et al., 1991); or surgical disruptions including creation of osteochondral fragments (Frisbie et al., 2007), focal contusion impact injuries (Bolam et al., 2006) and ligamentous transsection (Simmons et al., 1999). While these models capably demonstrate maximal activation of a complexity of inflammatory mechanisms within cartilage and associated subchondral bone and soft tissues, they represent a predominately traumatic inflammatory response. They are less representative of the more subtle biochemical, functional and pathophysiological changes in incipient or sub-acute articular inflammation that characterize most cases of lameness in racing horses (Steel et al., 2006).
[0140] While non-steroidal anti-inflammatory drugs (NSAIDs) and corticosteroids remain important therapeutic resources for treatment of overt clinical lameness, nutraceuticals are becoming widespread as a therapeutic and prophylactic management strategy for horses with low-grade, sub-acute articular damage and for those at risk of developing articular problems (Trumble 2005; Neil et al., 2005). Most research reported on the efficacy and/or safety of these products in arthritis uses in vitro models (Pearson et al., 2007; Chan et al., 2006), or traumatic injury or clinical in vivo research in non-equine species (McCarthy et al., 2006; Cho et al., 2003). Though useful as screening tools, in vitro models cannot account for the systemic effects of a dietary product which may influence outcomes in the articular space.
[0141] The objectives of this section are to a) produce and characterize a reversible, sub-clinical model of IL-1-induced intra-articular inflammation in the horse with respect to PGE 2 and NO production, and GAG release from cartilage; and b) to apply this model to the evaluation of SEQ in mammals, particularly in horses.
[0142] Method
[0143] Diets:
[0144] SEQ powder was prepared by combining Abalone (AB), New Zealand Green Lipped Mussel (NZGLM), Shark cartilage (SC) and Biota oil (Interpath Pty Ltd, Australia) according to the composition provided in Table 2. SEQ mixed ration was prepared by combining SEQ powder (10 g/kg), molasses (20 g/kg) and flavoring (Essential Sweet Horse Essence D 2344. Essentials Inc. Abbotsford, BC.) (1 g/kg) to a sweet feed horse ration (Table 2), and blending in a diet mixer in 5 kg batches until fully mixed. Control ration (CON) was prepared using the same sweet feed diet blended with molasses (˜20 g/kg) and flavoring (1 g/kg).
[0145] Horses:
[0146] 11 healthy horses without signs of articular inflammation (3 thoroughbred, 8 standardbred; age 5-12 years; 10 geldings, 1 mare) were randomly allocated to either Group A (SEQ; 1.5 kg/day; n=6) or Group B (CON; 1.5 kg/day; n=5). The 28-day experiment consisted of two phases—Phase 1: pretreatment (14 days); Phase 2: treatment (14 days). Supplementation began on Day 0 and continued for the duration of the experiment ( FIG. 6 ). Sample collection occurred on days 0 (pre), 14 (inj-1), 15 (2 samples: inj-2—taken immediately before injection; inj-2-2—taken 8 h post-injection), 16 (day 1), 18 (day 3), 21 (day 7) and 28 (day 14); on these days blood was collected from the jugular vein, and synovial fluid was sampled from both intercarpal joints by aseptic arthrocentesis (see below). An inflammatory challenge—recombinant interleukin-1β (IL-1)—was injected into the left or right intercarpal joint on day 14 (inj-1; 10 ng in 500 μL sterile saline) and 15 (inj-2; 100 ng in 500 μL sterile saline). An equal volume of sterile saline was injected into the contralateral intercarpal joint. Joint circumference as an indicator of joint effusion was measured with a tape measure at each sampling of joint fluid.
[0147] All horses were turned out in paddocks during the day and housed in box-stalls overnight. They were bedded on wood shavings and offered hay, water and mineral salts ad libitum. All procedures were approved by the University of Guelph Animal Care Committee in accordance with guidelines of the Canadian Council on Animal Care.
[0148] Arthrocentesis: The knees of both the left and right legs were shaved, and the area aseptically prepared using chlorhexadine (4%), and rinsed with 70% isopropyl alcohol. A sterile 22 gauge, 1.5″ needle was inserted into the lateral aspect of the left intercarpal joint. A 3 cc sterile syringe was then attached, and approximately 1.5-2 mL of synovial fluid was aspired and immediately injected into a sterile K 2 -heparin vacutainer. The procedure was then repeated for the right intercarpal joint. On days 14 (inj-1) and 15 (inj-2), IL-1 (500 μL) was injected into either the right or left intercarpal (500 μL saline injected into contralateral joint) after aspiration of synovial fluid and before removal of the needle hub. Approximately 1.5 mL of synovial fluid was removed from the vacutainer and placed into a microcentrifuge tube and spun at 11,000×g for 10 minutes to remove cellular debris. Supernatant was placed into another microcentrifuge tube containing 10 μg indomethacin, and frozen at −80° C. until analyzed for PGE 2 , GAG and NO. Indomethacin was added to synovial fluid after it was collected in order to prevent further formation of PGE 2 during storage of samples. The remaining ˜0.5 mL synovial fluid was sent to the Animal Health Laboratory (University of Guelph) for cytological analysis.
[0149] Synovial Fluid Cytology
[0150] 1.0-1.5 mL of fluid was removed from the vacutainer for PGE 2 , NO and GAG analysis (see below), and approximately 0.5 mL was analyzed for total nucleated cell count (Coulter Z2 counter; Beckman Coulter Canada Inc. Mississauga ON), protein (refractometer) and cell differential (on 100 nucleated cells) at the Animal Health Laboratory.
[0151] Synovial Fluid [PGE 2 ]:
[0152] Synovial fluid was thawed to room temperature then incubated with 20 μL hyaluronidase (10 mg/mL) on a tube rocker for 30 minutes at 37° C. to digest hyaluronic acid. Sample was then diluted 1:2 with formic acid (0.1%), and centrifuged 12,000×g for 10 minutes. The supernatant was decanted and analyzed for PGE 2 by a commercially available ELISA kit (GE Amersham, Baie D'Urfé, Québec). PGE 2 was extracted from the sample using provided lysis reagents to dissociate PGE 2 from soluble membrane receptors and binding proteins, and then quantified according to kit protocol. Plates were read using a Victor 3 microplate reader (Perkin Elmer, Woodbridge ON) with absorbance set at 450 nm. A best-fit 3 rd order polynomial standard curve was developed for each plate (R 2 ≧0.99), and these equations were used to calculate PGE 2 concentrations for samples from each plate.
[0153] Synovial Fluid [GAG]:
[0154] Hyaluronic acid in synovial fluid samples were digested with hyaluronidase as described above. GAG concentration of synovial fluid was determined using a 1,9-DMB spectrophotometric assay as described by Chandrasekhar et al. (1987). Samples were diluted 1:3 with dilution buffer and placed into a 96-well microtitre plate. Guanidine hydrochloride (275 g/L) was added to each well followed immediately by addition of 150 μL, DMB reagent. Plates were incubated in the dark for 10 minutes, and absorbance was read on a Victor 3 microplate reader at 530 nm. Sample absorbance was compared to that of a bovine chondroitin sulfate standard (Sigma, Oakville ON). A best-fit linear standard curves was developed for each plate (R 2 ≧0.99), and these equations were used to calculate GAG concentrations for samples on each plate.
[0155] Synovial Fluid [NO]:
[0156] Nitrite (NO 2− ), a stable oxidation product of NO, was analyzed by the Griess reaction (Fenton et al., 2002). Undiluted TCM samples were added to 96 well plates. Sulfanilamide (0.01 g/mL) and N-(1)-Napthylethylene diamine hydrochloride (1 mg/mL) dissolved in phosphoric acid (0.085 g/L) was added to all wells, and absorbance was read within 5 minutes on a Victor 3 microplate reader at 530 nm. Sample absorbance was compared to a sodium nitrite standard.
[0157] Data Analysis and Presentation
[0158] Two-way repeated measures (RM) analysis of variance (ANOVA) was used to detect differences between treatments. When a significant F-ratio was obtained, the Holm Sidak post-hoc test was used to identify differences between treatments. One-way RM ANOVA was used to detect differences within treatments with respect to time. For blood and synovial fluid data, one-way comparisons of data were made against pre- and inj-1 data, as each represented baseline for diet and IL-1 injections, respectively. Data are presented as means±SEM. Graphs for biochemistry and hematology data are scaled to physiological reference intervals unless otherwise stated. Reference intervals are those published by the Animal Health Laboratory, University of Guelph (http://www.labservices.uoguelph.ca/units/ahl/files/AHL-userguide.pdf).
[0159] Results
[0160] Synovial Fluid
[0161] PGE 2 :
[0162] CON Horses:
[0163] There was no significant change in synovial fluid [PGE 2 ] in saline-injected joints at any time ( FIG. 7 , A). Relative to pre-injection concentrations, [PGE 2 ] was significantly increased at inj-2-2 (321.3±161.8 pg/mL; p=0.04) in IL-1-injected joints, at which time synovial fluid [PGE 2 ] was significantly higher in IL-1-injected joints than in saline-injected joints (p<0.001).
[0164] SEQ Horses:
[0165] Data represent n=5, as one outlier horse was removed from the analysis. PGE 2 did not change in saline-injected joints of SEQ horses. Like CON horses, there was a spike in [PGE 2 ] increased at inj-2-2 (175.4±89.2 pg/mL) in IL-1-injected joints of SEQ horses ( FIG. 7 , B). However, this increase was not significant when compared with pre-injection concentrations. PGE 2 response to saline injection was not different in SEQ horses compared with CON horses. There was no significant difference in PGE 2 response to IL-1 injection compared with saline in SEQ horses.
[0166] Although mean [PGE 2 ] at inj-2-2 in SEQ horses was approximately 55% that of CON horses, variability about the means resulted in no significant difference between diets.
[0167] GAG:
[0168] CON Horses:
[0169] Synovial fluid [GAG] increased in saline-injected joints between inj-1 (18.3±6.8 μg/mL) and day 1 (48.1±9.6 μg/mL) ( FIG. 8 , A). Injection of IL-1 (10 ng) caused a rapid and significant increase in synovial fluid [GAG] between inj-1 (24.5±7.3 μg/mL) and inj-2 (77.6±4.4 μg/mL). Synovial fluid [GAG] remained significantly elevated in IL-1-injected joints at inj-2-2 (66.0±9.6 μg/mL) and day 1 (53.3±11.4 μg/mL) compared with pre-injection concentrations. The magnitude of increase in synovial fluid [GAG] was significantly higher in IL-1-injected joints than in saline-injected joints (p=0.003).
[0170] SEQ Horses:
[0171] Synovial fluid [GAG] tended to increase (p=0.09) in both saline- and IL-1-injected joints between pre (saline: 29.3±5.9 μg/mL; IL-1: 27.0±10.8 μg/mL) and inj-1 (saline: 85.5±28.0 μg/mL; IL-1: 83.2±27.9 μg/mL), suggesting an effect of diet on synovial fluid [GAG] ( FIG. 8 , B). There was no change in synovial fluid [GAG] in saline- or IL-1-injected joints over the course of the experiment. There was no significant difference in synovial fluid [GAG] of IL-1-injected and saline-injected joints.
[0172] Synovial fluid [GAG] in IL-1- and saline-injected joints was significantly higher in SEQ horses than CON horses (p<0.001). This difference was mainly an effect of diet, and not an effect of IL-1, as evidenced by the fact that the majority of the increase occurred prior to any IL-1 injection.
[0173] NO:
[0174] CON Horses:
[0175] Synovial fluid [NO] was low and variable over the course of the experiment in both saline- and IL-1-injected joints. There was no significant effect of either saline or IL-1 injection on NO levels in CON horses over time (data not shown). The magnitude of synovial fluid [NO] was not different between IL-1- and saline-injected joints.
[0176] SEQ Horses:
[0177] There was no change in synovial fluid [NO] in IL-1- or saline-injected joints at any time over the course of the experiment. There was no significant difference between IL-1 or saline at any time.
[0178] There was no significant effect of diet on synovial fluid [NO] in IL-1- or saline-injected joints.
[0179] Synovial Fluid Cytology:
[0180] CON Horses:
[0181] Pre-injection total cell count (0.61±0.1×10 9 /L) was significantly elevated by provision of exogenous IL-1 (10 ng) at inj-2 (40.17±16.1×10 9 /L). Cell count was not further increased following the 2 nd IL-1 injection (100 ng), but remained slightly (but not significantly) elevated through day 1. Inj-1 cell count in saline-injected joints (0.6±0.2×10 9 /L) increased mildly, reaching a maximum at day 1 (6.0±2.6×10 9 /L), but this increase was not significant. Total cell counts of saline- and IL-1 injected joints were significantly different from each other at inj-2 [ie. 24 h after the 1 st IL-1 injection (10 ng)]. The increase in cell count was due mainly to an increase in the relative percentage of neutrophils. Percent neutrophils significantly increased in both IL-1- and saline-injected joints after the first injection. Neutrophil counts significantly declined in both IL-1- and saline-injected joints between day 1 and 3 without further increase for the remainder of the experiment. There was no difference in % neutrophils between IL-1- and saline-injected joints (data not shown).
[0182] SEQ Horses:
[0183] Pre-injection total cell count (0.4±0.03×10 9 /L) was significantly elevated by provision of exogenous IL-1 (10 ng) by inj-2 (27.5±8.7×10 9 /L). Cell count was not further increased by inj-2-2, but remained significantly elevated through day 1. Inj-1 total cell count in saline-injected joints (0.4±0.1×10 9 /L) increased mildly, reaching a maximum at inj-2-2 (4.0±2.6×10 9 /L), but this increase was not significant. Total cell counts of saline- and IL-1 injected joints were significantly different from each other at inj-2 (ie. 24 h after the 1 st IL-1 injection of 10 ng), inj-2-2 (ie. 8 h after the 2 nd IL-1 injection of 100 ng), and day 1 (ie. 24 h after the 2 nd IL-1 injection of 100 ng). Percent neutrophils significantly increased in both IL-1- and saline-injected joints after the first injection. Increase in neutrophil concentration of saline-injected joints may have been attributable to minor inflammation being caused by injection trauma. Neutrophil counts (%) significantly declined in both IL-1- and saline-injected joints between day 1 and 3 with a second significant spike on day 7. There was no difference in % neutrophils between IL-1- and saline-injected joints.
[0184] There was no significant difference in the effect of SEQ and CON diets on total cells counts or % neutrophils in IL-1- or saline-injected joints.
[0185] CON Horses:
[0186] Synovial fluid [protein] was significantly increased by injection of 10 ng IL-1 (20±0.0 g/L to 39.4±4.0 g/L) ( FIG. 9 , A). [Protein] was not further increased by injection of 100 ng IL-1, and significantly declined 24 h after the 100 ng injection. Injection of saline also resulted in a significant increase in [protein] immediately after the first injection, returning to baseline concentrations by day 1 (25.5±1.5 g/L). The magnitude of increase in [protein] over the course of the experiment was significantly higher in IL-1-injected than saline-injected joints (p=0.01).
[0187] SEQ Horses:
[0188] Injection of 10 ng IL-1 resulted in a significant increase in synovial fluid protein on inj-2 (38.7±4.9 g/L), inj-2-2 (36.2±4.4 g/L), and day 1 (27.8±3.8 g/L) compared with inj-1 (20±0 g/L) ( FIG. 9 , B). There was no further effect of the 2 nd IL-1 injection of 100 ng on [protein]. Saline injection also resulted in a significant increase in [protein] on inj-2-am (27.5±3.0 g/L) and inj-2-pm (25.8±2.5 g/L) compared with inj-1 (20.6±0.6 g/L). The magnitude of increase in synovial fluid [protein] was significantly higher in IL-1-injected joints than in saline-injected joints (p=0.003).
[0189] There was no significant difference in the effect of SEQ and CON diets on synovial fluid [protein] in IL-1- or saline injected joints.
[0190] Joint Circumference:
[0191] CON Horses:
[0192] There was no significant change in circumference over time in IL-1- or saline-injected joints, and there was no significant difference in joint circumference between IL-1- and saline-injected joints ( FIG. 10 , A).
[0193] SEQ Horses:
[0194] There was a significant increase in joint circumference in IL-1-injected joints between inj-1 (31.1±0.2 cm) and inj-2 (31.9±0.5 cm) in SEQ horses ( FIG. 10 , B). Joint circumference remained significantly elevated at inj-2-2 (31.7±0.4 cm) before declining to pre-injection levels. Exactly the same pattern was shown in the saline-injected joints of SEQ horses.
[0195] Joint circumference of IL-1-injected joints was significantly lower in SEQ horses than CON horses (p<0.001).
[0196] Discussion
[0197] This data shows a minimally invasive, reversible model of early stage articular inflammation that can be used to evaluate putative anti-inflammatory nutraceuticals.
[0198] The double IL-1 injection protocol resulted in a statistically significant increase in PGE 2 at 8 h after the 2 nd injection. None of the CON horses were overtly lame at the walk or brief trot at any time during the experiment, despite mean peak synovial fluid [PGE 2 ] (498 pg/mL) being commensurate with that associated with lameness in horses (488 pg/mL; de Grauw et al., 2006). The increase in PGE 2 was not accompanied by a concomitant increase in NO. This provides a possible explanation as to why these horses were not lame, as transmission and perception of nociceptive pain occurs predominately as a result of combined effect of elevated PGE 2 and NO. CON horses may have demonstrated a low-grade lameness had they been subjected to moderate exercise, but this was not undertaken due to the confounding effect of exercise on synovial fluid [PGE 2 ] (van den Boom et al., 2005). The observed increase in synovial fluid [PGE 2 ] in CON horses provides good evidence for a low-grade IL-1-induced inflammation within the joint. We hypothesized that this increase would be blunted by dietary provision of an efficacious anti-inflammatory nutraceutical.
[0199] Trafficking of inflammatory cells and release of glycosaminoglycan into the synovial fluid were more sensitive to stimulation with IL-1 than production of PGE 2 , as an increase in synovial fluid [GAG] and [neutrophils] was observed 24 h after the initial 10 ng IL-1 injection. Synovial fluid [protein] was also elevated immediately after the 1 st IL-1 injection. These parameters were not further increased by provision of a higher IL-1 challenge. These responses are consistent with a ‘pre-arthritic’ inflammatory state (Adarichev et al., 2006). Genes turned on in the early stage of arthritis are predominately those associated with transcription of chemokines, cytokines (notably, IL-1), and metalloproteinases, notably, MMP-13 and MMP-9. Chemokines are potent signals for inflammatory cell migration into the synovial space. As synoviocytes and endothelial cells of the synovial membrane become activated to express cell adhesion molecules and produce chemokines, neutrophil extravasation into the joint space greatly increases, as was observed in the studies described herein as a steep increase in synovial fluid [neutrophils]. Cells of the synovial membrane also become more permeable to serum proteins (Middleton et al., 2004) resulting in the observed rapid increase in synovial fluid [protein]. MMP-13 (Yammani et al., 2006) and MMP-9 (Soder et al., 2006) are key degradative enzymes in articular cartilage, and the increase in IL-1-induced synovial fluid [GAG] observed in the current study support studies demonstrating substantial upregulation of genes encoding these enzymes in early arthritis (Adarichev et al., 2006; Kydd et al., 2007). Micro-array analysis of pre-arthritic cartilage in PG-stimulated mice revealed that genes encoding for phospholipase C 2 , the enzyme catalyzing release of arachidonic acid from nuclear membranes, was not elevated (Adarichev et al., 2006). This may explain, at least in part, why PGE 2 required a longer time course for elevation subsequent to IL-1 stimulation than cell migration and release of GAGs.
[0200] Intra-articular challenge with IL-1 did not result in a consistent increase in synovial fluid nitric oxide. IL-1-induced nitric oxide has been frequently reported in cartilage explant models (Pearson et al., 2007; Petrov et al. 2005), cells taken from animal models of acute articular inflammation (Kumar et al., 2006) and clinical cases of articular inflammation (Karatay et al., 2005). This data provides support for evidence that genes encoding inducible nitric oxide synthase are not upregulated in early stage arthritis (Kydd et al., 2007), which delays IL-1-induced formation of nitric oxide.
[0201] SEQ provided protection to IL-1-stimulated joints as evidenced by: 1) no significant increase in synovial fluid [PGE 2 ]; 2) increased [GAG] in the synovial fluid prior to IL-1 challenge, then preventing IL-1-induced increase in GAG; and 3) limited effusion into the joint space subsequent to IL-1 challenge.
[0202] As part of the diet for 2 weeks prior to an intra-articular IL-1 challenge, SEQ prevented significant elevation in IL-1-induced PGE 2 . Similar to CON horses, PGE 2 response to IL-1 in SEQ horses peaked at 8 h after the second IL-1 injection, but the peak was lower, and did not result in statistically significant changes over time or significant differences between IL-1 and saline injection. This shows that SEQ reduces inflammation and pain associated with elevated PGE 2 in horses with early stage arthritis, and implies that feeding SEQ to horses prior to articular damage may impede progression of the disease to a more advanced stage.
[0203] The observed increase in synovial fluid [GAG] of SEQ horses in both saline- and IL-1-injected joints between pre and inj-1—ie. before inflammatory challenge—provides evidence for the post-absorptive accumulation of dietary GAGs within the synovial space.
[0204] The effectiveness of SEQ in preventing biochemical indicators of early-stage arthritis results from a synergistic effect of its four ingredients.
[0205] Published reports have reported significant improvement in arthritic signs in dogs provided with dietary NZGLM (Pollard et al., 2006), and significant protection by glucosamine and chondroitin—the major bioactive constituents of SC—of cartilage explants against degradation by IL-1 (Dechant et al., 2005). However, the in vitro PGE 2 -inhibitory effect of SEQ is greater than that of any of its four constituents alone, per gram of product (Pearson et al. unpublished), suggesting a level of synergism between the ingredients.
[0206] Fractionation of Biota Oil
[0207] Chromatography
[0208] Oil from the seeds of Biota Orientalis was fractionated using an Agilent 1200 Preparative HPLC equipped with a diode array detector and an automated fraction collector. The column used was an Agilent Prep C18, 10 μm (30×250 mm) with the following gradient at a flow rate of 20 ml/minute with a 900 μL injection of Constituent 4. 0-5 minutes 80% water 20% Acetonitrile. 5-7 minutes Gradient change to 10% water 90% Acetonitrile, 7-25 minutes isocratic 10% water 90% Acetonitrile. Fraction detection was achieved at 254 nm.
[0209] Mass Spectrometry:
[0210] The mass spectrometry detection was performed on an Agilent 6210 MSD Time of Flight mass spectrometry in both positive and negative ion mode. The following electrospray ionization conditions were used, drying gas: nitrogen (7 mL min-1, 350° C.); nebuliser gas: nitrogen (15 psi); capillary voltage: 4.0 kV; vaporization temperature: 350° C. and cone voltage: 60V.
[0211] FIG. 14 shows the chromatographic spectrum of the oil, and various fractions were collected and numbered as shown.
[0212] (B) Anti-Inflammatory Potential of Fractions from Biota Oil
[0213] To study the anti-inflammatory activities, assays Fr 1, Fr i, Fr V and Fr Vi were selected and tested at a concentration of ≦64 μg/ml. The assays carried out to measure the 1) Nitric Oxide (NO) levels, 2) prostaglandin PGE2 levels, 3) prostaglandin PGF2α levels. NHAC cells at passage 3, were stimulated first with proinflammatory cytokine IL-1β at a predetermined concentration 10 ng/ml overnight, NHAC Cells were then treated with fractions in the presence of IL-1β 10 ng/ml for 24 hours and cell culture supernatant was collected to measure NO, PGE2 and PGF2α levels. Griess Reagent Kit for Nitrite Determination (Molecular Probes, Invitrogen) was used as per kit instructions. For estimation of PGs, High Sensitivity PGE2 & PGF2α EIA kits (Assay Designs Inc.) were used.
[0214] As shown in FIG. 15 , fractions 1 (Fr 1), Fr I, and Fr V reduced the NO levels (highly significant) in a dose dependent manner. Fr1 was found to be the most effective among all the four fractions with Fr Vi the least effective, although still showing some effect.
[0215] The non steroidal anti inflammatory drug Indomethacin used as a positive control significantly reduced the IL-1β induced PGE2 levels. All the four fractions had no effect on these levels at any of the concentrations tested ( FIGS. 16 & 17 ).
[0216] Indomethacin significantly reduced the IL-1β induced PGF2α levels. Fr 1 showed no effect at all on the PGF2α levels, while Fr i, Fr V and Fr Vi reduced these levels, in a dose dependent manner (64-32 μg/ml) ( FIGS. 18 & 19 ).
[0217] The effectiveness of the biota oil extract fractions has until now not been known. The use of the compounds of F1.1-1.4 either separately or as a mixture with one or more of the other fractions provides for a remarkable improvement in the treatment of conditions, such as osteoarthritis.
[0218] Any improvement may be made in part or all of the method steps and systems components. All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended to illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. Any statement herein as to the nature or benefits of the invention or of the preferred embodiments is not intended to be limiting, and the appended claims should not be deemed to be limited by such statements. More generally, no language in the specification should be construed as indicating any non-claimed element as being essential to the practice of the invention. This invention includes all modifications and equivalents of the subject matter recited as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contraindicated by context.
[0219] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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BACKGROUND OF THE INVENTION
Conventionally, there are a variety of physical remedy apparatuses including the one that diminishes subcutaneous fat from abdomen for promoting weight-reduction beauty treatment like a device that discharges either pressurized air or water from the tip of nozzle for stimulating abdomen using applied pressure for example, or such a device that diminishes subcutaneous fat from abdomen by promoting blood circulation simultaneous with stimulation by controlling temperature of pressurized air or water to either raise or lower temperature. Nevertheless, these conventional devices still had problems to solve. More particularly, any of these devices needed a large-scale supplementary units such as a compressor for generating a specific pneumatic or hydraulic pressure. Since provision of any supplentary unit unavoidably results in the enlarged configuration of the entire system, it prevents households from easily using any of these.
OBJECT OF THE INVENTION
The primary object of the present invention is to provide a novel thermoelectric physical remedy apparatus which is capable of effectively applying stimulation to abdomen and promoting faster blood circulation and perspiration to eventually diminish or remove superfluous flesh from abdomen by repeating hot and cold temperature cycles by placing junction pieces onto abdomen via cloth by effectively causing junction pieces to be heated and cooled by means of Peltier effect by inversing the polarity of DC power-supply source applied to the thermoelectric elements like thermomodule for example.
Another object of the present invention is to provide a novel thermoelectric physical remedy apparatus which allows any household to easily use it by dispensing with any of large-size supplementary units a compressor otherwise needed for any conventional systems, thus resulting in the significantly compact constitution of the entire unit.
A still another object of the present invention is to provide a novel thermoelectric physical remedy apparatus which is capable of easily switching the junction pieces from the heated condition (i.e., generation of heat) to the cooled condition (i.e., absorption of heat) by merely shifting the direction of DC powder source applied to said thermoelectric electric elements between the positive and negative poles by switching means for example.
A still further object of the present invention is to provide a novel thermoelectric physical remedy apparatus which is capable of promoting the heat absorption and radiation effect by allowing air to pass through a ventilation path formed inside of soft-material external housing covering the thermoelectric elements.
A still further object of the present invention is to provide a novel thermoelectric physical remedy apparatus which is capable of executing multifunctional treatments merely by applying this apparatus using soft-material external housing that can smoothly come into contact with any affected part including hands, legs, and other body parts suffering from either contusion, sprain, or muscular fatigue, in addition to abdomen part for diminishing subcutaneous fat.
Still further objects of the present invention will be better understood from the detailed description given hereinbelow and the accompanying drawings which are provided by way of illustration only, and thus are not limitative of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the perspective view of the thermoelectric physical remedy apparatus denoting one of the preferred embodiments of the present invention;
FIG. 2 is the sectional view of the thermoelectric physical remedy apparatus reflecting one of the preferred embodiments of the present invention; and
FIG. 3 is the simplified block diagram denoting the constitution of the circuit of the thermoelectric physical remedy apparatus related to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more particularly to the accompanying drawings, one of the preferred embodiments of the present invention is described below.
Drawings denote the constitution of the thermoelectric physical remedy apparatus related to the present invention, in which FIG. 1 denotes that the thermoelectric physical remedy apparatus is provided with controller unit 1 and thermoelectric part 2. Housing 3 of the controller unit 1 is provided with temperature-adjusting knob 4, cooling switch 5, heating switch 6, automatic cold-temperature switch 7, and connector 9 of the connection cable 8.
As shown in FIGS. 1 and 2, the thermoelectric part 2 is provided with the following: Ventilation apertures 10 and 10 in both ends in its length direction, belt-like external cover 12 made from soft polyvinyl chloride internally provided with ventilation path 11, blower fans 14 and 14 provided inside of ventilation apertures 10 and 10 of the belt-like external cover 12 via supporter member 13, and a total of 10 pieces of thermo-modules 15 which are substantially the thermoelectric elements aligned in two rows on the front surface of the belt-like external cover for example.
Each of these thermo-modules (or called thermoelements) 15 contains a plurality of metal pieces or metallic compound pieces being connected to each other in series between upper and lower flat ceramic plates with the lower ceramic plate being shown at 15a. These thermo-modules 15 are respectively held by a flexible belt-like external cover, in which the flat ceramic plates 15a functioning as junction pieces are external bared as shown in FIG. 1. A plurality of heat-radiating fins 16 are provided for the internal surface of each thermo-module 15. Each of these thermo-modules 15 radiates and absorbs heat by applying the incoming DC current in accordance with Peltier effect. Functions of the thermo-modules used for the thermoelectric physical remedy apparatus related to the present invention are denoted by the equation show below;
Q=βI
where Q denotes the quantity of heat generated and/or absorbed, I denotes the DC current flowing through these elements, and β denotes proportional constant corresponding to Peltier coefficient.
Note that Peltier coefficient β is equal to the multiple of Seebeck coefficient α and the absolute temperature, i.e., β=αT. When the direction of the flowing DC current is inversed, generation of heat is converted into aborption of heat and vice versa.
Normally, each of these thermo-modules 15 is heated to a specific temperature corresponding to the sum of normal temperature and 20° through 25° C. to a maximum of 100° C. during the heating cycle. Conversely, when the cooling cycle is entered, temperature is lowered to a certain level about 15° C. below the normal temperature to a minimum of -20° C.
FIG. 3 is the simplified block diagram of the thermoelectric electric physical remedy apparatus related to the present invention. The commercial power-supply circuit 17 feeding 100 V AC for example is connected to the following full-wave rectifier circuit 18 incorporating diode bridge, smoothing capacitor, and other elements for example in order that the commercial AC power can be rectified and smoothened into the designated DC current by the full-wave rectifier circuit 18.
This circuit 18 is connected to the following DC-voltage control circuit 19 including temperature-adjusting knob 4. The DC-voltage control circuit 19 generates about 7 V DC/2A of the rated DC power source, while it also variably controls DC voltage and current output from the circuit 19 itself by applying voltage-varying volume connected to knob 4.
The output terminal of this DC-voltage is connected to switching circuit 20 containing switches 5 through 7, while the switching circuit 20 is connected to blower fan 14 and each of these thermo-modules 15 via connection cable 8.
When cooling switch 5 of the switching circuit 20 is activated, each of these thermo-modules 15 absorbs heat. When heating switch 6 is activated, each of these thermomodules generates heat, whereas when the automatic cold-hot temperature alternating switch 7 is activated, each of these thermo-modules alternately executes generation and absorption of heat at about 1 minute intervals.
Referring now to the accompanying drawings, functions of the thermoelectric physical remedy apparatus related to the present invention are described below.
For example, to diminished superfluous flesh from abdomen part of a man, belt-like external cover securing a plurality of thermo-modules and being made from soft PVC material is first placed onto the abdomen part via underwears. Next, he turns the power switch (not shown) ON and rotates the temperature-adjusting knob 4 to a desired position, and then when he turns the automatic hot-cold temperature alternating switch ON, each of these thermo-modules alternately repeats heating and cooling cycles at about 1 minute intervals.
By repeatedly and alternately applying hot and cold temperature at specific intervals, stimulation is repeatedly applied to the abdomen part, while simultaneously promoting faster blood circulation and perspiration as well, and a result, superfluous flesh can eventually be eliminated from the abdomen part.
In particular, since the thermoelectric physical remedy apparatus embodied by the present invention dispenses with a large-dimensional compressor otherwise needed for any conventional apparatus of this kind, the entire apparatus related to the present invention can be built in a compact size, thus allowing anyone to easily operate it at home.
In addition, unlike a conventional hot-temperatureapplied moxa cautery, by turning the DC current delivered to each of these thermo-modules 15 over to either of switches 5 and 6 or to the automatic hot-cold temperature alternating switch 7 of switching circuit 20, the junction piece 15a can easily be switched from the heated condition (generation of heat) into the cooling condition (absorption of heat). This is extremely effective for applying remedy like elimination of subcutaneous fat for example.
Furthermore, the thermoelectric physical remedy apparatus related to the present invention provides the ventilation path 11 formed inside of the belt-like external cover 12 with wind generated by blower fan 14. This effectively prevents heat from remaining inside of the belt-like external cover 12 and each thermo-module 15 from being heated. In particular, when the automatic hot-cold temperature alternating switch 7 is activated, ventilation wind effectively prevents thermal interference from occuring between hot-and-cold temperature cycles.
In addition, since the preferred embodiment of the invention employs the belt-like external cover 12 made from soft PVC material, in addition to abdomen part mentioned above, the flexible soft belt-like external cover 12 can smoothly fit against any affected part such as hands, legs, and other parts sufffering from either contusion, sprain, or muscular fatigue, and the like, thus allowing the apparatus to provide multifunctional physical treatments.
Furthermore, as described earlier, a plurality of ventilation apertures 10 are provided in vertical edges of both sides in the length direction of the belt-like external cover 12. The preferred embodiment provides a plurality of blower fans 14 and 14 inside of the apertures 10 and 10. Even when the user wears clothes above the belt-like external cover 12 of the thermoelectric physical remedy apparatus related to the invention while operating it, ventilation effect cannot be obstructed by clothes. In particular, the belt-like external cover 12 made from soft PVC material securely insulates the power-connected parts from the human body.
In addition to those objects of applying the apparatus related to the invention thus far described, the apparatus can also effectively be made available for cooling the human heat and other portions in place of a water pillow or an ice bag.
The present invention being thus described, however, it will be obvious that the same may be varied in may ways. Such variations are not regarded to be a departure from the spirit and scope of the invention, while all such modifications and variations are intended to be included within the scope of the following claims. | The present invention relates to a thermoelectric physical remedy apparatus applicable to physical remedy processes for dealing with weight-reduction beauty-treatment like removal of superfluous flesh from abdomen for example, contusion, sprain, muscular fatigue, and others, which features compact size of the entire unit, easy application in house holds, and easy switching between high and low temperature by means of covering thermoelectric elements with the externally exposed junction pieces of thermoelectric elements as well as by providing soft external housing unit containing ventilation path. | 0 |
This is a continuation of International Application PCT/CN2010/073703, with an International Filing Date of Jun. 9, 2010, which claims priority to Chinese Application No. 200910260372.7, filed Dec. 17, 2009, each of which is incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to the technical field of mobile terminal devices, and in particular to a system, a method and a mobile terminal for sharing a battery between mobile terminals.
BACKGROUND OF THE INVENTION
As a portable device, a mobile terminal is more frequently used than other portable devices and has become the most frequently used portable device of a user and a main carrier for the communication, information management and entertainment of the user. Due to the characteristics of a portable device, the mobile terminal, whose power supply is realized by means of a built-in battery, usually does not use an external power supply to supply power after being charged. Therefore, the continuous using time of the mobile terminal is completely determined by the electricity quantity of the battery in the device. With respect to a portable device, the using time of the battery is an important technical reference index.
Currently, the power supply of the mobile terminal is basically based on the built-in rechargeable battery in the mobile terminal. Even for mobile terminals of the same type, their batteries are used independently. When one mobile terminal runs out of power, it is only possible to take out the battery of another mobile terminal and then replace the battery of the mobile terminal, which runs out of power, with the battery of the another mobile terminal, however, the another mobile terminal can not be used at the same time, causing inconvenience to the users. Therefore, in a working environment without charging fittings and with special requirements, the user desires to use the mobile terminals simultaneously when a mobile terminal runs out of power.
SUMMARY OF THE INVENTION
The present invention provides a system, a method and a mobile terminal for sharing a battery between mobile terminals, so as to address the problem that the battery can not be shared between mobile terminals in the prior art.
To solve the technical problem above, in one aspect, a system for sharing a battery between mobile terminals is provided, which comprises a mobile terminal of a power supply end and a mobile terminal of a power utilization end; wherein,
the mobile terminal of the power supply end comprises a battery of the power supply end, a circuit interface of the power supply end and a power supply control unit of the power supply end, wherein the power supply control unit of the power supply end is coupled with the battery of the power supply end and the circuit interface of the power supply end respectively;
the mobile terminal of the power utilization end comprises a battery of the power utilization end, a circuit interface of the power utilization end, a power supply control unit of the power utilization end and a power management unit of the power utilization end, wherein the power management unit is coupled with the battery of the power utilization end and comprises a power supply switch subunit;
wherein the circuit interface of the power utilization end is coupled with the circuit interface of the power supply end; the power supply control unit of the power supply end is configured to control the battery of the power supply end to supply power to the mobile terminal of the power utilization end through the circuit interface of the power supply end;
the power supply switch subunit, coupled with the circuit interface of the power utilization end, the battery of the power utilization end and the power supply control unit of the power utilization end respectively, is configured to control the circuit interface of the power utilization end or the battery of the power utilization end to couple with the power supply control unit of the power utilization end; and the power supply control unit of the power utilization end is configured to supply power to the mobile terminal of the power utilization end.
Preferably, the mobile terminal of the power supply end further comprises:
a charging control unit of the power supply end, coupled with the battery of the power supply end, configured to perform charging control to the battery of the power supply end; and
a power supply interface control unit, coupled between the circuit interface of the power supply end and the power supply control unit of the power supply end in series and coupled with the charging control unit of the power supply end, configured to control the circuit interface of the power supply end to couple with the charging control unit of the power supply end or the power supply control unit of the power supply end.
Preferably, the power management unit further comprises: a charging and power supply mode control subunit and an electricity quantity detection switch subunit sequentially coupled between the circuit interface of the power utilization end and the power supply switch subunit in series, and an electricity quantity detection subunit coupled with the electricity quantity detection switch subunit; the mobile terminal of the power utilization end further comprises a charging control unit of the power utilization end coupled with the battery of the power utilization end; wherein,
the charging control unit of the power utilization end is configured to perform charging control to the battery of the power utilization end;
the charging and power supply mode control subunit, coupled with the charging control unit of the power utilization end, is configured to control whether the mobile terminal of the power supply end charges the battery of the power utilization end when the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end; and
the electricity quantity detection switch subunit is configured to control the electricity quantity detection subunit to detect an electricity quantity of the battery of the power utilization end or an electricity quantity of the battery of the power supply end.
In another aspect, a method for sharing a battery between mobile terminals is provided, comprising:
a mobile terminal of a power supply end supplying power to a mobile terminal of a power utilization end through a circuit interface of the power utilization end; and
the mobile terminal of the power utilization end opening a power supply circuit of the battery of the power utilization end and closing a power supply circuit of the circuit interface of the power utilization end at the same time, thus enabling the mobile terminal of the power supply end to supply power to the mobile terminal of the power utilization end.
Preferably, before the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, the method further comprises the steps of:
the mobile terminal of the power utilization end determining whether to charge the battery of the power utilization end in the mobile terminal of the power utilization end, if yes, coupling the circuit interface of the power utilization end with a charging circuit; if no, breaking a coupling between the circuit interface of the power utilization end and the charging circuit.
Preferably, during the procedure that the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, the method further comprises the steps of:
the mobile terminal of the power utilization end detecting and displaying an electricity quantity of the battery of the power supply end of the mobile terminal of the power supply end.
In another aspect, a mobile terminal is provided, the mobile terminal comprises a battery of a power supply end, and the mobile terminal further comprises:
a circuit interface of the power supply end; and
a power supply control unit of the power supply end, coupled with the battery of the power supply end and the circuit interface of the power supply end respectively, configured to control the battery of the power supply end to supply power externally through the circuit interface of the power supply end.
Preferably, the mobile terminal further comprises:
a charging control unit of the power supply end, coupled with the battery of the power supply end, configured to perform charging control to the battery of the power supply end; and
a power supply interface control unit, coupled between the circuit interface of the power supply end and the power supply control unit of the power supply end in series, and coupled with the charging control unit of the power supply end, configured to control the circuit interface of the power supply end to couple with the charging control unit of the power supply end or the power supply control unit of the power supply end.
In another aspect, a mobile terminal is provided, comprising a battery of a power utilization end and a power management unit which is coupled with the battery of the power utilization end and comprises a power supply switch subunit, the mobile terminal further comprises a circuit interface of the power utilization end and a power supply control unit of the power utilization end; wherein,
the circuit interface of the power utilization end is configured to couple with an external power supply device;
the power supply switch subunit, coupled with the circuit interface of the power utilization end, the battery of the power utilization end and the power supply control unit of the power utilization end respectively, is configured to control the circuit interface of the power utilization end or the battery of the power utilization end to couple with the power supply control unit of the power utilization end; and
the power supply control unit of the power utilization end is configured to supply power to the mobile terminal.
Preferably, the power management unit further comprises a charging and power supply mode control subunit and an electricity quantity detection switch subunit sequentially coupled between the circuit interface of the power utilization end and the power supply switch subunit in series, and an electricity quantity detection subunit coupled with the electricity quantity detection switch subunit; the mobile terminal further comprises a charging control unit of the power utilization end coupled with the battery of the power utilization end; wherein,
the charging control unit of the power utilization end is configured to perform charging control to the battery of the power utilization end;
the charging and power supply mode control subunit, coupled with the charging control unit of the power utilization end, is configured to control whether the external power supply device charges the battery of the power utilization end when the external power supply device supplies power to the mobile terminal of the power utilization end; and
the electricity quantity detection switch subunit is configured to control the electricity quantity detection subunit to detect an electricity quantity of the battery of the power utilization end or an electricity quantity of a battery of the external power supply device.
In accordance with the present invention, a mobile terminal having power supplying ability is able to supply power to a mobile terminal lacking power by an external power supply line, power control circuits of the power supply end and the power utilization end are controlled, the power utilization end is able to detect an electricity quantity of the power supply end, and the sharing of a battery between two mobile terminals can be achieved, thereby greatly increasing utilization modes of the battery without external charging power supply so as to facilitate the utilization of a user.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the structure of a mobile terminal of a power supply end in accordance with an embodiment of the present invention;
FIG. 2 is a schematic diagram of the structure of a mobile terminal of a power utilization end in accordance with an embodiment of the present invention;
FIG. 3 is a schematic diagram of the structure of another mobile terminal of a power supply end in accordance with an embodiment of the present invention;
FIG. 4 is a schematic diagram of the structure of another mobile terminal of power utilization end in accordance with an embodiment of the present invention;
FIG. 5 is a flowchart of a method for sharing a battery between mobile terminals in accordance with an embodiment of the present invention;
FIG. 6 is a flowchart when a mobile terminal of a power supply end supplies power externally in accordance with an embodiment of the present invention; and
FIG. 7 is a flowchart when a mobile terminal of a power utilization end receives power from external in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
To solve the problem that the battery can not be shared between mobile terminals in the prior art, a system, a method and a mobile terminal for sharing a battery between mobile terminals are provided in the present invention, which will be detailed hereinafter in conjunction with the accompanying figures and the embodiments. It shall be understood that the embodiments described herein are only to illustrate the present invention, rather than limit it.
As shown in FIGS. 1 and 2 , Embodiment 1 of the present invention relates to a system for sharing a battery between mobile terminals, comprising a mobile terminal of a power supply end and a mobile terminal of a power utilization end. The structure of the mobile terminal of the power supply end is as shown in FIG. 1 , comprising a battery 103 of the power supply end, a circuit interface 101 of the power supply end and a power supply control unit 102 of the power supply end, wherein the power supply control unit 102 of the power supply end is coupled with the battery 103 of the power supply end and the circuit interface 101 of the power supply end respectively. The structure of the mobile terminal of the power utilization end is as shown in FIG. 2 , comprising a battery 204 of the power utilization end, a circuit interface 201 of the power utilization end, a power supply control unit 203 of the power utilization end and a power management unit 202 , wherein the power management unit 202 is coupled with the battery 204 of the power utilization end and comprises a power supply switch subunit 2021 .
The circuit interface 201 of the power utilization end is coupled with the circuit interface 101 of the power supply end; the power supply control unit 102 of the power supply end is configured to control the battery 103 of the power supply end to supply power to the mobile terminal of the power utilization end through the circuit interface 101 of the power supply end;
the power supply switch subunit 2021 , coupled with the circuit interface 201 of the power utilization end, the battery 204 of the power utilization end and the power supply control unit 203 of the power utilization end respectively, is configured to control the circuit interface 201 of the power utilization end or the battery 204 of the power utilization end to couple with the power supply control unit 203 of the power utilization end; and the power supply control unit 203 of the power utilization end is configured to supply power to the mobile terminal of the power utilization end.
When the mobile terminal of the power supply end supplies power locally, namely when the mobile terminal of the power supply end does not enable its battery sharing function thereby not supplying power to the mobile terminal of the power utilization end, the battery 103 of the power supply end in the mobile terminal of the power supply end is coupled with the power supply control unit 102 of the power supply end, and supplies power locally through the power supply control unit 102 of the power supply end. When the mobile terminal of the power supply end enables its battery sharing function thereby supplying power to the mobile terminal of the power utilization end, the battery 103 of the power supply end, the power supply control unit 102 of the power supply end and the circuit interface 101 of the power supply end are coupled serially in sequence, at this time, the power supply control unit 102 of the power supply end realizes, on the premise of ensuring the local power supply to the mobile terminal of the power supply end, the function of supplying power to the mobile terminal of the power utilization end through the circuit interface 101 of the power supply end connected with the mobile terminal of the power utilization end.
When the mobile terminal of the power utilization end supplies power through the battery 204 of the power utilization end, the power supply switch subunit 2021 of the power management unit 202 is coupled with the battery 204 of the power utilization end, thus enabling the power of the battery 204 of the power utilization end to supply power to the mobile terminal of the power utilization end locally through the power supply switch subunit 2021 and the power supply control unit 203 of the power utilization end coupled with the power supply switch subunit 2021 . When the battery 204 of the power utilization end runs low or down, the circuit interface 101 of the power supply end is coupled with the circuit interface 201 of the power utilization end through a power supply line, so that the battery 103 of the power supply end in the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end. A power supply voltage no higher than a local voltage of the mobile terminal of the power supply end can be provided by controlling the output voltage of the circuit interface 101 of the power supply end through the power supply control unit 102 of the power supply end, thus supplying power to the mobile terminal of the power utilization end with a power supply voltage no higher than the above local voltage. At this time, the power supply switch subunit 2021 breaks its coupling with the battery 204 of the power utilization end and couples with the circuit interface 201 of the power utilization end, thus the power provided by the battery 103 of the power supply end is supplied to the power supply control unit 203 of the power utilization end through the circuit interface 101 of the power supply end, the circuit interface 201 of the power utilization end and the power supply switch subunit 2021 . The power supply control unit 203 of the power utilization end adjusts the voltage and the electricity quantity according to parameters (such as voltage, current and electricity quantity) used by the mobile terminal of the power utilization end and finally supplies power to the mobile terminal of the power utilization end. The sharing of the battery 103 of the power supply end between the mobile terminals of the power supply end and the power utilization end is realized, and the purpose of using the two mobile terminals of the power supply end and the power utilization end simultaneously is reached.
In addition, since most of the mobile terminals use rechargeable battery or require data transfer, a mobile terminal is usually provided with a charging interface or a data interface. Due to the requirements for the portability of a mobile terminal, they are limited in size and interface quantity. Moreover, considering that the charging interface or some data interfaces can be used as power supply interface, the additional use of the charging interface or data interfaces on the mobile terminal of the power supply end as the circuit interface 101 of the power supply end is designed in the embodiment.
As shown in FIG. 3 , on the basis of the embodiment above, the mobile terminal of the power supply end further comprises: a charging control unit 105 of the power supply end and a power supply interface control unit 104 , wherein the charging control unit 105 of the power supply end is coupled with the battery 103 of the power supply end; the power supply interface control unit 104 is coupled serially between the circuit interface 101 of the power supply end and the power supply control unit 102 of the power supply end and is coupled with the charging control unit 105 of the power supply end. The charging control unit 105 of the power supply end is configured to perform charging control to the battery 103 of the power supply end; and the power supply interface control unit 104 is configured to control the circuit interface 101 of the power supply end to couple with the charging control unit 105 of the power supply end or the power supply control unit 102 of the power supply end. Namely, when the circuit interface 101 of the power supply end is used as a charging interface, the power supply interface control unit 104 controls the circuit interface 101 of the power supply end to couple with the charging control unit 105 of the power supply end, and breaks the coupling between the circuit interface 101 of the power supply end and the power supply control unit 102 of the power supply end. In this way, the battery 103 of the power supply end can be charged and can supply power locally through the power supply control unit 102 of the power supply end.
When the circuit interface 101 of the power supply end is coupled with the power supply line, the user configures to enable the battery sharing function of the mobile terminal of the power supply end to supply power to the mobile terminal of the power utilization end. Namely, when the circuit interface 101 of the power supply end is used as the power supply interface, the power supply interface control unit 104 breaks the coupling between the circuit interface 101 of the power supply end and the charging control unit 105 of the power supply end, couples the circuit interface 101 of the power supply end with the power supply control unit 102 of the power supply end, reads configuration parameters such as voltage, and configures the power supply control unit 102 of the power supply end. Thus the battery 103 of the power supply end can supply power externally through the circuit interface 101 of the power supply end when simultaneously supplying power locally through the power supply control unit 102 of the power supply end.
Moreover, when the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, there may exist a case that the mobile terminal of the power utilization end cannot be coupled with the mobile terminal of the power supply end through the power supply line for a long period of time, so the user has the requirement of charging the mobile terminal of the power utilization end by the mobile terminal of the power supply end. In addition, when the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, the residual electricity quantity of the battery 103 of the power supply end is critical to the mobile terminal of the power supply end and the mobile terminal of the power utilization end, so it is necessary to detect the residual electricity quantity of the battery 103 of the power supply end, so as to remind the user to conduct corresponding operation. In view of the above, the mobile terminal of the power utilization end is further designed in the embodiment of the present invention.
As shown in FIG. 4 , on the basis of the embodiment above, the mobile terminal of the power utilization end also comprises a charging control unit 205 of the power utilization end coupled with the battery 204 of the power utilization end; the power management unit 202 also comprises a charging and power supply mode control subunit 2022 , an electricity quantity detection switch subunit 2023 and an electricity quantity detection subunit 2024 , wherein the charging and power supply mode control subunit 2022 and the electricity quantity detection switch subunit 2023 are coupled serially between the circuit interface 201 of the power utilization end and the power supply switch subunit 2021 in sequence, and the electricity quantity detection subunit 2024 is coupled with the electricity quantity detection switch subunit 2023 . The charging control unit 205 of the power utilization end is configured to perform charging control to the battery 204 of the power utilization end; the charging and power supply mode control subunit 2022 is coupled with the charging control unit 204 of the power utilization end and is configured to control whether the mobile terminal of the power supply end charges the battery 204 of the power utilization end when the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end; and the electricity quantity detection switch subunit 2023 is configured to control the electricity quantity detection subunit 2024 to detect the electricity quantity of the battery 103 of the power supply end or the electricity quantity of the battery 204 of the power utilization end.
After the circuit interface 201 of the power utilization end in the mobile terminal of the power utilization end is coupled with the power supply line, firstly, the mobile terminal of the power utilization end determines whether to charge the battery 204 of the power utilization end when the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, if the answer is yes, the charging and power supply mode control subunit 2022 controls the circuit interface 201 of the power utilization end to couple with the charging control unit 205 of the power utilization end so as to charge the battery 204 of the power utilization end through the charging control unit 205 of the power utilization end, and simultaneously keeps the coupling between the circuit interface 201 of the power utilization end and the power supply switch subunit 2021 so as to supply power to the mobile terminal of the power utilization end; if the answer is no, the charging and power supply mode control subunit 2022 breaks the coupling between the circuit interface 201 of the power utilization end and the charging control unit 205 of the power utilization end, and only keeps the coupling between the circuit interface 201 of the power utilization end and the power supply switch subunit 2021 so as to supply power to the mobile terminal of the power utilization end.
When the mobile terminal of the power utilization end is supplied with power through the battery 204 of the power utilization end, the electricity quantity detection switch subunit 2023 controls the electricity quantity detection subunit 2024 to detect an end voltage of the battery 204 of the power utilization end and a voltage attenuation, estimate a capacity of the battery 103 of the power supply end, write the estimated capacity in a PMU status register for the access of an UI (User Interface), and display the current electricity quantity. During the procedure that the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, the electricity quantity detection switch subunit 2023 controls the electricity quantity detection subunit 2024 to detect the end voltage of the battery 103 of the power supply end and the voltage attenuation, estimate the capacity of the battery 103 of the power supply end, write the estimated capacity in the PMU status register for the access of the UI, and display the current electricity quantity.
It can be seen from the embodiment above that, through supplying power to the mobile terminal of the power utilization end by the mobile terminal of the power supply end, the embodiment of the present invention achieves sharing the battery of the power supply end between the mobile terminals of the power supply end and the power utilization end, reduces the hardware added by the additional use of the interfaces, simplifies the structure and realizes the function of charging to the battery of the power utilization end, thus facilitating using of a user.
As shown in FIG. 5 , Embodiment 2 of the present invention relates to a method for sharing a battery between mobile terminals, comprising the steps as follows.
S 301 , a mobile terminal of a power supply end supplies power to a mobile terminal of a power utilization end through a circuit interface of the power utilization end.
As shown in FIG. 6 , if a charging interface of the mobile terminal of the power supply end is additionally used as the circuit interface of the power supply end in the mobile terminal of the power supply end, the step above comprises the steps as follows.
S 3011 , after the mobile terminal of the power supply end is coupled with the mobile terminal of the power utilization end through a power supply line, a power supply mode is enabled.
S 3012 , since the circuit interface of the power supply end is used as a charging interface when the mobile terminal of the power supply end does not supply power externally, the circuit interface of the power supply end is coupled with a charging circuit, namely the circuit interface of the power supply end is coupled with the charging control unit of the power supply end so as to charge the battery of the power supply end through the charging control unit of the power supply end. When the mobile terminal of the power supply end supplies power externally, the circuit interface of the power supply end is not used as a charging interface any more, thus it is required to break the coupling between the circuit interface of the power supply end and the charging circuit.
S 3013 , since a rated operational voltage in normal operation may vary with different mobile terminals, it is required to determine whether to configure a voltage reduction parameter before supplying power to the mobile terminal of the power utilization end, if the answer is yes, turn to S 3014 , otherwise, turn to S 3015 .
S 3014 , the voltage reduction parameter is configured according to parameters such as rated operational voltage and rated operational current of the mobile terminal of the power utilization end, and then turn to S 3016 .
S 3015 , the current voltage parameter of the battery of the power supply end is used, and turn to S 3016 .
S 3016 , the circuit interface of the power supply end is coupled with a discharge circuit of the battery of the power supply end, namely the circuit interface of the power supply end is coupled with the battery of the power supply end through the power supply control unit of the power supply end.
S 3017 , the power supply control unit of the power supply end supplies power, through the circuit interface of the power supply end, to the mobile terminal of the power utilization end connected with it when locally supplying power to the mobile terminal of the power supply end at the same time.
S 302 , the mobile terminal of the power utilization end opens a power supply circuit of the battery of the power utilization end and closes a power supply circuit of the circuit interface of the power utilization end.
As shown in FIG. 7 , in the case that the mobile terminal of the power supply end is also required to charge the battery of the power utilization end when supplying power to the mobile terminal of the power utilization end, S 302 specifically comprises the steps as follows.
S 3021 , power supply of the mobile terminal of the power supply end enters to supply power to the mobile terminal of the power utilization end.
S 3022 , firstly, it is determined whether it is required to charge the battery of the power utilization end in the mobile terminal of power utilization end when the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end, if it is required to do so, keep the coupling between the circuit interface of the power utilization end and the charging circuit, namely keep the coupling between the circuit interface of the power utilization end and the charging control unit of the power utilization end, then turn to S 3024 ; if it is not required to do so, turn to S 3023 .
S 3023 , the coupling between the circuit interface of the power utilization end and the battery of the power utilization end is broke, namely the coupling between the circuit interface of the power utilization end and the charging control unit of the power utilization end is broke, and then turn to S 3024 .
S 3024 , it is determined whether the mobile terminal of the power utilization end enables the battery sharing function, namely it is determined whether the mobile terminal of the power utilization end has an external power input, if the mobile terminal of the power utilization end has the external power input, it indicates that the battery sharing function is enabled, turn to S 3025 ; if the mobile terminal of the power utilization end has no external power input, it indicates that the battery sharing function is disabled, turn to S 3026 .
S 3025 , the mobile terminal of the power utilization end detects the end voltage of the battery of the power supply end in the mobile terminal of the power supply end and the voltage attenuation, estimates the capacity of the battery of the power supply end, writes the estimated capacity in the PMU status register for the access of the U 1 , and finally displays the current electricity quantity.
S 3026 , the power supply circuit of the battery of the power utilization end is opened (namely the coupling between the battery of the power utilization end and the power supply switch subunit of the PMU is broke), and at the same time the power supply circuit of the circuit interface of the power utilization end is closed (namely couple the circuit interface of the power utilization end with the power supply switch subunit).
S 3027 , the end, namely the circuit that the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end is completed.
S 303 , the mobile terminal of the power supply end supplies power to the mobile terminal of the power utilization end.
The using of USB (Universal Serial Bus) as circuit interfaces of the power supply end and the power utilization end is taken as an example to detail the solution of the embodiment.
Currently, the mobile terminals are usually provided with USB interfaces for data transfer and charging. A standard USB interface provides a voltage of 5V and an output current of 0.5A, and has 4 effective leads of two data cables and two power cords, wherein the power cords are coupled to the PMU pins respectively for charging and power supply. The USB interface of the mobile terminal of the power supply end is additionally used as the power supply circuit interface. The method for sharing a battery between mobile terminals comprises the steps as follows.
1. the USB interface is additionally used as the power supply circuit interface of the mobile terminal of the power supply end.
A USB interface control switch is added to control a charging circuit (power management unit, PMU) and a discharge circuit of the battery of the power supply end coupled with the USB interface. The user can configure the control switch to control the USB interface to couple with the charging circuit or the discharge circuit. If the battery of the mobile terminal provides an output voltage of 4.2V, the USB interface, in the case of coupling with the discharge circuit, can provide an output voltage of 4.2V. If a power supply IC is coupled serially, the interface can be controlled to provide an output voltage no higher than 4.2V by controlling the power supply IC. Or a diode can be coupled serially to provide a voltage output reduced to a fixed value.
2. the USB interface of the mobile terminal of the power utilization end is coupled with the PMU of the mobile terminal of the power utilization end. The PMU can control the closing or opening of the charging circuit and power supply circuit of the battery of the power utilization end by programming to switch the power supply and charging modes. The PMU can also control the range of the input voltage and reduce the input voltage to the allowable voltage range of the mobile terminal of the power utilization end, thus providing conforming current to supply power to the mobile terminal of the power utilization end. For example, if the power supply voltage of the mobile terminal of the power utilization end is 3.9V, the power supply circuit will provide a voltage output of 3.9V through voltage reduction. The charging circuit refers to the circuit involved in charging the battery of the power utilization end; and the power supply end refers to the circuit involved in supplying power to the mobile terminal of the power utilization end.
3. through configuring the mobile terminal of the power utilization end in battery sharing mode, the PMU switches the electricity quantity detection to entered power supply line so as to detect the voltage attenuation of the battery of the power supply end, estimate the capacity of the battery of the power supply end and write the estimated capacity into the status register of the PMU for the access of the UI and the display of the current electricity quantity.
It shall be known from the description above that, through the method, the existing interface can be additionally used with a few hardware added and low cost increased which can achieve battery sharing, especially in the case of no available charging fittings, can enrich the using modes of the battery between mobile terminals. Moreover, by way of controlling the mobile terminal of the power utilization end, the power supply voltage can be configured flexibly, ensuring the safe use of the mobile terminal of the power utilization end. The mobile terminal of the power utilization end can simulate the battery capacity of the mobile terminal of the power supply end by detecting the input voltage so as to facilitate using of a user. The mobile terminal of the power utilization end can be switched between the power supply mode and charging/power supply mode through configuration, which can utilize the battery capacity of the mobile terminal of the power supply end effectively and facilitate using of a user.
Although the preferable embodiments of the present invention are disclosed for exemplary purpose, those skilled in the art shall realize that various improvements, addition and replacement may be possible. Therefore, the scope of the present invention shall not be limited to the embodiments above. | A system, a method, and a mobile terminal for sharing a battery between mobile terminals are disclosed, which can solve a problem that the battery can not be shared between mobile terminals in the prior art. In accordance with the present invention, a mobile terminal having power supplying ability is able to supply power to a mobile terminal lacking power by an external power supply line, power control circuits of the power supply end and the power utilization end are controlled, the power utilization end is able to detect an electricity quantity of the power supply end, and the sharing of a battery between two mobile terminals can be achieved, thereby greatly increasing utilization modes of the battery without external charging power supply so as to facilitate the using of a user. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of art to which this invention pertains is oil recovery methods using surfactants and mobility control of surfactant slugs in oil recovery processing. Relevant art is contained in U.S. Classification 166-273, 274, and 275.
2. Detailed Description of the Prior Art
Relevant prior art includes additive compositions including those characterized as water-insoluble mineral oil additives which are produced from the reaction of alkenyl-substituted succinic acid anhydrides and a tertiary amine as disclosed in U.S. Pat. No. 2,588,412. Oil-soluble polyvalent metal salts of an alkenyl-succinic acid monoamide are also disclosed in U.S. Pat. No. 2,458,425. Both of these patents are classified in U.S. Classification 260-561 and are limited to the use of such materials as additives for mineral oil or lube oil uses.
It has been recognized in the petroleum industry that oil recovery methods using surfactants can be used to effectively remove oil from a subterranean reservoir which has been subjected to straight water flooding or polymer flooding operations. Without the use of surfactants or materials which can help remove this oil from the interstitial spaces within the reservoir, it is essentially non-recoverable.
The art has also recognized that when using surfactants many problems exist when these materials are used in reservoirs of elevated temperatures (temperatures around 140° F. or higher). An especially acute problem which results when passing surfactants into high-temperature reservoirs is that they will lose viscosity and will not perform to their optimum capabilities. Accordingly, then, mobility control additives are useful when added to such surfactant materials. Such thickening agents include materials such as heteropolysaccharides produced by the bacteria of the genus Xanthomonas. More particularly, such materials are disclosed in U.S. Pat. No. 3,964,972.
The use of thickeners in surfactant slugs in disclosed, at least concerning using the polysaccharide materials, in U.S. Pat. No. 3,719,606 in which microemulsions of oil-soluble alkali metal sulfonates are used along with co-surfactants and from about 0.05 to about 1 per cent by weight of a polysaccharide to enhance the viscosity of the microemulsion for improved oil recovery.
Some of the thickening agents now present on the market, including materials such as hydrolyzed polyacrylamides or copolymers of sodium acrylates or methacrylates and acrylamide, generally are not good candidates for use in surfactant slugs for oil recovery since in many instances these materials are not compatible with materials such as crude oil sulfonates, gas oil sulfonates of aliphatic polymer sulfonates. Many of the polyacrylamide-type materials when mixed with sulfonate surfactants precipitate forming coagulated gels which may increase the residual resistance of an oil-containing reservoir to a point that moving additional fluid through it becomes very difficult if not impossible.
Many of the thickeners used, such as the polysaccharides or other water-soluble polymers, themselves do not contain sufficient surfactant properties to be used in a surfactant slug without reducing the surfactant's ability to move oil unless additional surfactant is used.
It would therefore be advantageous to use water-soluble thickeners which also possess surfactant properties in order that an increase in the viscosity of a surfactant fluid could be attained without losing surfactant properties by dilution of the surfactant by the water-soluble polymer. Accordingly, the present invention attains this ideal situation by including, in one instance, in a surface-acting fluid a viscosity-enhancing additive material which also contains sufficient surfactant moieties in order to act both as a viscosity thickening agent and a surfactant agent.
In another instance, the present invention provides a surfactant which possesses sufficient viscosifying properties in order that it may be used by itself in certain instances for recovery of oil from oil reservoirs where high viscosity surfactants are necessarily needed.
SUMMARY OF THE INVENTION
The present invention can be summarized as a process for moving oil in a subterranean oil-bearing formation by contacting the formation with an aqueous fluid containing a succinamate surface-active agent having the following general formula: ##STR1## wherein R 1 is alkenyl; each R 2 is independently selected from hydrogen, lower alkyls, hydroxyl-substituted lower alkyls and hydroxyl-substituted ethoxylated lower alkyls; R 3 is selected from O or O--SO 3 ; and X is a cation.
The present invention can also be summarized as a process for moving oil in a subterranean oil-bearing formation which comprises contacting said formation with an aqueous fluid containing an anionic surfactant which incorporates as an improvement in the process an amount of a succinamate surface-active agent having the above general formula to enhance the viscosity of the resulting aqueous fluid for improved oil recovery from said reservoir.
It is an object of the present invention to present a process for moving oil from a subterranean oil-bearing formation by using a surface-active agent comprising an alkenyl succinamate compound.
It is another object of the present invention to provide increased viscosity to an aqueous fluid which contains an anionic surfactant, especially sulfonate materials, which comprises incorporating into the aqueous fluid containing said surface-active agent an additional surface-active agent also containing viscosifying properties which comprises an alkenyl succinamate surface-active agent.
In a broad embodiment, the present invention resides in a process for moving oil from an oil-bearing formation which comprises injecting into the formation an aqueous fluid containing an effective amount of succinamate surface-active agent having the following general formula: ##STR2## wherein R 1 is alkenyl having an average molecular weight in the range of from about 150 to about 600; each R 2 is independently selected from hydrogen, lower alkyls, hydroxyl-substituted lower alkyls, hydroxyl-substituted ethoxylated lower alkyls; R 3 is O or OSO 3 ; and X is a cation.
Another embodiment of our invention resides in a process for moving oil from an oil-bearing formation which comprises injecting into the formation an aqueous fluid containing an effective amount of an anionic surfactant, an improvement in such process which comprises incorporating into the aqueous fluid an effective amount of succinamate surface-active agent having the following general formula: ##STR3## wherein R 1 is alkenyl having an average molecular weight in the range of from about 150 to about 600; each R 2 is independently selected from hydrogen, lower alkyls, hydroxy-substituted lower alkyls, hydroxyl-substituted ethoxylated lower alkyls; R 3 is O or OSO 3 and X is a cation.
These and other objects and embodiments of the present invention will be more fully explained after a review of the below detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The succinamate surface-active agent incorporated as a surfactant for recovery of oil from oil-bearing formations or when used in conjunction with another anionic surfactant (preferably sulfonates) to increase the viscosity of such material is generally selected and represented by the following general formula: ##STR4##
The R 1 substituent in the above formulation is generally an alkenyl material having an average molecular weight of from about 150 to about 600. In particular, this material can be produced as an aliphatic polymer from the cationic polymerization of olefinic materials such as butene-1, or butene-2, or mixtures thereof. Depending upon the extent of polymerization and the catalyst and reaction conditions utilized, the R 1 substituent will possess a varying range of molecular weights. It is necessary that the molecular weight range of the R 1 and R 2 substituents be selected so as to not unduly interfere with the solubility of the produced succinate for both oil and water. A certain balance of solubility for water and oil is needed when this material is used either as a surface-active surfactant by itself or in conjunction with an anionic surfactant as a thickening agent possessing surfactant properties.
In some instances the R 1 alkenyl substituent itself can have radicals substituted thereon and still be considered an overall alkenyl substituent. For instance, there may be side chains of lower alkyl radicals or halide or other substituents present on this material as long as it does not unduly interfere with the basic property of this material, that is, possessing sufficient molecular weight for use in the present invention.
Especially useful R 1 substituents include materials produced from viscous polybutene polymers having average molecular weights, depending upon their source. Materials specifically contemplated will have average molecular weights of around 280, 320, 340, and 420. These specific molecular weights are those from commercially available viscous polybutenes. However, other sources of such viscous polymers are not precluded, as are other molecular weight materials in variance from those described above. Polypropylene is an excellent choice for the R 1 substituent.
Each R 2 substituent is independently selected from hydrogen, lower alkyls having less than about 7 carbon atoms per molecule, hydroxyl-substituted lower alkyls and hydroxyl-substituted ethoxylated lower alkyls, etc. In particular, lower alkyl materials which can comprise each R 2 substituents include materials such as normal and isopropyl radicals, normal butyl radicals, ethyl radicals, which themselves may contain hydroxyl substituents, variously ethoxylated amyl alcohols, or mixtures thereof.
The R 3 substituent is generally selected from --O-- or --OSO 3 -- radicals depending upon the particular synthesis involved in production of the succinamate material.
In the above formula X is represented as a cation and can be selected from those cations known in the art including alkali metals such as sodium, potassium, lithium, materials such as ammonium, or cations formed from primary, secondary or tertiary amines NH 3 NH 2 + , ammonium RNH 3 --; ##STR5## where R,R 4 and R 5 selected from lower alkyl, or other cations known in the art.
The succinamates described above can generally be prepared from the "ENE" reaction of maleic anhydride with polybutenes of average molecular weights of from about 100 to about 600 or greater. The resulting alkenyl succinic anhydride is then reacted, preferably in a nonaqueous environment, anywhere from about 0.7 to about 1.6 equivalents of ammonia, primary or secondary amines to give an intermediate half-acid, half-amide material. This adduct can then be neutralized with caustic, ammonia or amines (0.8 to 1.0 equivalents) to give the succinamate product as illustrated in the structure above.
The formation of the intermediate half-acid, half-amide should generally be carefully controlled especially when using primary amines or ammonia to prevent formation of imides or other major side reaction products. In the case of ammonia the reaction with the anhydride should be performed under pressure.
When using the claimed succinamate as the primary surface-active agent in miscible flooding for recovery of crude oil from underground formations, it is preferable to mix such surfactant with the connate water recovered from the reservoir or from the brine available from other sources. The aqueous mixture of succinamate in the brine is then pumped into a reservoir under well-known operating conditions to cause enhanced recovery of oil from the reservoir. Specifically, concentrations of the succinamate in the brine can vary on a weight basis of anywhere from a few to 25 or more weight percent of the total aqueous surfactant mixture injected into the formation. Additional components can be added to the aqueous mixture. These include cosurfactant materials known in the art including water-soluble alcohols such as isopropyl alcohol, the oil-soluble alcohols containing no more than about 10 carbon atoms, and the 2 to 12 mole ethylene oxide adducts of primary alcohols and amines having from 4 to 16 carbon atoms, including such materials as n-butanol, 2-ethylhexanol, n-hexanol, n-octanol, n-decanol, and the like. In general, it is preferred to use the 6 to 8 mole ethylene oxide adducts of n-hexanol. Other cosurfactant materials can be used and are well known in the art.
The cosurfactants can vary anywhere from few tenths of a percent to 25 weight percent or more of the succinamate material when it is the primary surface-active agent used in the miscible flooding process.
When the succinamate is used as an additive component in an aqueous mixture containing another anionic surfactant, its concentration can vary depending upon its molecular weight, reservoir conditions and type of other anionic surfactant used, from less than 1 to 200 or more percent by weight of the other anionic surfactant or surfactants. The effective amount of succinamate surface-active agent comprises about 1 to 15 weight percent of the aqueous fluid. The succinate can be present in the aqueous fluid in a weight ratio of succinate to anionic surfactant of from about 0.1 to 1.5. Specifically, when the succinamate material is incorporated with other surfactants, these materials can include materials such as the sulfonates produced from 700° to 1100° F. fractions of crude oil as described in U.S. Pat. No. 3,302,713; overbased alkyl aromatic-type sulfonates as described in U.S. Pat. No. 3,965,984; petroleum sulfonates having specific ratios of aliphatic to aromatic protons as described in U.S. Pat. No. 3,997,451; and other alkyl aromatic ether sulfonates, especially those described in U.S. Pat. No. 3,977,471; and other surfactants well known to those in the art.
In instances in which the succinamate material described above is itself used in an aqueous mixture as the primary surfactant for treating a reservoir, or in instances in which the succinamate is added to an anionic surfactant, it is preferable that the aqueous mixture containing the surfactant be followed by a mobility buffer slug. The mobility buffer slug is preferably an aqueous solution containing one or more mobility reducing agents including materials such as partially hydrolyzed high molecular weight polyacrylamides, high molecular weight polyalkylene oxide polymers, high molecular weight acrylamide polymers containing sulfo groups, copolymers of sodium acrylate or sodium methacrylate and acrylamide, biopolymers especially the polysaccharides, and other materials well-known in the art. The conditions under which these mobility buffers slugs are used will vary depending upon the reservoir conditions. In view of the well-known use of such materials, it is not necessary to further explain the specific manner in which these materials are used.
A water-drive can be injected into the reservoir to displace the aqueous mixture which contains the succinamate either as the primary surfactant or in combination with an anionic surfactant.
The following examples are presented to illustrate specific embodiments of the present invention and should not be used to unduly limit the scope of the claims.
EXAMPLE I
In this example sodium diethanolamine polybutene succinamates were used as surfactants in sodium chloride solutions having varying concentrations of brine. A vial screening method was used to determine general operability of the succinates as surfactants.
The aqueous solutions used for testing were made by dissolving four to five grams of the above succinamate in about 45 grams of brine. The brines possessed sodium chloride salinities ranging from 0.2 N to 1.7 N. In some cases cosurfactants were added to adjust fluid stability in the indicated weight ratios.
The above succinamate was produced by reacting polybutenes having the indicated average molecular weight with maleic anhydride. The resulting polybutene succinic anhydride was then reacted with diethanol amine to give an intermediate half-acid, half-amide. This material was then neutralized with caustic to give the indicated succinamate.
The vial screening method was performed by placing twenty grams of the aqueous solution containing the above succinamate surfactant in a small vial. Then two grams of a crude oil (Salt Creek Second Wall Creek Field in Wyoming) was placed in the vial. The vial was then gently turned over and it was observed whether or not the crude goes into the aqueous surfactant mixture or drops out of the solution entirely. The latter observation is indicative of a very high interfacial tension between the crude and aqueous surfactant phases and would generally indicate a poor recovery potential for crude from the pore volume of a subterranean formation.
If the crude and aqueous phases dissolve in each other or smear together than a low interfacial tension between the two phases can be predicted and an excellent miscibility rating is given. If some oil drops out of the aqueous solution a borderline miscibility rating is given. The miscibility of crude and aqeuous surfactant phases will sometimes fall between the two extremes and with a certain amount of skill can be generally given a moderate qualification as to interfacial tension with the crude.
The Table below indicates the relative range of miscibilities to the indicated brine concentrations. The surfactants tested were mixed in the indicated weight ratios with an ethoxylated cocoamine sold under the trade name "Armak C/25 Ethomeen." The R 1 substituents were polybutene having the indicated average molecular weights. The general structure of the succinamate is shown below: ##STR6##
TABLE I______________________________________Average Weight RatioMolecular Succinamate to Brine Concentration (N)Weight of R.sub.1 Cosurfactant 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.7______________________________________280 20/1 ... ... ----280 10/1 ...---------320 20/1320 15/1340 10/1...______________________________________ ------------ Excellent Miscibility ......... Borderline Miscibility
EXAMPLE II
In this example three miscellar solutions were made from a sodium salt of a polybutene sulfonate and, where indicated, a succinamate material. The sulfonate was about 49 percent active sulfonate, and had an average equivalent weight in the range of from about 400-450 with the equivalent weight ranging from about 200 to about 1000.
Each solution was made adding 5.3 grams of the above polybutene sulfonate to 50 grams of a sodium chloride brine having a specified sodium chloride concentration. To each solution was added 8 ppt, based on the brine, of a 6-mole ethoxylated hexyl alcohol cosurfactant. In instances where a succinamate was incorporated into the solution, the polybutene sulfonate quantity was reduced by the amount of succinamate added. The base solutions are identified below:
Solution I -- 0.3 N Brine
Solution II -- 0.4 N Brine
Solution III -- 0.6 N Brine
EXAMPLE III
In this example viscosity measurements were made on mixtures of the polybutene sulfonate of Example II containing sodium diethanolamine succinamate and compared to solutions containing the polybutene sulfonate alone.
The viscosity measurements were made with a Brookfield spinning viscometer having a Thermosel attachment for performing tests at 140° F. (62° C.) using a No. 18 spindle.
The succinamate used was prepared generally as described and had the following structural formula: ##STR7## where R 1 is polypropylene having an average molecular weight of about 500. This material is prepared by reacting a viscous polypropylene polymer having an average molecular weight of about 500 with maleic anhydride. The resulting succinic anhydride is then reacted with diethanol amine to produce a half-acid, half-amide which is thereafter neutralized with caustic.
TABLE II__________________________________________________________________________Micellar Fluid Viscosity (CPS) Using BrookfieldDescription No. 18 SpindleSolution Grams Polybutene Grams of 140° F. Room Temp. Sulfonate Succinamate 6rpm 12rpm 30rpm 1.5rpm 3rpm 6rpm__________________________________________________________________________I 5.3 -- 37 26 17 -- -- --I 4.1 1.2 g. 36 24 14 -- -- --II 5.3 -- 46 29 17 -- -- --II 4.1 1.2 g. 35 30 24 232 153 99II 4.1 1.2 g. -- 36 18 -- -- --III 5.3 -- -- 20 16 -- -- --III 4.1 1.2 89 44 22 400 200 100III 4.1 1.2 -- 46 29 308 158 100__________________________________________________________________________
EXAMPLE IV
In this Example the viscosity for base solutions II and III as described in Example II was measured at various shear rates at 140° F. and compared with a fluid which contained 4.1 g. polybutene sulfonate and 1.2 g. of the succinamate described in Example III. As noted in Example II the base solutions contained co-surfactant.
TABLE III______________________________________ Shear Rate ViscosityFluid Description (Sec..sup.-1) (CPS)______________________________________Solution II (5.3 g. Polybutene 8 31Sulfonate) 16 25" 40 18" 79 12Solution II (4.1 g. Polybutene 8 35Sulfonate + 1.2 G. Succinamate) 16 28" 40 20" 79 13Solution III (5.3 g. Polybutene 8 22Sulfonate) 16 20" 40 16" 79 13Solution III (4.1 g. Polybutene 8 60Sulfonate + 1.2 g. Succinamate) 16 42" 40 21" 79 14______________________________________ | A method is disclosed for moving and eventually recovering oil from a subterranean oil-bearing formation which comprises injecting into the formation an aqueous fluid containing a succinamate surface-active agent and method for mobility control (imparting viscosity) to a surfactant system used for recovery or moving of oil in an oil-bearing formation. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a time division multiplex (TDM) communication system and, in particular, to a frame phase alignment for use in a system.
In the TDM communication system, a plurality of data signals or channel signals are time-division multiplexed with each other to form a frame signal together with a transport overhead signal for controlling transportation of the data signals in the frame signal. That is, a frame format of the frame signal consists of a plurality of time slots. Some of the time slots are assigned for carrying the transport overhead signal and are called an overhead portion. The remaining time slots are assigned for carrying the data signals, respectively, and are called a subframe portion.
The data signals have different channel numbers and are assigned to the time slots in the subframe portion in the order of the channel numbers. Therefore, when a particular one of the time slots is indicated for carrying a leading one of the data signals, the remaining time slots are automatically determined for individually carrying the remaining data signals.
In order to indicate the position of the particular time slot in the frame signal, the overhead portion has information of the number of time slots from the overhead portion to the particular time slot which information is called a message pointer or a data pointer.
In the TDM communication system, a plurality of TDM signals are required to be synchronized with each other in order to, for example, perform exchange or switching between time slots in those TDM signals. To this end, a frame aligner is conventionally used in the TDM communication system.
A known frame aligner comprises a buffer memory in which an input frame signal is stored and is then read from the buffer memory under control of a frame synchronous signal on an output side, which will be referred to as an output frame synchronous signal, so that the input frame signal is phase shifted and is reproduced with a different frame phase synchronized with the output frame synchronous signal as an output frame signal. Thus, a plurality of TDM signals are synchronized with each other by use of frame aligners using a common output frame synchronous signal.
However, the known frame aligner has a disadvantage that the buffer memory has a memory capacity sufficient to store are of a single frame signal. Furthermore, when a large phase difference is between the input and the output frame signals, a large delay is caused at the buffer memory and therefore results in degradation of the signal in performance.
The TDM communication system sometimes deals with frame signals which are different from or asynchronous with each other in bit rates or clocks. In order to perform the frame phase alignment of those different TDM signals, it is required that those TDM signals are previously matched to each other in the bit rate.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and a system which enable the frame phase alignment with a reduced resultant delay in use of a buffer memory of a reduced memory capacity.
It is another object of the present invention to provide a frame phase aligner which enables frame alignment between frame signals of different bit rates.
According to the present invention, a method is obtained which is for phase-aligning a time-division multiplexed signal as an input frame signal to an output frame synchronous signal to produce an output frame signal, a frame format of the input frame signal consisting of an input subframe portion carrying a plurality of channel signals and an input overhead portion carrying a transport overhead signal for controlling transport of the channel signals, the input overhead portion comprising an input frame synchronous signal. The method comprises steps of: separating the input overhead portion as a separated overhead portion from the input frame signal, the channel signals of the input subframe portion being sequentially stored in a buffer memory as a stored channel signals; making an output overhead portion determined by a phase difference between the input and the output synchronous signals in response to the separated overhead portion; delivering the output overhead portion into a portion in the output frame signal in response to the output frame synchronous signal; and reading the stored channel signals from the buffer memory as read channel signals to deliver the read channel signals into the remaining portion in the output frame signal, so that the output frame signal consists of the output overhead portion and an output subframe portion carrying the read channel signals.
The present invention provides a device for phase-aligning a time-division multiplexed signal as an input frame signal to an output frame synchronous signal to produce an output frame signal, a frame format of the input frame signal consisting of an input subframe portion carrying a plurality of channel signals and an input overhead portion carrying a transport overhead signal for controlling transport of the channel signals, and the input overhead portion comprising an input frame synchronous signal. The device comprises: separating means receiving the input frame signal for separating the input frame signal into the input overhead portion and the input subframe portion as a separated overhead portion and a separated subframe portion, respectively; storing means coupled to the separating means for storing the separated subframe portion; making means coupled to the separating means and responsive to the separated overhead portion and the output frame synchronous signal for making an output overhead portion determined by a phase difference between the input and the output synchronous signals; and multiplexing means coupled to the storing means and the making means and responsive to the output frame synchronous signal for delivering the output overhead portion into a portion of the output frame signal, the multiplexing means reading the stored channel signal from the storing means as read channel signals to deliver the read channel signals into the remaining portion of the output frame signal, so that the output frame signal consists of the output overhead portion and an output subframe portion carrying the read channel signals.
Further, the present invention provides a device for phase-aligning an input time-division multiplexed signal having an input clock signal to an output frame synchronous signal synchronized with an output clock signal different from the input clock signal to produce an output frame signal, the device comprising converting means for converting the input frame signal of the input clock signal into a clock converted frame signal of the output clock signal, a frame format of the clock converted frame signal consisting of a converted subframe portion carrying a plurality of a converted channel signals and a converted overhead portion carrying a transport overhead signal for controlling transport of the channel signals, and the converted overhead portion comprising a converted frame synchronous signal. The device further comprises: separating means receiving the clock converted frame signal for separating the clock converted frame signal into the converted overhead portion and the converted subframe portion as a separated overhead portion and a separated subframe portion, respectively; storing means coupled to the separating means for storing the separated subframe portion; making means coupled to the separating means and responsive to the separated overhead portion and the output frame synchronous signal for making an output overhead portion determined by a phase difference between the converted and the output frame synchronous signals; and multiplexing means coupled to the storing means and the making means and responsive to the output frame synchronous signal for delivering the output overhead portion into a portion of the output frame signal, the multiplexing means reading the stored channel signals from the storing means as read channel signals to deliver the read channel signals into the remaining portion of the output frame signal, so that the output frame signal consists of the output overhead portion and an output subframe portion carrying the read channel signals.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic block diagram view of a known frame aligner;
FIG. 2 is a view illustrating time relationships between various signals in the aligner in FIG. 1;
FIG. 3 is a schematic block diagram view of a frame aligner according to an embodiment of the present invention;
FIG. 4 is a view illustrating time relationships between various signals in the aligner in FIG. 3;
FIG. 5 is a schematic block diagram view of a pointer arithmetic circuit in FIG. 3;
FIG. 6 is a block diagram view of a frame aligner according to another embodiment of the present invention;
FIG. 7 is a block diagram view of a clock converter used in FIG. 6; and
FIG. 8 is a view illustrating various signals in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Prior to description of preferred embodiments, a known frame aligner will be described with reference to FIGS. 1 and 2 so as to help the better understanding of the present invention.
Referring to FIG. 1, the known frame aligner 10 comprises a buffer memory 11 to which an input frame signal is stored under control of a writing circuit 12.
An input clock generating circuit 13 produces a clock signal as an input clock by derivation from the input frame signal or other known method. An input frame synchronous signal (F.S.P.) generating circuit 14 also produces the input frame synchronous signal by deriving a frame synchronous signal from the input frame signal. The input clock and the input synchronous signal are supplied to the writing circuit 12 so as to control the writing operation.
The frame signal stored in the buffer memory 11 is read as an output frame signal from the buffer memory 11 under control of a read circuit 15. An output clock generator 16 produces an output clock signal synchronous with the input clock signal, while an output frame synchronous signal generator 17 generates an output frame synchronous signal which is generated at a predetermined time instant and is different from or delayed from the input frame synchronous signal in phase.
FIG. 2 shows time relationships of the input frame synchronous signal 21, the input clock signal 22, the input frame signal 23, the output frame synchronous signal 24, the output clock signal 25 and the output frame signal 26. The output frame signal 26 is equal to the input frame signal but with a delay equal to the phase difference between the input frame synchronous signal 22 and the output frame synchronous signal 24. Accordingly, the buffer memory is required to have a capacity sufficient to store one entire frame signal in order to permit the maximum delay of the output frame synchronous signal, that is, one frame delay.
Now, description will be made as regards a format of the frame signal. As shown at 23 and 26 in FIG. 2, the frame signal comprises a plurality of time slots (nine time slots are shown) some of which (two in the figure) are assigned to an overhead portion 27 for carrying a transport overhead with the remaining time slots (seven slots in the figure) assigned to a subframe portion 28 for carrying data or message information. In the shown example, the overhead 27 consists of the frame synchronous signal F and the message pointer P, and the data information in the subframe 28 consists of seven channels a, b, . . . , g. The seven channels are assigned with channel numbers and are arranged in the order of the channel numbers in the subframe 28 following the first or leading channel assigned to a particular one or the third one of the time slots in the subframe 28 after the overhead 27, as shown in the figure. Accordingly, the pointer P in the overhead 27 indicates three (3).
Referring to FIG. 3, the frame aligner 30 shown therein according to an embodiment of the present invention comprises a buffer memory 11, a writing circuit 12, an input clock generator 13, an input frame synchronous signal generator 14, a read circuit 15, an output clock generator 16, and an output frame synchronous signal generator 17 similar to the known frame aligner 10 in FIG. 1, but the frame aligner 30 further comprises a demultiplexer 31 for separating the input frame signal into the overhead portion and the subframe portion as a separated overhead portion and a separated subframe portion, respectively, a multiplexer 32 for multiplexing a subframe signal read from the buffer memory 11 and a fresh overhead signal to produce the output frame signal, and a pointer arithmetic circuit 33 for preparing the fresh overhead signal.
The demultiplexer 31 receives the input frame signal 23 (FIG. 4), the input clock 22 (FIG. 4), and the input frame synchronous signal 21 (FIG. 4) and separates the overhead portion 27 from the subframe portion 28 of the frame signal to deliver the separated overhead portion and the separated subframe portion to the pointer arithmetic circuit 33 and the buffer memory 11, respectively. The demultiplexer 31 also produces a write unable signal to the writing circuit 12 when the demultiplexer 31 delivers the separated overhead portion to the pointer arithmetic circuit 33, while the demultiplexer 31 produces a write enabling signal to the writing circuit 12 when the demultiplexer 31 delivers the separated subframe portion to the buffer memory 11. Accordingly, the writing circuit 12 is responsive to the write enabling signal and writes the subframe portion to the buffer memory 11.
The multiplexer 32 receives the output clock 25 (FIG. 4), and the output frame synchronous signal 24 (FIG. 4). When the overhead portion 27' (FIG. 4) of the output frame signal should be delivered from the multiplexer 32, the multiplexer 32 takes into the fresh overhead signal from the pointer arithmetic circuit 33 and delivers the fresh overhead signal therefrom as the overhead portion of the output frame signal 35 (in FIG. 4), with a read unable signal to the read circuit 15. The multiplexer 32 also produces a read enabling signal to the read circuit 15 when the multiplexer 32 delivers a subframe portion 28' (FIG. 4) of the output frame signal therefrom. Accordingly, the read circuit 15 is responsive to the read enabling signal and reads the subframe portion stored in the buffer memory 11 as a read subframe signal. The read subframe signal is delivered from the multiplexer 32. Thus, the fresh overhead signal and the read subframe signal are multiplexed by the multiplexer 32 and are delivered therefrom as the output frame signal 35 shown in FIG. 4.
As described above, the subframe portion of the input frame signal is only stored in the buffer memory 11 and is then read from the buffer memory 11 only when the read circuit 15 receives the enabling signal from the multiplexer 32. That is, the subframe portion stored in the buffer memory 11 is not read from the buffer memory 11 when the fresh overhead portion is taken from the pointer arithmetic circuit 33 and delivered from the multiplexer 32. Accordingly, the buffer memory 11 stores and holds data signals in the subframe portion 28 which are provided to the buffer memory 11 when the read circuit 15 is unable.
In the embodiment shown, the overhead portion comprises two time slots and therefore, it is sufficient for the buffer memory 11 to have a capacity for storing the data signals carried by the two time slots so that no data signal in the subframe portion 28 is lost. When the read circuit 15 receives the enable signal after the fresh overhead portion is delivered from the multiplexer 32 as the overhead portion 27' in the output frame signal 35, the read circuit 15 starts to read the data signals stored in the buffer memory 11. Therefore, the order of the data signals or the channel signals in the subframe 28' in the output frame signal 35 is different from the order of the channel signals in the subframe portion 28 in the input frame signal 23 as seen in FIG. 4.
Therefore, the pointer arithmetic circuit 33 calculates a fresh message pointer Px from a delay of a phase difference of the output frame synchronous signal 24 and the input frame synchronous signal 21 and produces the fresh overhead 27' shown in FIG. 4.
Referring to FIG. 5, the pointer arithmetic circuit 33 comprises a pointer deriver 41 for deriving the message pointer P in the separated overhead portion applied thereto from the demultiplexer 31 and a subtractor 42 for calculating the delay y of the output frame synchronous signal from the input frame synchronous signal. The pointer arithmetic circuit 33 further calculates the fresh pointer Px from P, y and x which is the number of time slots assigned to the overhead portion 27 (in the embodiment shown, x=2), according to the following calculating method:
when P≦(y-x), Px=(P-y)mod f1,
when P>(y-x), Px=(P-y+x)mod f1,
where f1 represents the number of the time slots or a length of the single frame.
In order to carry out the above-described calculation, the pointer arithmetic circuit 33 comprises a first subtractor 43 for performing (y-x), a second subtractor 44 for calculating (P-y)mod f1, a third subtractor 45 for carrying out {P-(y-x)}mod f1, and a comparator 46 for comparing P and (y-x) to produce a selection signal. One of (P-y)mod f1 and (P-y+x)mod f1 from the second and the third subtractors 44 and 45 is selected by a selector 47 as Px according to the selection signal from the comparator 46.
A combiner 48 combines Px and F which is separated at the pointer deriver 41 and produces the fresh overhead 27'.
When the TDM communication system uses TDM signals of different bit rates, those TDM signals must be matched to each other in the bit rate before performing the frame alignment, as described in the preamble of the present description.
To this end, a clock converter 50 is used for converting a TDM signal of an input clock to a converted TDM signal of a different output clock at a previous stage of the frame aligner 30 as shown in FIG. 6. A clock converted frame signal from the clock converter 50 is applied to the frame aligner 30 as the input frame signal which has been described in connection with FIG. 3.
Although a known one can be used as the clock converter 50, a novel clock converter will be described with reference to FIGS. 7 and 8.
It is provided that the input TDM signal is made by use of first and second pulse stuffing synchronization, that is, twice pulse stuffing synchronization, for a data signal. Therefore, the TDM signal consists of the data signal and first and second stuff pulses. The TDM signal is required to be phase-aligned to an output clock different from those of the data signal, the TDM signal and a pulse-stuffed signal by the first pulse stuffing synchronization.
Referring to FIGS. 7 and 8, the clock converter 50 comprises a first destuffing circuit 51 for receiving an input TDM signal 61 and an input clock 71 to destuff the input TDM signal 61. The input TDM signal has first stuff pulse s1 and a second stuff pulse s2 in the six data pulses 1 through 6. The first destuff circuit 51 removes the second stuff pulse s2 from the input TDM signal 61 to deliver a first destuffed signal 62 to a first buffer memory 52. The first destuff circuit 51 also removes a clock pulse of the input clock 71 at a time position of the second stuff pulse s2 to deliver a first removed clock 72 to the first buffer memory 52. Thus, the first destuffed signal 62 is written into the first buffer memory 52.
A first stuffing circuit 53 delivers a second clock 73 to the first buffer memory and reads out the first destuffed signal stored therein as a first read signal 63. A phase comparator 54 compares a phase of the first removed clock 72 and a phase of the second clock 73 and produces a first error signal. The first stuffing circuit 53 receives the output clock 74 and produces the second clock 73 under control by the first error signal so that the first removed clock signal 72 and the second clock signal 73 have a common mean frequency. The first stuffing circuit 53 also adds a third stuff pulse s3 to the first read signal 63 to produce a first stuffed signal 64 which is synchronized with the output synchronous signal 74.
Then, a second destuff circuit 55 receives the first stuffed signal 64 and the output synchronous signal 74 and removes the third stuff pulses s3 from the first stuffed signal 64 and delivers a second destuffed signal 65 to a third destuffing circuit 56. The second destuff circuit 55 also removes clock pulses of the output synchronous signal 74 at time positions of the third stuff pulses s3 and delivers as a second removed clock 75 to the third destuffing circuit 56.
The third destuffing circuit 56 receives the second destuffed signal 65 and the second removed clock 75 and removes the first stuff pulse s1 to deliver a third destuffed signal 66 to a second buffer memory 57. The third destuffing circuit 56 also removes a clock pulse of the second removed clock 75 at a time position of the first stuff pulse s1 and delivers a third removed clock 76 to a second buffer memory 57.
The second buffer memory 57 receives the third destuffed signal 66 and the third removed clock 76 and stores the third destuffed signal 66.
A second stuffing circuit 59 provides a third clock 77 to the second buffer memory and reads the destuffed signal 66 stored in the second buffer memory 57 as a second read signal 67.
A second phase comparator compares a phase of the third removed clock 76 and a phase of the third clock 77 to produce a second error signal.
The second stuffing circuit 59 receives the output clock 74 and produces the third clock 77 under control by the second error signal so that the third removed clock 76 and the third clock 77 have a common mean frequency. The second stuffing circuit 59 also adds fourth stuff pulses s4 to the second read signal 67 to produce a second stuffed signal 68 which is synchronized with the output synchronous signal 74.
Thus, it is possible to obtain from the input data signal a stuffed signal of the data signal which is stuffing synchronized with the output synchronous signal. | In a frame aligner for frame aligning an input time-division multiplexed (TDM) signal to an output frame synchronous signal, an input frame signal of the TDM signal is separated into a transport overhead carrying an input frame synchronous signal and a message pointer and a subframe carrying data signal. A fresh overhead having a fresh pointer is made corresponding to a phase difference between said input and said output frame synchronous signals and said subframe is sequentially written into and read from a buffer memory. The fresh overhead and the subframe read are multiplexed to form an output TDM frame signal which is synchronized with the output frame synchronous signal. The buffer memory is permitted to have a reduced memory capacity storable a number of channel signals equal to that of time slots carrying the overhead. When the input frame signal is asynchronous with an output clock signal, the input frame signal is converted to a converted frame signal which is synchronized with the output clock signal before the frame alignment is performed. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to fibrous-material grinding apparatus of the kind which includes a housing which incorporates at least one material inlet and at least one material outlet, rotatable grinding device of substantially cylindrical configuration mounted in said housing, and a plurality of stationary grinding devices disposed around the rotatable grinding device and capable of being pressed towards the rotatable grinding device and which together form a grinding gap in which the fibre material is worked and transported from material inlet to material outlet as a result of rotation of the rotatable grinding device.
HISTORY OF THE RELATED ART
Known drum refiners of this kind include a plurality of grinding segments disposed around the rotatable grinding device. These grinding segments are mounted for movement in a radial direction towards the mantle surface of the rotatable grinding device and can be pressed axially against the rotatable grinding device by a respective hydraulic piston-cylinder device mounted behind each grinding segment. A large number of such grinding segments are provided, in order to cover the desired area of grinding surface on the mantle surface of the rotatable grinding device, and adjustment of the size of the grinding gap necessitates individual adjustment of each hydraulic piston-cylinder device acting on a grinding segment. This task is made highly complicated by the large number of grinding segments which need to be adjusted to essentially the same radial distance from the mantle surface of the rotatable grinding device.
SUMMARY OF THE INVENTION
The prime object of the present invention is to provide a grinding apparatus of the kind described in the introduction in which the extent to which the material is ground can be regulated in a simple and effective fashion as the rotatable grinding device rotates.
This and other objects are achieved with an inventive grinding apparatus having the characteristic features set forth in the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with reference to a preferred embodiment of the grinding apparatus and with reference to the accompanying drawings.
FIG. 1 is a cross-sectional view of the inventive grinding apparatus, and FIG. 2 is a corresponding longitudinal sectional view of the apparatus. FIGS. 3 and 4 are respective cross-sectional views of grinding segments and adjustable channel walls. FIG. 6 is a view of the grinding apparatus shown in FIG. 5 as seen from the left. FIG. 7 is an enlarged sectioned view of the housing and one of the stationary grinding devices in the apparatus illustrated in FIGS. 5 and 6. FIG. 8 is a sectional view taken on the line VIII--VIII in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The illustrated grinding apparatus comprises a robust stand 9 which supports a drive motor (not shown) in a known manner and a shaft 10 which is connected to the drive motor and which is journalled in the stand 9 in a bearing unit 11 which includes a spherical and a cylindrical bearing. The apparatus housing 1 is supported on the left end of the stand 9, as seen in FIG. 2, by two bracket structures which are positioned centrally on the housing 1 and secured thereto with the aid of bolts, for example. The drive shaft 10 extends into the housing 1 via a water-cooled stuffing box 12 and carries at one end the rotatable grinding device or rotor 4, which is non-rotatably connected to the shaft. The mantle surface of the rotor 4 is configured with grinding surfaces which may have the form of a relief pattern or patterned grinding segments 17 such as to form a grinding surface which includes grooves and flutes in a technically known manner. The housing 1 is fitted with a sealing jacket 20 and O-rings, so as to prevent leakage between outlet and housing.
Disposed around the mantle surface of the rotatable grinding device or rotor 4 are a number of stationary grinding segments or flaps 5, which are curved with essentially the same radius of curvature as the cylindrical rotor 4 and which are located at a small distance from the rotor 4. The side of respective stationary grinding flaps which faces towards the mantle surface of the rotor is also provided with a patterned surface 16 of grooves and flutes which form a grinding surface. The flaps 5 are elongated and are pivotally journalled at one end to the housing 1 with the aid of journalling devices 7 and are journalled at the other end for movement towards and away from the mantle surface of the rotor 4, the movement being effected with the aid of pressing devices 8 in which the flaps or segments 5 are pivotally journalled with the aid of pivot shafts.
According to one preferred embodiment, the devices 7 by means of which the segments or flaps are pivotally journalled in the housing 1 preferably have the form of flap-adjusting devices which enable the flaps 5 at said one end to be adjusted radially towards and away from the mantle surface of the rotor 4, thereby enabling the grinding gap formed between the flap and the mantle surface of the rotor 4 to be adjusted to a basic setting.
In order to enable fibre material or other material to be worked in the grinding gap of the apparatus to be delivered to the gap, the apparatus includes a material inlet 2 which communicates with a central channel 15 surrounding the rotor 4.
The fibre material is dogged or otherwise entrained to the material outlets 3 by rotation of the rotor 4, as shown in FIG. 2, while being worked between the flaps and the mantle surface of the rotor 4, the material leaving the apparatus through outlets 3. Although the illustrated embodiment is shown to have four grinding flaps or segments, which cover the major part of the mantle surface of the rotor 4, it will be understood that the number of stationary grinding segments or flaps 5 can be varied without departing from the inventive concept. Several material inlets 2 and material outlets 3 may also be provided at different locations along the periphery of the housing 1 and the rotor 4.
In operation, the fibre material to be ground, such as lignocellulosic material, is fed through the inlet 2 to the grinding gap between the flaps 5 and the rotor 4 and accompanies rotation of the rotor while being worked between the respective patterned grinding surfaces of the rotor 4 and of the flaps 5, whereafter the ground material exits from the apparatus through the outlet 3. The basic setting of the grinding gap in the various grinding zones of the apparatus formed between respective flaps 5 and the rotor 4 is effected with the aid of the adjusting devices 7 and the size of the grinding gap is thereafter adjusted with the aid of the pressing devices 8. As the fibre suspension passes through the grinding apparatus, the degree of grinding, i.e. the absorption of energy; is adjusted in the described manner through the separate pressing devices 8 which are adjusted by means of control devices not shown. The pressure generated from the pulp as it is ground is taken-up by the front bearing in the stand 9. In operation, the fibre material passes through the input conduit 2, which is connected to a resilient pad 13 and connected directly to adjustable grinding devices. The fibre material is then transported from the inlet opening 14 and through a center channel 15 which distributes the material to the segments 16, 17, which work the fibre material in an axial direction and the material flows through the grooves 18, 19 to the material outlets 3. The fibre material can be repeatedly recycled and reworked, by connecting the outlet 3 in series with, for instance, the inlet to a following flap while, at the same time, ensuring that an axially movable partition wall or baffle 6 is in its lower or inwardly located position.
As before described, the fibre material passes through the inlet 2, the opening 14 and into the center channel 15 which surrounds the rotor and a part of which lies in the rotor and a further part lies in the stator (FIG. 1). The center channel 15 which distributes the fibre material around the rotor is divided into sections by the displaceable partition walls or baffles 6 which project down into the center channel 15 (FIG. 3) and which can be positioned so as either to throttle the flow of fibre material in the channel or to completely cut-off the flow. In the case of the illustrated embodiment, the flow of fibre material is caused to pass through a plurality of grooves or flutes which are either curved, such as the grooves 18 in FIG. 3, or angled, such as the grooves 19 in FIG. 3, so that the fibre material will pass through the grinding gap at least once with respect to the grooves 19 and at least twice in respect of the grooves 18. The fibre material will therewith flow from the center channel 15 towards both sides of the rotor and to the outlet 3 which extends along the curved path of the grinding gap. As illustrated in FIG. 1, the position of the outlet 3 can be varied so as to discharge ground material from the apparatus at an earlier or at a later stage. Outlets 3 can be provided for all grinding zones and, as before mentioned, the grinding zones can be connected in series so as to enable the fibre material to be worked several times, or can be connected in parallel for removal of ground material from the apparatus for further treatment.
FIGS. 5-8 illustrate a modified form of the inventive grinding apparatus As shown in FIG. 5, the housing 21 and the bearing house 22 are carried by a stand 23. The rotatable grinding device or rotor 24 is mounted in the housing and connected non-rotatably to the shaft of the bearing house. In this embodiment, the rotor 4 includes a hub 25 to which there is connected by means of bolts 26 (FIG. 7) a rotor ring 27 provided with a center channel 28. Connected to the rotor ring 27 are stationary grinding segments 29, which extend around the mantle surface of said ring (FIGS. 7 and 8).
Similar to the embodiment illustrated in FIGS. 1-4, stationary grinding segments 30 are arranged around the mantle surface of the rotor and terminate short of the rotor surface so as to define a grinding gap therewith. The grinding segments 30 of this embodiment are elongated but, distinct from the earlier described embodiment, are not pivotally mounted but are instead radially movable in one piece towards and away from the mantle surface of the rotor 24. This movement is produced with the aid of the pressing device 31, which acts on abutment surfaces on the grinding-segment body 30. The grinding-segment body 30 is guided by a piston 32 connected to the body, the piston in turn being guided in a cylinder 33 by means of piston rings 34. A sealing annulus 35 is mounted between the piston 32 and the housing 21, to prevent the ingress of grinding material past the piston 32.
The embodiment illustrated in FIGS. 5-8 includes four stationary grinding segments 30 which coact with four cylinders 33, all of which are provided with a sealing cover 36 with the exception of the cylinder 33 shown furthest to the left in FIG. 6, this latter piston being connected to a grinding material inlet 37. The piston 32 is a hollow piston through which grinding material is delivered to the center channel 28 in the rotor 24, the material passing from the inlet 37, through the cylinder 33 and the piston 32 via an opening 40 in the stationary grinding device (FIG. 8) and to the channel 28 formed in the rotor 24. As illustrated in FIG. 6, the inlet 37 may be arranged at any desired angle in relation to the cylinder 33.
The embodiment described with reference to FIGS. 5-8 includes one single, centrally located outlet 38 which lies on the side of the apparatus remote from the bearing house 22. The grinding segments 29, 30 are located in that part of the housing 21 which faces towards the drive motor 22, and in order to enable grinding material, which leaves the rotor through said grinding segments, to flow to the central outlet 38, the rotor disc 27 is provided with a plurality of openings 39 around the disc periphery, through which the ultimately ground material can pass to that side of the rotor 24 which faces towards the outlet 38.
Apart from those differences concerning the manner in which the grinding segments 30 are guided and the arrangement of inlets 37 and outlets 38, the method of operation of the embodiment illustrated in FIGS. 5-8 is the same as that of the grinding apparatus described with reference to FIGS. 1-4. Thus, the material to be ground passes from the inlet 37, the piston 32, the opening 40 in the stationary grinding device 30, to the center channel 28 in the rotor 24, from where the material is distributed in the grinding gap between the grinding segments 29, 30, where the material is worked and then leaves the gap on both sides of the rotor. The ground material then flows to the outlet 38 either directly, or alternatively through the openings 39 in the rotor 24.
It will be understood that the described and illustrated embodiment can be modified and changed within the scope of the following claims and that the invention is not restricted to this embodiment. | A fibrous material grinding apparatus which includes a rotatable grinding device mounted within a housing about which is disposed a number of stationary grinding devices and which are selectively spaced and moveable with respect to the rotatable grinding device to vary a grinding gap therebetween and wherein the fibrous material is introduced into a channel which extends centrally around the periphery of the rotatable grinding device so as to distribute the fibrous material to the grinding gap spaces between the rotary and stationary grinding devices. | 3 |
This Application claims priority from U.S. Provisional Application No. 61/436,597, filed on 26 Jan. 2011, which is hereby incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
The present invention relates to systems and methods useful in developing knowledge bases. Specifically, embodiments of the present invention relate to automated knowledge base configuration and development.
BACKGROUND OF THE INVENTION
The Deep Web is the part of the Internet that is inaccessible to conventional search engines, and consequently, to most users. Deep Web content includes information in private databases that are indirectly accessible over the Internet but not crawlable by typical search engines. For example, libraries maintain data bases of books that are accessible to the public but in order to access them a user needs to fill out a web form in order to access the content.
In general, it is assumed that deep Web was growing much more quickly than the surface Web and that the quality of the content within it was significantly higher than the vast majority of surface Web content. Although most of this content is publicly available, it's accessibility to typical Internet end users is very limited.
It would be highly advantageous to have a platform that would enable end users to effectively configure and access surface web and deep web data sources remotely.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples provided herein are illustrative only and not intended to be limiting.
Implementation of the method and system of the present invention involves performing or completing certain selected tasks or stages manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of preferred embodiments of the method and system of the present invention, several selected stages could be implemented by hardware or by software on any operating system of any firmware or a combination thereof. For example, as hardware, selected stages of the invention could be implemented as a chip or a circuit. As software, selected stages of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In any case, selected stages of the method and system of the invention could be described as being performed by a data processor, such as a computing platform for executing a plurality of instructions.
Although the present invention is described with regard to a “computer” on a “computer network”, it should be noted that optionally any device featuring a data processor and/or the ability to execute one or more instructions may be described as a computer, including but not limited to a PC (personal computer), a server, a minicomputer. Any two or more of such devices in communication with each other, and/or any computer in communication with any other computer may optionally comprise a “computer network”.
The present invention relates at least partly to a method for enabling automated content aggregation based on deep Web sources, comprising: analyzing a plurality of deep web sources to detect a plurality of fields; selecting at least one field; and aggregating content provided to a plurality of deep web sources through the at least one field. The present invention also relates at least partly to a method for automatically generating domain based knowledge bases based on deep Web sources, comprising: selecting a plurality of deep web sources according to a domain; analyzing the plurality of deep web sources to detect a plurality of fields; selecting at least one field at least partially according to the domain; and aggregating content provided to a plurality of deep web sources through the at least one field.
BRIEF DESCRIPTION OF THE DRAWINGS
The principles and operation of the system, apparatus, and method according to the present invention may be better understood with reference to the drawings, and the following description, it being understood that these drawings are given for illustrative purposes only and are not meant to be limiting, wherein:
FIG. 1A is a system diagram describing a system enabled to execute automated knowledge base construction of deep web data sources, according to some embodiments;
FIG. 1B is a system diagram describing a system enabled to aggregate search results from deep web data sources, using a domain based knowledge base, according to some embodiments;
FIG. 2 is a system diagram illustrating an example of a work flow used in creating an automated knowledge base of deep web data sources, according to some embodiments; and
FIG. 3 is a flow chart showing an example of a process in which a Domain Knowledge base is generated, according to one embodiment.
It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements throughout the serial views.
DETAILED DESCRIPTION OF THE INVENTION
The following description is presented to enable one of ordinary skill in the art to make and use the invention as provided in the context of a particular application and its requirements. Various modifications to the described embodiments will be apparent to those with skill in the art, and the general principles defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the particular embodiments shown and described, but is to be accorded the widest scope consistent with the principles and novel features herein disclosed. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
The term “deep web” as used herein may encompass the Deepnet, the invisible Web, the dark Web, the hidden Web or other terms representing data sources that are not typically indexed by the standard search engines. The term “surface web” as used herein may encompass the visible Web or indexable Web, or other parts of the World Wide Web that is indexed by conventional search engines.
Non-limiting embodiments of the present invention enable automated knowledge base construction for extracting information from deep web resources, according to some embodiments. In some embodiments, the system may be used to automatically build domain specific knowledge bases substantially without prior knowledge of fields or values associated with the domain knowledge bases being built. Further, in some embodiments, the system may be used to automatically create a unified, normalized Database of deep web content from multiple data sources, whether the sources are surface or deep. In additional embodiments the system may be used to facilitate automated user designed field searches.
Reference is now made to FIG. 1A which is a system diagram describing a system enabled to execute automated knowledge base construction of deep web resources, according to some embodiments. As can be seen in FIG. 1A , Knowledge Base Construction System (KBCS) 100 may be in communication with external databases 101 , which are optionally deep web databases, accessible through web site interfaces 102 , or other suitable interfaces, in order to fetch data from related sites. KBCS 100 may feature a Deep Web crawler 105 for crawling Websites internally for content and forms (or other entry points) to access data content relating to a search request.
Deep Web crawler 105 retrieves information as described for example in U.S. patent application Ser. No. 12/567,773, filed on 27 Sep. 2009, owned in common with the instant application and hereby incorporated by reference as if fully set forth herein. queries related sites and analyzes the result retrieved from each site. Such results can be retrieved from HTML/XML pages or from any other text format pages. According to this embodiment, a web browser 104 optionally applies its rendering composer engine on the HTML document to determine one or more geometrical properties of the document, for example optionally by generating a Document Object Model (DOM) tree, wherein each mark-up language tag (such as each HTML or XML tag) is associated with a node in the DOM-tree. For each node in the tree, the browser 104 also associates its geometrical representation for rendering the corresponding web page. The geometric representation is denoted, for example, by the XY origin offset, width, height and the like. The geometrical properties of such a tree are preferably analyzed to determine the layout of the document. Information is preferably then retrieved from the document according to the document layout. Optionally, semantic analysis is also applied as described in greater detail below.
In some embodiments Website lists may be generated by domain based crawler 112 , an operator, machine or any combination. Sites list 109 can optionally reside in a file or alternatively be collected by domain based crawlers 112 , for example, a specialized crawler that collects sites relevant for a certain domain (ie—for a certain area of knowledge or of interest, which searches for web sites having specific content). For example, domain based crawler 112 may optionally be provided with a list of content terms or with a collection of relevant web sites, and then searches for relevant web sites according to the terms and/or other information in the provided relevant web sites. Deep Web crawler 105 may use Website lists 109 , generated by Domain Based Crawler 112 which is configured to run code to search for Websites relevant to a search request or field, to populate Websites list 109 .
It is noted that the Deep Web crawler 105 may, if and when needed, execute automated web-form filling. For example, Deep Web crawler 105 may use the knowledge base Constructor 114 (described in greater detail below) to generate relevant queries in order to fill out the relevant web-forms in order to access selected data sources. Knowledge base constructor 114 receives the decomposed web page, which is decomposed by analyzing the page with the geometrical analyzer, which determines the record listings, without content analysis. Knowledge base constructor 114 analyzes the content in order to search for repeating terms and hence for repeating fields. The field may optionally be determined only according to location or only according to semantic analysis (such as a specific term or terms), but is preferably determined according to a combination of such parameters.
Knowledge base constructor 114 repeats this process for a plurality of web sites, and then cross-analyzes the fields and content for the plurality of web sites, for example to determine equivalent terms (such as for example “make” vs. “manufacturer”). Preferably fields of importance are determined according to statistical analysis of equivalent terms, such that the most frequently appearing fields are considered to be important. Knowledge base constructor 114 also preferably eliminates fields as being less important by detecting fields that do not appear in many web sites by statistical analysis. Preferably only the most important terms, according to statistical weighting, are then retained by knowledge base constructor 114 .
Knowledge base constructor 114 is preferably first trained on highly structured web sites, for which the geometric analyzer 107 is able to more easily decompose the web sites into a plurality of fields. However, once knowledge base constructor 114 has been trained on some minimum number of web sites (which may for example optionally be set by an administrator user), then knowledge base constructor 114 is more easily able to analyze less structured web sites.
KBCS 100 may feature a Scheduler 106 , which may run a program to control or manage the instructions to Deep Web crawler 105 . For example, scheduler 106 may schedule the crawler 105 to automatically query the data bases 101 via the web sites interfaces 102 in order to retrieve relevant or updated data. In one example, such data being searched may be art gallery events, where a user wants to learn about upcoming art exhibitions in the world or in a region. In such as example, the KBCS System 100 will search and aggregate requested data from multiple art sites in accordance to the definitions of the search request entered.
System 100 may include a visual or Geometric analysis module 107 , for using geometrical analysis of Web forms, tables, listings, text and other formats. In one example, a geometrical analysis tool such as that taught in the previously described U.S. patent application Ser. No. 12/567,773. Geometrical analyzer 107 typically receives the rendered pages from crawler 105 , including the DOM-tree along with page geometric representation. The geometrical analyzer 107 analyzes the regularities on a selected web page layout and decomposes the web page into records 110 representing reoccurring sequences (patterns). In some embodiments, the geometrical analyzer finds regularities in the layout of web pages and creates a pattern for each such reoccurring (regular) sequence.
System 100 further includes a Knowledge Base Constructor module 114 , which is an active module configured to run code or programs to communicate with geometrical analyzer 107 to receive at least the geometrically decomposed pages. In some examples the geometric analyzer 107 may execute code to decompose a webpage into records, from which patterns may be identified. Such patterns may initially be identified within a single webpage, yet once found, these patterns may be matched with other pages of the website. Optionally, a semantic module (not shown) may further analyze the text within the matched pattern. The knowledge base creator 114 may also be in communication with Deep web crawler 105 . In some embodiments, Deep Web crawler 105 may execute instructions to search for a link to the next results page preferably only if the page has been identified as a relevant results page. Knowledge base Constructor 114 may run code to identify the fields that comprise records of the Deep Web source sites, and may execute a program to create a knowledge base, based on the description above, and the workflow described below with reference to FIG. 2 .
Constructor 114 may, for example, utilize records generated by Geometric Analyzer 107 and compare/process and compile meaningful records, for example, the analysis may be done, for example, by comparing the different records of each site to each other and analyzing repetitive and non repetitive parts of the records. The knowledge base creator 114 may use records data 110 , and optionally communicate with deep web crawler 105 , to integrate data based on previous queries from records 110 , and to optionally generate new queries in addition deep web sites. The knowledge base is a database that may contain semantic information relevant to one or more selected domains, such as field names, potential values, recognition rules and more.
According to some embodiments, Knowledge base creation module 114 may be used to analyze the text in the patterns recognized by the visual analysis, to identify structures that may be used for automated formation of fields and values relating to specific data fields. For example, Knowledge base construction module 114 may run an analysis on the records of art galleries, and identify common fields such as dates, addresses, artists etc. that are in common in multiple sites. Initially such an analysis may be run on a single site, and subsequently it may be run on multiple other sites, using cross referencing by analyzing field names/field values similarity. In this way, KBCS system 100 is able to use automated analysis of geometric + semantic results to provide dynamic, growing and learning databases and lists of field and value specific content from deep web and surface web data sources.
In some embodiments there may be no need for the list of websites to scan 109 and/or the scheduler 106 , since the Knowledge base creation module 114 may facilitate substantially real time configuration and searching of selected queries by an end user.
In some embodiments, in a second phase, as can be seen with reference to FIG. 1B , the KBCS system may execute an Aggregation Engine or Module 130 to help automatically construct a search results database 135 . Aggregation module 130 receives records from knowledge base creator module 114 and then constructs a database of aggregated results from all examined relevant web sites. The results of the analysis may comprise, for example, records, data and links to the relevant web pages, which may be stored in search results data base 135 .
When a user queries for information, such as, for example a list of all higher education programs in the user's area, using for example a search engine 111 , the information is retrieved from the results data base 135 . Optionally an automated user may request the information, such as an automated feed provider. The information delivered to the requesting entity preferably comprises data and links to relevant sites for retrieving additional data, according to the analysis performed above.
Reference is now made to FIG. 2 , which describes an implementation of the Knowledge base creation module 200 , according to some embodiments. Knowledge base creation module 200 may feature a Field/value Recognition module 210 to identify similar fields that are described in different ways in different sites. Such an identification may allow normalization of substantially same fields from different data sources into one consolidated database. Field/value Recognition module 210 , as described previously for Knowledge base creation module 114 , recognizes the fields as being fields, according to repeat structure and/or content. Field/value Recognition module 210 then determines the type of values that may be found in such a field.
Knowledge base creation module 200 may further feature a Field Ranking module 220 , for identifying ranking of fields based on repetition/usage in the source sites. Greater frequency with which the field appears in a plurality of web sites is one non-limiting example of a parameter which may increase the importance of a field. Another non-limiting example of such a parameter is the connection between a particular field and other fields. Yet another non-limiting example of such a parameter is the content of the field, which may optionally for example be determined to be important.
The Knowledge base creation module 200 may further feature a Refinement module 225 , for analyzing the ranked fields to improve machine confidence and accuracy of the operation of Knowledge base creation module 200 . Refinement module 225 determines which fields are clearly correctly designated as fields and also determines which fields are clearly not correctly designated (for example terms that do not repeat across many web sites or that do not repeat within a band of statistical confidence). Fields which are clearly not correctly designated as such are preferably removed. Terms which may or may not represent field labels are preferably further analyzed to determine whether they are to be accepted as fields or not.
For example, after understanding similarity of structures in a single site, and subsequently verifying and improving the identification of such structures across multiple sites, the Refinement module 225 can generate greater confidence and accuracy by learning from previous experience in identifying structures, such that when identified and verified structures are seen again, the probability of identification with increasing accuracy increases.
Knowledge base creation module 200 may further feature an Expansion module 230 for preferably expanding the analysis to other web sites for expanding scope and accuracy. Expansion module 230 considers the degree of statistical confidence of the known fields and also how much more information was added in the last iteration. If a statistically significant amount of information was added in the last iteration, expansion module 230 determines how many more web sites should be considered in a new iteration. Alternatively, expansion module 230 may optionally determine that a significant amount of new information was not added in the last iteration and so the iterations may be finished.
According to some embodiments, expansion module 230 can define limits or thresholds at which to start expansion to analyze more new web sites. For example, the module may determine that once a selected confidence level of field identification has been achieved, then a further number if sites may be crawled and processed. On the other hand, if a selected threshold of accuracy has been reached, such that further expansion will not be expected to enhance accuracy substantially, the expansion module may determine that no more expansion be required or executed. Expansion module 230 may be in communication with domain based crawler 205 , for new sources from which to add data to the domain knowledge base. Of course, other structures and dimensions, or combinations of elements, may be used.
The above described modules may be used to automatically derive a Domain Knowledge base 250 , in accordance with the descriptions above and with reference to FIG. 2 .
In an additional phase, domain knowledge base 250 may be used in conjunction with aggregation module 260 to generate a results database 240 .
The above described components of the KBCS system 100 may work together to generate automated field-specific knowledge bases, thereby enabling highly accurate delivery of field data and values in accordance with user requests. Further, such knowledge bases may be based on unlimited data sources, whether surface web and/or deep web. Additionally, the system 100 learns and grows in accuracy as the number of sources used to contribute to the knowledge base increases.
In accordance with an example of a work flow used in executing an automated knowledge base configuration of deep web resources, field/value recognition module 210 may optionally identify similar values from field analysis based on multiple field based sources; this module may also additionally optionally refine value certainly based on quantity of sources and by following internal links from sources. Field ranking module 220 may optionally perform ranking to identify ranking of fields based on repetition/usage parameters. Refinement module 225 may optionally grow or develop machine confidence and accuracy based on refining and correcting knowledge base records. Expansion module 230 may optionally expand the scope and accuracy of the knowledge base, by including automated expansion to new sources, and processing/refining of new knowledge base elements. Any steps or combination of the above steps may be implemented. Further, other steps or series of steps may be used.
Reference is now made to FIG. 3 , which is a flow chart showing an example of a process in which a Domain Knowledge base is generated, according to some embodiments of the present invention. As can be seen in FIG. 3 , at stage 305 records may be automatically extracted, using visual, geometric and/or structural analysis, from Websites' results pages or other relevant pages, as previously described (for example optionally by using DOM-trees, also as previously described). At stage 310 fields may be extracted, along with their associated values from the extracted records by analyzing recurring patterns within the extracted records. Again as previously described, such recurring patterns may optionally be analyzed statistically in order to determine the significance of such patterns and/or optionally in order to eliminate patterns that are less important or non-important.
At stage 315 fields may be mapped or consolidated from one or more sites, for example, according to field name and field value similarity. Such mapping enables similar fields having similar content to be grouped together for example, so that synonymous or similar names (or field labels) and/or content may optionally be grouped according to their degree of similarity. At stage 320 fields may be ranked, for example, based on the frequency of their occurrence in the source sites. At stage 325 the system confidence or level of accuracy may be refined, for example relative to top ranked fields and values. At decision stage 330 , the Constructor considers or determines whether substantial new fields or values were discovered. If not, then a field and values entries may be added into the knowledgebase, at stage 335 . If a substantial number of new fields or values were discovered at stage 330 , then at stage 340 new sites may be added for processing, using the expansion step.
According to some embodiments, the system may be used to automatically build field specific knowledge bases without prior knowledge of fields or values associated with the field knowledge bases being built.
According to some embodiments, the system may be used to automatically develop a unified, normalized Database of deep web content from multiple data sources, whether the sources are surface or deep.
According to some embodiments, the system may be substantially language independent, since the visual analyzer enables patterns to be recognized and fields and values to be accurately synchronized and refined in spite of specific languages used in the knowledge base sources.
The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be appreciated by persons skilled in the art that many modifications, variations, substitutions, changes, and equivalents are possible in light of the above teaching. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A method for enabling automated content aggregation based on deep Web sources, comprising: analyzing a plurality of deep web sources to detect a plurality of fields; selecting at least one field; and aggregating content provided to a plurality of deep web sources through said at least one field. | 6 |
This application is a division of Ser. No. 07/568,150, filed Sep. 21, 1990, now U.S. Pat. No. 5,140,891.
TECHNICAL FIELD
The invention relates generally to a system for the rapid area clearance of unexploded ordnance from critical air base sortie generation facilities for air base rapid recovery after attack (BRAAT) or explosive infested ranges. More particularly, the present invention relates to a system for neutralizing unexploded ordnance so that such unexploded ordnance may be safely removed from the infested area.
BACKGROUND OF THE INVENTION
Historically, explosive-filled ordnance such as mines and hidden explosive devices have proven to be a significant obstacle to be overcome in both low and high intensity conflicts. Mines and hidden explosive-filled ordnance destroyed over 25 percent of the vehicles lost in World War II, a percentage that almost tripled in the Viet Nam War. Because of the continued improvement in flexibility, sophistication, kill power, ease of use and effectiveness of such mines, the potential for the continued use of such mines and hidden explosives for area denial and barrier munitions will continue to play a vital role in successful defensive tactics.
Current explosive-filled ordnance neutralization techniques include plows, rollers or flails attached to the front of an armored vehicle, as well as projected explosive charges. One such technique is illustrated in U.S. Pat. No. 3,771,413 issued to Sieg et al. The mine neutralization device of this type employs wheels which are mounted on the vehicle, such as a tank, and are utilized to neutralize; i.e., detonate pressure actuated land mines buried in the ground which are in the vehicle's path of travel. Such neutralization techniques are rarely used until the presence of a mine field is established; and once established, these techniques are slow and vulnerable to covering fire. A mine field protected by covering fire can be extremely difficult to breach. Further, some of the mines in the mine field may be missed because of the use of an advanced fuze system or the use of infrequent individual mines.
The range clearance system set forth in U.S. Pat. No. 4,449,239 issued to Pedersen illustrates a method of clearing a target range or other areas such as a war zone of buried unexploded ordnance by enhancing oxidation of ferrous ordnance in situ. This method advances the natural galvanic electrochemical corrosion whereby ferrous parts of the unexploded ordnance are simply rusted away at an accelerated rate and rendered harmless within five to ten years. However, while such a system may be effective in clearing a target range for future use, this system is both impractical and unusable where it is desired to quickly and effectively clear explosive infested areas such that troops or other personnel may readily occupy the previously infested area.
Various other techniques have been employed to neutralize explosive devices. Examples of such are set forth in U.S. Pat. No. 4,046,055 issued to McDaniels et al. and U.S. Pat. No. 3,800,715 issued to Boller. Each of these devices employ the use of liquid nitrogen to cool the device to a temperature at which the device becomes inoperative. One such device requires penetrating the individual casing of the unexploded ordnance with the subsequent injection of liquid nitrogen into the device. With the device of Boller, an unexploded ordnance is drawn into an open-ended tubular shell which is then filled with liquid nitrogen to freeze the bomb to deactivate the explosive material contained therein. However, each of these devices is used to merely deactivate a single bomb and cannot readily or safely be used to neutralize unexploded ordnance scattered over a large explosive infested area. Remote clearing of mine fields from a distance may also be carried out by the use of projected explosive charges which can quickly clear paths. This procedure; however, requires large amounts of explosives and causes large airblasts which are often undesirable. Moreover, this procedure is often only effective in detonating single-impulse pressure mines. Consequently such a procedure may not reliably clear the unexploded ordnance infested area.
Clearly, there is a need for both a system and method for readily neutralizing unexploded ordnance and clearing explosive infested areas such that maneuvers may be continued in a rapid and a confident manner. Further, such neutralization and clearing must be capable of being carried out safely with the unexploded ordnance being continuously maintained in an inert state.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the shortcomings associated with the above referenced prior art.
It is yet a further object of the present invention to provide a system that copes with all possible variations in expected unexploded ordnance types with reference to range, type and characteristics of explosive contained therein as well as volume, weight, arming/fuzing devices, influence, etc. Further, the system must account for the anticipated future development of munitions, including area denial munitions, combined effects munitions, smart weapons, sophisticated munitions, canister bomb units, submunitions, scatterable munitions and mines.
Rarely is the attack on an air base continuous, thus area denial munitions are often included as part of the attack so as to prolong the attack's effect. Therefore, it is yet another object of the present invention to provide a system which renders such area denial munitions inert and safe to remove.
Another object of the present invention is to provide a method of neutralizing unexploded ordnance and clearing explosive infested areas such that maneuvers can be both readily and confidently continued without significant delay. This may be accomplished by initially spraying the explosive infested area with a cryogenic liquid to neutralize the unexploded ordnance and reduce an output voltage of a detonator of the unexploded ordnance thereby rendering the unexploded ordnance inert, gathering the now inert unexploded ordnances and submerging the inert unexploded ordnances in a tank containing the same, or similar cryogenic liquid so that the unexploded ordnances are maintained in a supercooled and inert state and disposing of the unexploded ordnances.
In addition to the above, the neutralization of unexploded ordnance and clearing of explosive infested areas may be carried out by spraying the explosive infested area with liquefied methane to neutralize the unexploded ordnance and reduce an output voltage of a detonator of the unexploded ordnance to render such ordnance inert, igniting the liquefied methane, deflagrating the unexploded ordnance at a temperature less than that required for detonation and subsequently removing the unexploded ordnance from the explosive infested area.
Yet another object of the present invention is to provide a system for carrying out the above-mentioned process without subjecting personnel to unnecessary risk of explosion. The system includes a device for dispersing the cryogenic liquid about the explosive-infested area to render the unexploded ordnances inert, an armored bulldozer or similar device for gathering the inert unexploded ordnances, and a removal device for removing the gathered unexploded ordnances from the explosive-infested area.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the neutralization system in accordance with the present invention; and
FIG. 2 is a schematic illustration of the neutralization system in accordance with an alternative embodiment of the present invention.
FIG. 3 is a schematic representative of the overall system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, the cryogenic system for disbursing cryogenic liquids about an explosive infested area is illustrated. FIG. 1 illustrates a dispersion unit 10 which may be readily mounted on the underside of a helicopter. The dispersion unit 10 includes an insulated refrigeration tank 12 which accommodates a cryogenic liquid storage tank 14. The flow of the cryogenic liquid is controlled by the valve 16 which when opened allows the cryogenic liquid from tank 14 to be pumped by the centrifugal pump 18 through the dispersion nozzle 20. While the particular characteristics of the dispersion nozzle 20 are not critical to the operation of the dispersion unit 10, the nozzle must be capable of dispersing cryogenic liquid over a large area.
Similarly, the dispersion unit 100 illustrated in FIG. 2 includes an insulated refrigeration tank 112 which receives a cryogenic liquid storage tank 114. The flow of cryogenic liquid through the dispersion unit 110 is controlled by valve 116 with a centrifugal pump 118 being of the capacity to supply a significant amount of cryogenic liquid through the upper dispersion nozzle 120 and lower dispersion nozzle 122. Because the dispersion unit 110 is to be mounted on a land vehicle, in order to disperse cryogenic liquid over a significant area, the upper dispersion nozzle 120 is mounted on a turret 125 so as to enable the upper dispersion nozzle 120 to pivot to and fro in order to disperse the cryogenic liquid over a path which is at least three times the width of the vehicle, or approximately 20-30 feet. The lower dispersion nozzle 122 is mounted close to the ground so as to soak an area approximately the width of the vehicle with cryogenic liquid. The dispersion nozzle 120 is mounted so as to disperse the cryogenic liquid at least 100 feet ahead of the vehicle. This allows for the immediate cooling of the unexploded ordnance prior to the time at which the vehicle reaches the unexploded ordnance.
In accordance with a first embodiment of the present invention, the cryogenic liquid storage tank 14, 114 may be filled with a variety of cryogenic liquid such as liquid nitrogen or liquid air. Liquid nitrogen would, in effect, be the preferred cryogenic liquids in that the presence of oxygen in liquid air may enhance the ever present threat of fire when dealing with flammables. Consequently, liquid nitrogen which is not readily susceptible to fire would be the preferred cryogenic liquid to be used in accordance with the present invention.
The cryogenic liquid may be either remotely produced and brought to the site for dispersion or produced by a mobile cryogenic liquid production plant of a capacity sufficient enough to produce an amount of cryogenic liquid appropriate to disperse a sufficient layer of cryogenic liquid over an unexploded ordinance infested area such as an air base. Mobile cryogenic liquid production plants capable of producing the requisite amounts of such product are presently commercially available.
Once produced, the cryogenic liquid is dispersed over an area by use of either the dispersion unit 10 which is carried by a helicopter or the dispersion unit 110 which is mounted to a land vehicle such as a tank. When using the latter system, a magnetic silencer and signature reduction devices must be fitted to the delivery vehicles so as to reduce noise and vibrations admitted by the vehicle in order to minimize the chance of the detonation of influence fuzing unexploded ordnances. If a significant amount of influence fuzing unexploded ordnance are present, a low influence remotely controlled robotic vehicle would be used to allow the neutralization process to be safely implemented. However, if influence fuzing unexploded ordnances are not present, the use of a helicopter as a delivery vehicle would more efficiently and more expeditiously render the infested area neutralized.
Once a specified area has been adequately covered by layer of approximately 1/2 inch of cryogenic liquid, the unexploded ordnances will be neutralized by the supercooling interference with the detonator within the explosive process. The system neutralizes what are known as smart munitions to reduce the battery output voltage to the point that electronic fuzing will not function. The neutralizing of the batteries of the unexploded ordnances causes a malfunction in the detonator and renders the unexploded ordnance inert or at least unable to detonate while neutralized.
Once the unexploded ordnances are rendered inert, they may be removed from the infested area by the use of an armored bulldozer or other type of removal equipment 210. The removal equipment may also be remotely controlled in order to ensure the safety of the operating personnel. Once the now neutralized unexploded ordnances are gathered together in one area, the unexploded ordnances may again be soaked with the cryogenic liquid in order to ensure the neutralization of the unexploded ordnances. The unexploded ordnances must then be reliably transported away from the infested area. In order to do so, the unexploded ordnances are placed in a tank 220 containing the cryogenic liquid so that the unexploded ordnances may be safely transported. The unexploded ordnances may be picked up by a remote manipulator so as to again ensure the safety of the operating personnel. Because the unexploded ordnances are now held safe in a neutralized state, the final disposition of the unexploded ordnances may be either done immediately or delayed until such time that the proper equipment and personnel may be used.
The system described hereinabove may be used for the neutralization of unexploded ordnances of a variety of types. The above neutralization system is effective regardless of the range, type an characteristics of the explosive contained within the unexploded ordnance, volumes, weights, arming/fuzing devices, etc. as well as anticipated future development of explosive ordnances. Moreover, because the neutralized unexploded ordnances are removed by an armored vehicle having a plow-type structure on its front, additional debris such as fragments of explosives as well as other objects that are found on runways or other infested areas will be removed.
The preceding embodiment of the present invention first sprays an area of approximately 25 feet in width and 100 feet in length, the armored vehicle then plows the sprayed area in order to move the unexploded ordnances to a small concentrated area. To be sure that the unexploded ordnances remain neutralized, the piled unexploded ordnances may be sprayed with an additional amount of cryogenic liquid. The removal vehicle then picks up the piled and neutralized unexploded ordnances and loads the unexploded ordnances into a tank containing the same or similar cryogenic liquid. Once the tank has been filled with unexploded ordnances, it is securely closed and transported for disposal and replaced by another tank containing the cryogenic liquid. This process would continue until the entire infested area has been neutralized.
As an alternative to the preceding embodiment of the present invention, cryogenic liquid methane or natural gas may be used as the neutralizing cryogenic liquid. In addition to the foregoing, a system employing cryogenic liquid methane is effective in neutralizing anti-personal and anti-amphibious vehicle mines usually encountered in surf areas, as well as those encountered on land.
The cryogenic liquid methane cools the mines to a temperature that renders the mines safe to burn without explosion and without the associated air blast. The effects of the very low temperatures on the unexploded ordnances causes the malfunction of the igniter and renders the explosives inert or at least unable to detonate while neutralized by reducing the battery output voltage of the detonator to the point that electronic fusing will not function. The cryogenic liquid methane may be produced by cascade refrigeration using several refrigerants in series. The refrigeration process would include cooling the gas, first by propane, then by ethylene, and finally by self-refrigeration. The ethylene is condensed by propane and the propane is condensed by water. The final methane pressure reduction may be achieved by the well-known Joule-Thomson effect of cooling by throttling. As with the previous embodiment, the cryogenic liquid methane may be brought to the site in tanks or produced in situ aboard the vehicle depending upon the type and size of the mine field to be cleared.
When neutralizing surf mines, a helicopter is used as the delivery vehicle; however, when influence fuzing unexploded ordnances are present in a field, a low influence remotely controlled robotic vehicle should be used to carry out the neutralization process. In either case, the delivery vehicle will spray the infested area with cryogenic liquid methane or natural gas which is then followed by the remote deflagration of the unexploded ordnances. In doing so, the explosives will burn but will not explode.
When neutralizing an unexploded ordnance infested surf area, a helicopter or other robotic aircraft carrying the dispersion unit 10 set forth in FIG. 1 is used to disperse cryogenic liquid methane about the area to be cleared. In addition to the dispersion unit 10, an igniter 24 containing flammable material and an adhering material for ignition of the boiling methane dispersed about the area will also be carried by the helicopter along with a launcher 22 to launch the flammable igniter.
The neutralization of the unexploded ordnance infested area is carried out by initially spraying an area of approximately 15 feet by 150 feet with the cryogenic methane, backing off away from the area and launching the igniter into the area to burn the disabled mines. Once this is accomplished, a new area is sprayed and the process is repeated until the entire area is neutralized. Each section takes approximately 4-5 minutes to burn when a layer of approximately 1/2 inch of cryogenic liquid methane is dispersed.
The igniter 24 which initiates the deflagration of the enabled mines may consist of a canister containing a highly flammable liquid such as methane and an adhesive such as rubber to ensure the ignition of a localized area. The igniter 24 would thereby be similar to a Molotouf cocktail.
When clearing mine fields a low influence armored vehicle, including the dispersion unit 110, illustrated in FIG. 2 would be used in dispersing the cryogenic liquid methane. The low influence armored vehicle would also include a launcher 126 for launching an igniting canister 128. The armored vehicle would initially spray a specified area with a layer of cryogenic liquid methane. The armored vehicle would then back away from the sprayed area and launch the igniting canister 128 containing a highly flammable liquid and an adhesive such as rubber into the sprayed area, thereby igniting the boiling liquid methane. Upon the total deflagration of the explosives in the initial area, the armored vehicle would then proceed to an adjacent area to be neutralized. Upon the total deflagration of the explosives, the now neutralized unexploded ordnances may be readily removed from the neutralized area by gathering the now neutralized shells, thus allowing personnel to occupy the area.
Therefore, by carrying out the above described procedures, a workable solution for the complete, overall and rapid clearance of unexploded ordnances from an infested area is provided. Furthermore, the above described systems provides a highly reliable neutralization system which is easy to deploy and capable of clearing large areas at high sweeping rates, with minimal logistics and manpower support.
While the invention has been set forth with reference to particular embodiments, it will be appreciated by those skilled in the art that the invention may be practiced otherwise than has been described without departing from the spirit and scope of the invention. It is, therefore, to be understood that the spirit and scope of the invention is to be limited only by the appended claims.
Industrial Applicability
While the above-described invention is particularly suited for the neutralization and the clearing of areas infested by unexploded ordnances, after an attack, the present invention may also be employed to clear artillery ranges and other test facilities of unexploded ordnances or to freeze food crops, as well as sea food crops, in situ prior to their harvesting. | A system and process for neutralizing unexploded ordnances and clearing explosive infested areas such that maneuvers can be both readily and confidently continued without significant delay is disclosed. The system clears such unexploded ordnances infested areas by initially spraying the explosive infested area with a cryogenic liquid to neutralize the unexploded ordnances and reduce an output voltage of a detonator of the unexploded ordnances thereby rendering the unexploded ordnances inert, gathering the now unexploded ordnances and submerging the inert unexploded ordnances in a tank containing the same or similar cryogenic liquid so that the unexploded ordnances are maintained in a neutralized and inert state to allow for disposal. Alternatively, the neutralization of unexploded ordnance and clearing of explosive infested areas may be carried out by spraying the explosive infested area with liquefied methane to neutralize the unexploded ordnance and reduce an output voltage of a detonator of the unexploded ordnances to render such ordnance inert, igniting the liquefied methane, deflagrating the unexploded ordnances at a temperature less than that required for detonation and subsequently removing the neutralized ordnances from the explosive infested area. | 5 |
[0001] The invention relates to a chain guide for a driving chain of a mining machine, in particular for a plow chain for moving a winning plow, comprising driving and/or return stations which are provided on or can be arranged on end regions of the mining machine and have driving or return sprockets for the driving chain, and comprising at least one chain guide element which is arranged in spatial proximity to the sprockets at the driving and/or return station and can be adjusted, or is engaged in operational use, transversely to the direction of movement of the chain against its load strand and/or return strand.
BACKGROUND OF THE INVENTION
[0002] A chain guide arrangement on a mining machine is known (DE 20 2004 000 924 U) in which a chain guide element is formed by a hold-down device which has a pressure surface and can be inserted into an accommodating pocket in the region of the chain guide in such a way that it can be put, with a pin receptacle open on one side, onto a hinge pin arranged in the region of the accommodating pocket and is then pivoted about said hinge pin into the pocket until its bottom pressure surface presses against the driving chain and it can be locked in this position by a locking arrangement. It is possible to quickly exchange the hold-down device together with the pressure surface formed thereon for a new chain guide element of corresponding design, whereby downtimes in the event of wear of the pressure surface of the hold-down device can be minimized. At the same time, the known chain guide elements, past which the driving chain is moved with a considerable pressure force and at a considerable speed, is subjected to high wear, and therefore it is necessary to exchange it within relatively short time intervals in order to ensure the proper operation of the mining machine.
SUMMARY OF THE INVENTION
[0003] An object of the invention is to avoid these disadvantages and provide a chain guide of the type mentioned at the beginning with which the wear in the region of the chain guide element is markedly reduced.
[0004] This object is achieved by the invention in that the chain guide element has at least one pressure roller which is adjusted or can be adjusted against the chain links of the driving chain.
[0005] Through the use of a pressure roller on the chain guide element, sliding contact between said chain guide element and the driving chain is at least largely prevented, for the peripheral speed at which the pressure roller rotates is the same as the passage speed of the chain, against which it presses in order to guide it. Even if coal dust or other material, possibly also abrasive material, gets between chain and pressure roller, the wear caused by this on the pressure roller track, which in a preferred configuration of the invention can be adapted to the envelope curve defined by the chain links, is only slight, for which reason it is not necessary to exchange the chain guide element substantially formed by the pressure roller until after a period of use considerably longer than was the case with the chain guide elements used hitherto.
[0006] The pressure roller is preferably rotatably mounted on a roller axle and can be exchanged together with the latter. The roller axle, in a construction unit with the pressure roller which is rotatably mounted thereon, is then removed and exchanged for a corresponding new part, wherein the downtimes of the mining machine are reduced to a minimum. The pressure roller can then be arranged or mounted in an especially advantageous manner on an attachment which can be interchangeably inserted or is interchangeably inserted in the entry region of the driving and/or return station. In this especially advantageous design, the pressure roller is therefore arranged on an attachment which can be interchangeably inserted in an accommodating pocket and which can then also contain still further components of the chain guide, such as, for example, a catch, known per se, for the chain, said catch being used when the driving or return sprockets of the driving or return stations are exchanged in order to keep the chain tensioned during such maintenance work.
[0007] According to an advantageous configuration, the roller axle of the pressure roller can be supported on one or more bearing blocks which are preferably interchangeably fitted in an accommodating pocket. In this case, a bottom bearing block and a top bearing block can preferably be provided on both sides of the roller. In this configuration, the bearing blocks can more preferably be secured against release in the accommodating pocket by means of a preferably hinged lid. Alternatively, the bearing blocks can be secured against release in the accommodating pocket by means of at least one sliding bolt. In this configuration, it is especially advantageous if a top bearing block is provided with sliding guides for sliding bolts. The sliding guides can consist in particular of hook-like strips which vertically fix and at the same time guide in a horizontally movable manner the one sliding bolt or preferably the two sliding bolts displaceable relative to one another. In this case, retaining blocks having locking pockets which face one another are more preferably fitted above the accommodating pocket, and/or the sliding bolts have locking lugs which engage in the locking pockets in the locking state in order to secure the top bearing block against release in the locking state of the locking bolts.
[0008] In an especially preferred configuration having form-fitting bolt securing for the bearing blocks, a pair of sliding bolts are provided, wherein each sliding bolt has a U-shaped base having three legs, of which one marginal leg and an intermediate leg are provided, on outer sides facing away from one another, with guide strips for form-fitting engagement in sliding guides, and of which the second marginal leg has a through-hole for a securing screw. A bottom axle receptacle for the roller axle can be arranged directly at the bottom of the recess and can preferably be fixedly formed on or fastened to the attachment.
[0009] In particular if it is necessary to guide and keep under tension especially long and/or heavy chains using a chain guide element according to the invention, a design which has a plurality of pressure rollers which are arranged one behind the other in the passage direction of the chain and are adjusted against the chain can be advantageous, as a result of which the requisite, high pressure force can be distributed over a plurality of rollers and the surface pressures between chain and running surface of the pressure rollers can be kept low or reduced. The pressure roller can be adjusted against the chain under the effect of at least one spring element and/or of at least one shock absorber, thereby making it possible for the chain to yield in a direction transversely to its passage direction, for example if shock-like loads occur, but without the pressure roller lifting from the chain, not even temporarily, and thereby no longer being able to perform its guide function, even if only briefly.
[0010] These and other objects, aspects, features, developments, embodiments and advantages of the invention of this application will become apparent to those skilled in the art upon a reading of the Detailed Description of Embodiments set forth below taken together with the drawings which will be described in the next section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
[0012] FIG. 1 shows a chain guide for a driving chain of a coal plow in longitudinal section;
[0013] FIG. 2 shows a chain guide according to FIG. 1 in an oblique perspective illustration from above, partly in section;
[0014] FIG. 3 shows the pressure roller used in the chain guide according to FIGS. 1 and 2 , in section;
[0015] FIG. 4 shows an attachment which can be inserted in the chain guide according to FIGS. 1 and 2 and has a pressure roller accommodated therein, in a perspective illustration, according to a first embodiment variant;
[0016] FIG. 5 shows an attachment which can be inserted in the chain guide according to FIGS. 1 and 2 and has a pressure roller accommodated therein, in a perspective exploded illustration, according to a second embodiment variant;
[0017] FIG. 6 shows a longitudinal section through the attachment according to FIG. 5 in the fitted state of the pressure roller; and
[0018] FIG. 7 shows a perspective detailed view of the sliding bolt pair.
DETAILED DESCRIPTION OF EMBODIMENTS
[0019] Referring now to the drawings wherein the showings are for the purpose of illustrating preferred and alternative embodiments of the invention only and not for the purpose of limiting the same, FIGS. 1 and 2 show a scraper chain conveyor at one of its end regions, said scraper chain conveyor being provided, in a manner known per se, with a plow guide for a coal-winning plow. The plow (not shown) is driven by means of a driving chain 11 which is accommodated in a chain box 10 lying below the conveying plane.
[0020] To this end, the arrangement has a first chain passage 13 for the load strand 14 of the driving to chain and a second chain passage 15 through which the return strand 16 of the driving chain runs. Located at the end regions of the chain passages 13 , 15 is a driving station 17 having a driving sprocket 18 , around which the driving chain 11 is looped and with which the chain is pulled through the chain passages in a known manner. Arranged in the transition region 19 between the second chain passage 15 and the driving station 17 is a chain guide 20 having a chain guide element 21 which pushes the return strand of the chain downward and thereby deflects said return strand out of the chain passage for the return strand toward the driving sprocket 18 and which has a pressure roller 22 , or consists substantially of such a pressure roller, which presses from above with its track 23 against the driving chain 11 and thereby deflects the chain toward the driving sprocket and keeps the chain under tension.
[0021] The chain guide 20 , which consists of an attachment 25 interchangeably fitted into a gap 24 above the chain passage 15 at the transition region 19 of the mining machine, is shown in more detail in a first embodiment in FIGS. 3 and 4 . It can be seen that the attachment 25 consists of a housing having two side walls 26 and a rear end wall 27 , wherein the two side walls 26 are provided with upwardly open recesses as accommodating pockets 40 for bearing blocks 28 , 28 A which accommodate a roller axle 29 for the pressure roller 22 in a rotationally fixed manner. The accommodating pocket 40 is defined at the rear by the end wall 27 and at the bottom and at the front by the respective side wall 26 . Both bearing blocks 28 , 28 A are formed congruently with the circumferential wall of the accommodating pocket 40 and are accommodated in the latter in a form-fitting manner. The bottom bearing block 28 , if need be, may also be fixedly anchored in the accommodating pocket and, for example, welded in place for this purpose. The top bearing block 28 A, once the nuts 41 have been released from the two vertically disposed threaded rods 42 anchored in the bottom bearing block 28 or in the side wall 26 , can be removed upward, as a result of which the roller axle 29 is exposed and can then also be removed together with the pressure roller 22 from the bottom bearing block 28 and exchanged for another pressure roller 22 plus roller axle 29 .
[0022] The pressure roller 22 is rotatably mounted on the roller axle 29 with two tapered roller bearings 30 in back-to-back arrangement and is provided with lateral sealing covers 31 to prevent the ingress of coal dust or other contaminants. It can be seen in particular in FIG. 3 that the track 23 of the pressure roller 22 has a concave shape adapted to the envelope curve 34 defined by the chain links 33 , such that the pressure roller, when it acts on the chain, not only keeps said chain under tension and deflects it, but at the same time also prevents lateral running of the chain.
[0023] During operation, the pressure roller 22 accommodated in the attachment 25 or in the accommodating pocket 24 is covered at the top by a hinged lid 35 which prevents, to the greatest possible extent, coal dust or rock fragments from reaching the roller but, after it has been opened, allows easy access to the pressure roller 22 and thus enables dust or other contaminants which have nonetheless settled in the region of the pressure roller and/or in the accommodating pocket to be removed again with simple means. If it should transpire during such an inspection that the functioning of the roller is no longer reliably ensured due to wear, said roller can be exchanged quickly and simply by the lid 35 mounted on one side on the hinge spindle 45 being swung open and then, as described above, by the bearing blocks 28 , 28 A being opened and by the pressure roller 22 together with its roller axle 29 being lifted out and exchanged for a new roller with roller axle. If both the bottom bearing block 28 and the top bearing block 28 A sit loosely in the accommodating pocket 40 , i.e. in such a way as to be removable upward here, the lid 35 can at the same time form the securing element which presses the bearing blocks 28 , 28 A downward into the accommodating pocket 40 and secures them against release. However, the lid 35 can also hold only the top bearing block 28 A in the closed position.
[0024] FIGS. 5 and 6 show an alternative configuration of a chain guide 120 according to the invention, which again consists substantially of an attachment 125 which, via the side wall 126 , here the rear side wall 126 , designed as a bearing plate having strip-shaped edges, can be fastened to a spill plate, designed for accommodating the bearing plate, of a driving station of a plow installation. In the exemplary embodiment of the attachment 125 shown, the front side wall 126 , only shown in FIG. 6 , can be fastened to a spar or a side spill plate of the driving station via a tilting hinge 160 , as a result of which, provided the retaining hooks for the rear side wall 126 are released, the entire attachment 125 can be pivoted in order to be able to carry out, for example, repair work on a scraper chain conveyor laid parallel to the plow installation. As in the previous exemplary embodiment, a catch 161 is also pivotably linked between the two chain walls 126 in the case of the attachment 125 in order to be able to secure the chain strand of the plow chain for repairs when the closing lid 162 is removed or swung up. An accommodating pocket 140 is again formed in the left-hand half of the attachment 125 , in which accommodating pocket 140 a pressure roller 122 rotatably mounted on a bearing axle 129 and forming the actual chain guide element 121 can be interchangeably fastened, wherein the pressure roller 122 can be pressed in an adjustable manner, or with its track, as already described further above, against a plow chain (not shown in FIGS. 5 and 6 ). In the operating state, the plow chain passes through a passage opening 151 in the end wall 127 , here the front end wall 127 , and a passage opening 152 in the end wall 127 A, here the rear end wall 127 A. In the fitted state of the attachment 125 at the driving station, the top chain guide passage for the plow chain adjoins the front passage opening 151 , whereas the plow chain behind the rear passage opening 152 enters the driving or return sprocket for the plow chain. With the pressure roller 122 , the plow chain can be preloaded downward between both passage openings 151 , 152 , thereby enabling the top chain strand of the plow chain to enter the plow chain sprocket (not shown) with low wear in an optimum manner without the plow chain coming into contact with, for example, the edges of the rear passage opening 152 . As in the previous exemplary embodiment, here, too, the pressure roller 122 and roller axle 129 are designed as a construction unit, for which reason the entire pressure roller 122 can be exchanged for another pressure roller without any problems and quickly if wear has occurred at the envelope curve of the pressure roller 122 or the mounting thereof.
[0025] In order to enable the pressure roller 122 together with roller axle 129 to be exchanged as simply as possible and at the same time achieve stable and reliable locking of the roller axle 129 even in the event of disproportionately high vertical forces on the pressure roller 122 , the roller axle 129 , with its two axle journals 129 A which project laterally beyond the pressure roller 122 , is inserted in axle receptacles 155 in a rotationally fixed manner, wherein the bottom axle receptacle 155 is formed directly on a wall section 126 A of the side wall 126 , here the front side wall 126 , and the rear bottom axle receptacle is formed on a rear wall section in the rear side wall 126 . In this case, the axle receptacle 155 can either consist of a correspondingly integrally formed recess in the wall section 126 A or, as shown in FIG. 5 , can be formed inside a ring segment 156 which is welded to the wall section 126 A and could also be exchanged in the event of repair if the axle receptacle 155 is worn. The axle receptacle 155 together with ring segment 156 therefore forms a bottom bearing block in the attachment 125 of the chain guide 120 , this bearing block being formed fixedly and in one piece on the attachment 125 , whereas only a top bearing block designated overall by reference numeral 128 can be removed. The top bearing block 128 at the same time forms the lid for the pressure roller 122 , and the bearing block 128 has two side webs 171 which in this case have a rectangular cross section and can be inserted in an accurately form-fitting manner into the correspondingly congruently designed accommodating pockets 140 in the wall sections 126 A. Both side webs 171 are provided at their bottom edge with further ring segments 176 , which, like the bottom ring segments 156 on the wall sections 126 A, each form one half of the axle receptacle, here therefore the top half of the axle receptacle 155 , and, in the fitted state, accommodate the axle journal 129 A in a rotationally fixed manner between both ring segments 156 , 176 , said axle journal 129 A having a noncircular, preferably approximately oval cross section in the exemplary embodiment shown.
[0026] The bearing block 128 designed as a lid is provided with a cover web 172 which connects the two side webs 171 and above which two lateral, approximately L-shaped hook strips 173 are welded on, which form, with their undercut sections, sliding guides for two sliding bolts 190 of identical design, with which the locking position of the top bearing block 128 can be secured in order to prevent unintentional release of the bearing block 128 and in this respect also the displacement of the roller axle 129 of the pressure roller 122 .
[0027] Reference will now first be made to FIG. 7 , in which the two sliding bolts 190 of identical design, which are used as a pair of sliding bolts 190 , are shown. Each sliding bolt 190 has a substantially U-shaped basic body 191 having a short marginal leg 192 , a longer marginal leg 193 and an intermediate leg 194 which runs perpendicularly to both marginal legs 192 , 193 . Both the intermediate leg 194 and the end face of the longer marginal leg 193 are each provided at the margin with a step, as a result of which guide strips 195 and 196 are formed on the marginal leg 193 and intermediate leg 194 , respectively, with which the sliding bolts 190 can each be secured in a form-fitting manner to the strips ( 173 , FIG. 5 ), forming the sliding guide, in such a way as to be guided in a vertically fixed and horizontally movable manner. The shorter marginal leg 192 in each case is dimensioned in such a way that, in the fitted state, the guide strip 196 on the intermediate leg 194 and the substantially shorter guide strip 195 on the end face of the marginal leg 193 lie such as to be plane-parallel relative to one another. Due to the U-shaped configuration, the respectively shorter marginal leg 192 plunges into the intermediate space 197 between the two marginal legs 192 , 193 , and the distance between the two longer marginal legs 193 can be reduced by pushing apart the two shorter marginal legs 192 . Only in this position, which is not shown in the figure, can the top bearing block ( 128 , FIG. 5 ) be fitted or removed in the accommodating pocket in order to open or close the mounting for the roller axle ( 129 , FIG. 5 ). To lock the bearing block by a form fit, the longer marginal legs 193 are provided on the outside with locking lugs 198 , the top sides of which taper in a wedge shape toward the free ends and which, for locking the bearing block 128 , as shown in FIG. 6 , to engage in locking pockets 165 which are formed on retaining blocks 166 , which in turn are fitted on the top surfaces of the two end walls 127 , 127 A with locking pockets 165 facing one another.
[0028] In order to prevent the sliding bolts 190 from being released from one another and from the locking position, even during vibrations, and at the same time in order to be able to apply as high a clamping force as possible, in each case the shorter marginal leg 192 is provided with a through-hole 199 , through which a clamping screw 180 passes. The distance between the two shorter marginal legs 192 can be reduced via the clamping screw 180 , as a result of which the distance between the two outer, longer marginal legs 193 increases and the locking lugs 198 engage correspondingly deeper in the locking pockets 165 .
[0029] The invention is not restricted to the exemplary embodiments shown and described, but rather various modifications and additions are conceivable without departing from the scope of the invention. It is thus possible, for example, to provide a plurality of pressure rollers arranged one behind the other in the passage direction of the chain in order to provide a guide for the chain over a longer distance, said guide working largely free of wear. It is also possible to adjust the pressure roller against the chain under the effect of a spring element and/or of a shock absorber, whereby reliable contact between roller and chain is always ensured, even during shock-like loads on the driving chain. The chain guide according to the invention can alternatively or additionally act on the load strand of the driving chain and is of course suitable not only for a plow chain but also, for example, for driving chains of scraper chain conveyors. The bearing blocks can also be inserted in accommodating pockets which are formed directly on the side cheeks of the driving or return stations.
[0030] Further, while considerable emphasis has been placed on the preferred embodiments of the invention illustrated and described herein, it will be appreciated that other embodiments, and equivalences thereof, can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. Furthermore, the embodiments described above can be combined to form yet other embodiments of the invention of this application. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. | A chain guide for a driving chain of a winning plow or the like, the chain guide being provided with a chain guide element which is arranged in spatial proximity to the sprockets at a driving or return station and is against the chain transversely to the direction of movement of the latter, provision is made according to the invention for the chain guide element to have at least one pressure roller which can be adjusted against the chain links of the driving chain, as a result of which the wear on the chain guide element is considerably reduced. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical lens system for taking image, and more particularly to a miniaturized optical lens system for taking image used in a mobile phone camera.
2. Description of the Prior Art
In recent years, with the popularity of the mobile phone camera, the optical lens system for taking image has become thinner and thinner, and the electronic imaging sensor of a general digital camera is typically a CCD (Charge Coupled Device) or CMOS (Complementary Metal Oxide Semiconductor) sensor. Due to advances in semiconductor manufacturing, the pixel size of sensors has been reduced continuously, and miniaturized optical lens systems for taking image have increasingly higher resolution. Therefore, there's increasing demand for image quality.
A conventional mobile phone camera usually consists of three lens elements: from the object side to the image side: a first lens element with positive refractive power, a second lens element with negative refractive power and a third lens element with positive refractive power, such as the optical lens system for taking image described in U.S. Pat. No. 7,145,736.
As the pixel size of electronic imaging sensors gradually becomes smaller and smaller, the system requires higher image quality. The conventional optical lens system comprising three lens elements cannot satisfy the requirements of higher resolution optical lens systems.
U.S. Pat. No. 7,365,920 discloses a four-piece lens assembly, in which the first lens element and the second lens element, both glass spherical lens elements, are bonded to each other to form a doublet lens element for eliminating chromatic aberration. However, it suffers from the following disadvantages: the degree of freedom available in the optical system is insufficient since there are too many glass spherical lens elements, making it difficult to reduce the length of the optical system; and the manufacturing difficulty is increased due to the difficult process of bonding the glass lens elements.
The present invention mitigates and/or obviates the afore-mentioned disadvantages.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide an optical lens system for taking image comprising four lens elements to improve image quality, and effectively reduce the volume of the optical lens system.
An optical lens system for taking image in accordance with the present invention comprises: in order from the object side to the image side: a first lens element with positive refractive power; a second lens element with negative refractive power; a third lens element with negative refractive power having a convex object-side surface and a concave image-side surface; a fourth lens element with negative refractive power being provided with at least one aspheric surface. In the optical lens system for taking image, the number of lens elements with refractive power is limited to four. Such lens arrangements can effectively improve image quality.
In the present optical lens system for taking image, the refractive power of the system is mainly provided by the first lens element with positive refractive power. The second lens element with negative refractive power mainly serves to correct the chromatic aberration. The third lens element and the fourth lens element serve as correction lens elements to balance and correct various aberrations caused by the optical lens system. In addition, the third lens element and the fourth lens element are negative so that the principal point of the system will be far away from the image plane, so that the total track length of the optical lens system will be effectively reduced.
The first lens element provides a strong positive refractive power, and the aperture stop is located close to the object side, so that the total track length of the optical lens system can be effectively reduced, and the exit pupil of the optical lens system will be far away from the image plane. Therefore, the light will be projected onto the sensor with a relatively small incident angle, this is the telecentric feature of the image side, and this feature is very important to the photosensitive power of current solid-state sensors, since they are more sensitive when the light is incident at a small angle. This also reduces the probability of the occurrence of shading. The inflection points formed on the third lens element and the fourth lens element will contribute to a better correction of the incident angle of the off axis light with respect to the sensor.
In addition, in wide angle optical systems, it is especially necessary to correct the distortion and the chromatic aberration of magnification, and this can be solved by locating the aperture stop at the balance point of the refractive power of the system. In the present optical lens system for taking image, if the aperture stop is located in front of the first lens element, the telecentric feature of the optical lens system becomes emphasized, the total track length of the optical lens system will become shorter. If the aperture stop is located between the first and second lens elements, the wide field of view becomes emphasized, and the optical system is less sensitive as well.
With the trend of miniaturization of the optical lens system and the requirement of increasing the field of view, the focal length of the optical lens system is becoming very short. Therefore, the radius of curvature and the size of the lens elements must be very small, and it is difficult to make such glass lens elements by the use of conventional grinding. Plastic material is introduced to make lens elements by injection molding, using a relatively low cost to produce high precision lens elements. The lens elements are provided with aspheric surfaces, allowing more design parameters (than spherical surfaces), so as to better reduce the aberration and the number of the lens elements, thus effectively reducing the total track length of the optical lens system.
According to one aspect of the present invention, in the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the focal length of the third lens element is f3, and they satisfy the relation:
| f/f 3|<0.5.
If f/f3 satisfies the above relation, the third lens element serves as a correction lens element to balance and correct various aberration caused by the optical lens system, it will be favorable to correct the astigmatism and the distortion caused by the optical lens system, improving the resolution of the optical lens system. Further, it will be better if f/f3 satisfies the relation:
| f/f 3|<0.2.
According to another aspect of the present invention, in the present optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
25.2 <V 1 −V 2<35.0.
If V1 and V2 satisfy the above relation, the chromatic aberration of the optical lens system can be effectively corrected, improving the image quality of the optical lens system. Further, it will be better if V1 and V2 satisfy the relations:
30.6 <V 1 −V 2<34.0;
V2<25.0.
According to another aspect of the present invention, in the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the on-axis distance between the second lens element and the third lens element is T23, and they satisfy the relation:
( T 23 /f )*100>3.5.
If T23/f satisfies the above relation, it will be favorable to correct the high order aberrations of the system.
According to another aspect of the present invention, in the present optical lens system for taking image, the inflection points formed on the object-side surface of the second lens element can effectively correct the off-axis aberration of the system.
According to another aspect of the present invention, in the present optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relation:
R 3 /R 4>3.0.
If the value of R3/R4 is smaller than the above lower limit, it will be difficult to correct the chromatic aberration caused by the system.
According to another aspect of the present invention, in the present optical lens system for taking image, the on-axis distance between the first lens element and the second lens element is T12, the focal length of the optical lens system for taking image is f, and they satisfy the relation:
0.6<( T 12 /f )*100<5.0.
If T12/f satisfies the above relation, it can allow better correction of the high order aberrations of the system.
According to another aspect of the present invention, in the present optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
1.50<N1<1.58.
If N1 satisfies the above relation, the plastic optical material with the refractive index within the above range will better match the optical lens system.
According to another aspect of the present invention, in the present optical lens system for taking image, the radius of curvature of the object-side surface of the third lens element is R5, the radius of curvature of the image-side surface of the third lens element is R6, the radius of curvature of the object-side surface of the fourth lens element is R7, the radius of curvature of the image-side surface of the fourth lens element is R8, and they satisfy the relations:
1.1< R 5 /R 6<1.3;
1.1< R 7 /R 8<1.3.
If R5/R6 and R7/R8 satisfy the above relations, the third lens element and the fourth lens element serve as correction lens elements to correct the high order aberrations of the system, improving the image quality of the optical lens system.
According to another aspect of the present invention, in the present optical lens system for taking image, an object to be photographed is imaged on an electronic imaging sensor, the total track length of the system is TTL, the image height of the system is Imgh, and they satisfy the relation:
TTL/ImgH< 1.95.
The above relation can maintain the objective of miniaturization of the optical lens system for taking image.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows an optical lens system for taking image in accordance with a first embodiment of the present invention;
FIG. 1B shows the aberration curves of the first embodiment of the present invention;
FIG. 2A shows an optical lens system for taking image in accordance with a second embodiment of the present invention;
FIG. 2B shows the aberration curves of the second embodiment of the present invention;
FIG. 3A shows an optical lens system for taking image in accordance with a third embodiment of the present invention;
FIG. 3B shows the aberration curves of the third embodiment of the present invention;
FIG. 4A shows an optical lens system for taking image in accordance with a fourth embodiment of the present invention; and
FIG. 4B shows the aberration curves of the fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1A , which shows an optical lens system for taking image in accordance with a first embodiment of the present invention, and FIG. 1B shows the aberration curves of the first embodiment of the present invention. An optical lens system for taking image in accordance with the first embodiment of the present invention comprises: in order from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with negative refractive power has a convex object-side surface 21 and a concave image-side surface 22 , the object-side surface 21 and the image-side surface 22 of the second lens element 20 are aspheric, and inflection points are formed on the object-side surface 21 of the second lens element 20 .
A plastic third lens element 30 with negative refractive power has a convex object-side surface 31 and a concave image-side surface 32 , the object-side surface 31 and the image-side surface 32 of the third lens element 30 are aspheric, and inflection points are formed on the object-side surface 31 and the image-side surface 32 of the third lens element 30 .
A plastic fourth lens element 40 with negative refractive power has a convex object-side surface 41 and a concave image-side surface 42 , the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 are aspheric, and inflection points are formed on the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 .
An aperture stop 50 .
An IR cut filter 60 is located behind the fourth lens element 40 and has no influence on the focal length of the optical lens system.
An image plane 70 is located behind the IR cut filter 60 .
The equation for the aspheric surface profiles of the first embodiment is expressed as follows:
X
(
Y
)
=
(
Y
2
/
R
)
/
(
1
+
sqrt
(
1
-
(
1
+
k
)
*
(
Y
/
R
)
2
)
)
+
∑
i
(
Ai
)
*
(
Y
i
)
wherein:
X: the height of a point on the aspheric lens surface at a distance Y from the optical axis relative to the tangential plane at the aspheric surface vertex;
Y: the distance from the point on the curve of the aspheric surface to the optical axis;
k: the conic coefficient;
Ai: the aspheric surface coefficient of order i.
In the first embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the focal length of the third lens element is f3, and they satisfy the relations:
f=3.67 mm;
| f/f 3|=0.05.
In the first embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the on-axis distance between the first lens element and the second lens element is T12, the on-axis distance between the second lens element and the third lens element is T23, and they satisfy the relations:
( T 12 /f )*100=2.0
( T 23 /f )*100=18.6.
In the first embodiment of the present optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.544.
In the first embodiment of the present optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relations:
V2=23.4;
V 1 −V 2=32.5.
In the first embodiment of the present optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, the radius of curvature of the object-side surface of the third lens element is R5, the radius of curvature of the image-side surface of the third lens element is R6, the radius of curvature of the object-side surface of the fourth lens element is R7, the radius of curvature of the image-side surface of the fourth lens element is R8, and they satisfy the relations:
R 3 /R 4=14.52;
R 5 /R 6=1.16;
R 7 /R 8=1.22.
In the first embodiment of the present optical lens system for taking image, an object to be photographed is imaged on an electronic imaging sensor, the total track length of the system is TTL, the image height of the system is Imgh, and they satisfy the relation:
TTL/ImgH= 1.76.
The detailed optical data of the first embodiment is shown in table 1, and the aspheric surface data is shown in table 2, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 1
(Embodiment 1)
f(focal length) = 3.67 mm, Fno = 2.8, HFOV (half of field of view) = 33.0 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
Plano
−0.079
Stop
2
Lens 1
1.51538(ASP)
0.527
Plastic
1.544
55.9
2.86
3
50.00000(ASP)
0.073
4
Lens 2
50.00000(ASP)
0.580
Plastic
1.632
23.4
−5.88
5
3.44250(ASP)
0.684
6
Lens 3
3.81180(ASP)
0.599
Plastic
1.544
55.9
−73.42
7
3.28710(ASP)
0.252
8
Lens 4
1.23700(ASP)
0.556
Plastic
1.514
56.8
−72.42
9
1.01460(ASP)
0.300
10
IR-filter
Plano
0.300
Glass
1.517
64.2
11
Plano
0.386
12
Image
Plano
TABLE 2
Aspheric Coefficients
Surface #
2
3
4
5
7
k =
−5.13663E+00
−1.00000E+00
−1.00000E+00
−4.39965E+00
−1.00000E+02
A4 =
1.53617E−01
−3.12081E−01
−3.16152E−01
−4.39472E−02
−8.35248E−02
A6 =
−1.27962E−01
1.91343E−01
3.63725E−01
1.54627E−01
5.44434E−02
A8 =
1.08041E−01
1.00841E−01
−1.11663E−01
−5.92434E−02
−2.52417E−02
A10 =
−3.39184E−01
−1.40160E−01
2.42472E−01
8.60832E−02
−5.15593E−03
A12 =
1.45082E−01
−2.42513E−02
4.37432E−02
2.94293E−02
3.35439E−03
A14 =
1.64510E−01
8.19930E−02
−4.35646E−02
−2.37080E−03
−3.92832E−04
A16 =
1.96686E−01
3.33814E−01
−1.85699E−01
−4.22691E−02
Surface #
6
8
9
k =
4.30199E+00
−1.22186E+00
−3.14835E+00
A1 =
A2 =
A3 =
A4 =
−4.60552E−02
−6.80733E−01
−2.98953E−01
A5 =
A6 =
−6.57535E−02
5.56282E−01
2.30102E−01
A7 =
A8 =
6.11730E−02
−3.46545E−01
−1.16085E−01
A9 =
A10 =
−4.21537E−02
1.23560E−01
3.08330E−02
A11 =
A12 =
−1.95882E−02
−3.94254E−03
A13 =
A14 =
8.25495E−04
1.90488E−04
Referring to FIG. 2A , which shows an optical lens system for taking image in accordance with a second embodiment of the present invention, and FIG. 2B shows the aberration curves of the second embodiment of the present invention. The second embodiment of the present invention comprises: in order from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a convex image-side surface 12 , and the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with negative refractive power has a concave object-side surface 21 and a convex image-side surface 22 , the object-side surface 21 and the image-side surface 22 of the second lens element 20 are aspheric, and inflection points are formed on the object-side surface 21 of the second lens element 20 .
A plastic third lens element 30 with negative refractive power has a convex object-side surface 31 and a concave image-side surface 32 , the object-side surface 31 and the image-side surface 32 of the third lens element 30 are aspheric, and inflection points are formed on the object-side surface 31 and the image-side surface 32 of the third lens element 30 .
A plastic fourth lens element 40 with negative refractive power has a convex object-side surface 41 and a concave image-side surface 42 , the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 are aspheric, and inflection points are formed on the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 .
An aperture stop 50 .
An IR cut filter 60 is located behind the fourth lens element 40 and has no influence on the focal length of the optical lens system.
An image plane 70 is located behind the IR cut filter 60 .
The equation for the aspheric surface profiles of the second embodiment has the same form as that of the first embodiment.
In the second embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the focal length of the third lens element is f3, and they satisfy the relations:
f=3.36 mm;
| f/f 3|=0.10.
In the second embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the on-axis distance between the first lens element and the second lens element is T12, the on-axis distance between the second lens element and the third lens element is T23, and they satisfy the relations:
( T 12 /f )*100=8.5
( T 23 /f )*100=13.2.
In the second embodiment of the present optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.544.
In the second embodiment of the present optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relations:
V2=23.4;
V 1 −V 2=32.5.
In the second embodiment of the present optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, the radius of curvature of the object-side surface of the third lens element is R5, the radius of curvature of the image-side surface of the third lens element is R6, the radius of curvature of the object-side surface of the fourth lens element is R7, the radius of curvature of the image-side surface of the fourth lens element is R8, and they satisfy the relations:
R 3 /R 4=0.50;
R 5 /R 6=1.24;
R 7 /R 8=1.21.
In the second embodiment of the present optical lens system for taking image, an object to be photographed is imaged on an electronic imaging sensor, the total track length of the system is TTL, the image height of the system is Imgh, and they satisfy the relation:
TTL/ImgH= 1.66.
The detailed optical data of the second embodiment is shown in table 3, and the aspheric surface data is shown in table 4, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 3
(Embodiment 2)
f(focal length = 3.36 mm, Fno = 2.45, HFOV (half of field of view) = 35.5 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
Plano
−0.060
Stop
2
Lens 1
1.54484(ASP)
0.627
Plastic
1.544
55.9
2.27
3
−5.29770(ASP)
0.284
4
Lens 2
−1.39141(ASP)
0.500
Plastic
1.632
23.4
−5.14
5
−2.77443(ASP)
0.442
6
Lens 3
2.72988(ASP)
0.523
Plastic
1.530
55.8
−33.27
7
2.20703(ASP)
0.257
8
Lens 4
1.13726(ASP)
0.399
Plastic
1.544
55.9
−33.16
9
0.93756(ASP)
0.300
10
IR-filter
Plano
0.300
Glass
1.517
64.2
11
Plano
0.392
12
Image
Plano
TABLE 4
Aspheric Coefficients
Surface #
2
3
4
5
7
k =
−5.53255E+00
6.38809E+00
1.21884E+00
5.42590E+00
−3.01061E+01
A4 =
1.28420E−01
−1.79386E−01
−5.35538E−02
−3.77510E−03
6.84213E−03
A6 =
−2.01356E−01
−1.42295E−01
5.01720E−01
3.50685E−01
−3.04665E−02
A8 =
1.81403E−01
−4.44714E−02
−6.47578E−01
−2.21828E−01
1.43383E−02
A10 =
−6.01302E−01
−2.25945E−02
7.63205E−01
1.76997E−01
−9.40929E−03
A12 =
2.60630E−03
A14 =
−2.58440E−04
Surface #
6
8
9
k =
−7.89116E−01
−1.56630E+00
−3.40421E+00
A1 =
A2 =
A3 =
A4 =
−1.23612E−01
−6.35756E−01
−3.09660E−01
A5 =
A6 =
3.60447E−02
5.72114E−01
2.36697E−01
A7 =
A8 =
−1.68977E−02
−3.55406E−01
−1.19986E−01
A9 =
A10 =
−8.36898E−03
1.20839E−01
3.04869E−02
A11 =
A12 =
−1.97397E−02
−3.78247E−03
A13 =
A14 =
1.22445E−03
2.04583E−04
Referring to FIG. 3A , which shows an optical lens system for taking image in accordance with a third embodiment of the present invention, FIG. 3B shows the aberration curves of the third embodiment of the present invention. The third embodiment of the present invention comprises: in order from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with negative refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and the object-side surface 21 and the image-side surface 22 of the second lens element 20 are aspheric.
A plastic third lens element 30 with negative refractive power has a convex object-side surface 31 and a concave image-side surface 32 , the object-side surface 31 and the image-side surface 32 of the third lens element 30 are aspheric, and inflection points are formed on the object-side surface 31 and the image-side surface 32 of the third lens element 30 .
A plastic fourth lens element 40 with negative refractive power has a convex object-side surface 41 and a concave image-side surface 42 , the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 are aspheric, and inflection points are formed on the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 .
An aperture stop 50 is located between the first lens element 10 and the second lens element 20 .
An IR cut filter 60 is located behind the fourth lens element 40 and has no influence on the focal length of the optical lens system.
An image plane 70 is located behind the IR cut filter 60 .
The equation for the aspheric surface profiles of the third embodiment has the same form as that of the first embodiment.
In the third embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the focal length of the third lens element is f3, and they satisfy the relations:
f=3.34 mm;
| f/f 3|=0.05.
In the third embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the on-axis distance between the first lens element and the second lens element is T12, the on-axis distance between the second lens element and the third lens element is T23, and they satisfy the relations:
( T 12 /f )*100=11.1;
( T 23 /f )*100=14.9.
In the third embodiment of the present optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.544.
In the third embodiment of the present optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relations:
V2=30.2;
V 1 −V 2=25.7.
In the third embodiment of the present optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, the radius of curvature of the object-side surface of the third lens element is R5, the radius of curvature of the image-side surface of the third lens element is R6, the radius of curvature of the object-side surface of the fourth lens element is R7, the radius of curvature of the image-side surface of the fourth lens element is R8, and they satisfy the relations:
R 3 /R 4=0.65;
R 5 /R 6=1.13;
R 7 /R 8=1.18.
In the third embodiment of the present optical lens system for taking image, an object to be photographed is imaged on an electronic imaging sensor, the total track length of the system is TTL, the image height of the system is Imgh, and they satisfy the relation:
TTL/ImgH= 1.63.
The detailed optical data of the third embodiment is shown in table 5, and the aspheric surface data is shown in table 6, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 5
(Embodiment 3)
f(focal length = 3.34 mm, Fno = 2.45, HFOV (half of field of view) = 35.8 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Lens 1
1.43006(ASP)
0.491
Plastic
1.544
55.9
2.73
2
33.33330(ASP)
0.004
3
Aperture
Plano
0.366
Stop
4
Lens 2
−1.48914(ASP)
0.414
Plastic
1.583
30.2
−9.11
5
−2.28042(ASP)
0.498
6
Lens 3
2.06128(ASP)
0.372
Plastic
1.530
55.8
−65.88
7
1.82470(ASP)
0.377
8
Lens 4
1.11987(ASP)
0.401
Plastic
1.530
55.8
−64.93
9
0.95005(ASP)
0.300
10
IR-filter
Plano
0.300
Glass
1.517
64.2
11
Plano
0.422
12
Image
Plano
TABLE 6
Aspheric Coefficients
Surface #
1
2
4
5
7
k =
−3.61827E+00
−1.00000E+00
2.34991E+00
4.80509E+00
−1.80143E+01
A4 =
1.42853E−01
−1.14092E−01
5.40654E−03
7.68887E−02
6.65340E−02
A6 =
−2.49310E−01
−2.67101E−02
4.55536E−01
1.45374E−01
−8.32263E−02
A8 =
4.64347E−01
−4.49494E−01
−5.82235E−01
1.35792E−01
2.92310E−02
A10 =
−7.09956E−01
3.85751E−01
1.03560E+00
9.32809E−02
−8.61967E−03
A12 =
1.66434E−03
A14 =
−2.18982E−04
Surface #
6
8
9
k =
−3.21854E−02
−1.06356E+00
−3.47029E+00
A1 =
A2 =
A3 =
A4 =
−1.04877E−01
−6.32273E−01
−2.93822E−01
A5 =
A6 =
1.50127E−02
5.63406E−01
2.32183E−01
A7 =
A8 =
−2.79927E−02
−3.55078E−01
−1.20439E−01
A9 =
A10 =
1.07764E−02
1.21075E−01
3.04996E−02
A11 =
A12 =
−3.48241E−03
−1.97628E−02
−3.78366E−03
A13 =
A14 =
1.22013E−03
2.21387E−04
Referring to FIG. 4A , which shows an optical lens system for taking image in accordance with a fourth embodiment of the present invention, FIG. 4B shows the aberration curves of the fourth embodiment of the present invention. The fourth embodiment of the present invention comprises: in order from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a convex image-side surface 12 , and the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with negative refractive power has a convex object-side surface 21 and a concave image-side surface 22 , the object-side surface 21 and the image-side surface 22 of the second lens element 20 are aspheric, and inflection points are formed on the object-side surface 21 of the second lens element 20 .
A plastic third lens element 30 with negative refractive power has a convex object-side surface 31 and a concave image-side surface 32 , the object-side surface 31 and the image-side surface 32 of the third lens element 30 are aspheric, and inflection points are formed on the object-side surface 31 and the image-side surface 32 of the third lens element 30 .
A plastic fourth lens element 40 with negative refractive power has a convex object-side surface 41 and a concave image-side surface 42 , the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 are aspheric, and inflection points are formed on the object-side surface 41 and the image-side surface 42 of the fourth lens element 40 .
An aperture stop 50 is located between the first lens element 10 and the second lens element 20 .
An IR cut filter 60 is located behind the fourth lens element 40 and has no influence on the focal length of the optical lens system.
An image plane 70 is located behind the IR cut filter 60 .
The equation for the aspheric surface profiles of the fourth embodiment has the same form as that of the first embodiment.
In the fourth embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the focal length of the third lens element is f3, and they satisfy the relations:
f=3.75 mm;
| f/f 3|=0.10.
In the fourth embodiment of the present optical lens system for taking image, the focal length of the optical lens system for taking image is f, the on-axis distance between the first lens element and the second lens element is T12, the on-axis distance between the second lens element and the third lens element is T23, and they satisfy the relations:
( T 12 /f )*100=1.3
( T 23 /f )*100=17.8.
In the fourth embodiment of the present optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.544.
In the fourth embodiment of the present optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relations:
V2=23.4;
V 1 −V 2=32.5.
In the fourth embodiment of the present optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, the radius of curvature of the object-side surface of the third lens element is R5, the radius of curvature of the image-side surface of the third lens element is R6, the radius of curvature of the object-side surface of the fourth lens element is R7, the radius of curvature of the image-side surface of the fourth lens element is R8, and they satisfy the relations:
R 3 /R 4=17.87;
R 5 /R 6=1.22;
R 7 /R 8=1.23.
In the fourth embodiment of the present optical lens system for taking image, an object to be photographed is imaged on an electronic imaging sensor, the total track length of the system is TTL, the image height of the system is Imgh, and they satisfy the relation:
TTL/ImgH= 1.75.
The detailed optical data of the fourth embodiment is shown in table 7, and the aspheric surface data is shown in table 8, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 7
(Embodiment 4)
f(focal length) = 3.75 mm, Fno = 2.8, HFOV (half of field of view) = 32.5 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Lens 1
1.64666(ASP)
0.490
Plastic
1.544
55.9
2.61
2
−9.16500(ASP)
−0.026
3
Aperture
Plano
0.076
Stop
4
Lens 2
50.00000(ASP)
0.733
Plastic
1.632
23.4
−4.72
5
2.79740(ASP)
0.666
6
Lens 3
3.03410(ASP)
0.474
Plastic
1.544
55.9
−37.46
7
2.49560(ASP)
0.343
8
Lens 4
1.36512(ASP)
0.512
Plastic
1.544
55.9
−37.25
9
1.10994(ASP)
0.300
10
IR-filter
Plano
0.300
Glass
1.517
64.2
11
Plano
0.358
12
Image
Plano
TABLE 8
Aspheric Coefficients
Surface #
1
2
4
5
7
k =
−7.41945E+00
−1.00000E+00
−1.00000E+00
−7.47594E+00
−5.00000E+01
A4 =
1.40023E−01
−2.84203E−01
−2.00112E−01
5.80191E−02
6.00068E−02
A6 =
−2.15228E−01
2.80117E−01
3.93072E−01
5.50929E−02
−8.20842E−02
A8 =
−1.66631E−02
4.53042E−02
6.98231E−02
6.02792E−02
2.65167E−02
A10 =
−3.70623E−03
−2.99683E−01
−2.59688E−01
1.23563E−01
−8.74730E−03
A12 =
−2.98268E−01
2.38291E−03
A14 =
1.96156E−01
−4.01475E−04
A16 =
−2.70353E−05
Surface #
6
8
9
k =
1.13153E+00
−7.97350E−01
−3.87796E+00
A1 =
A2 =
A3 =
A4 =
−5.87055E−02
−5.95051E−01
−2.83270E−01
A5 =
A6 =
−3.03233E−02
5.41886E−01
2.26263E−01
A7 =
A8 =
−2.71474E−02
−3.55590E−01
−1.17136E−01
A9 =
A10 =
2.89742E−02
1.22235E−01
3.04097E−02
A11 =
A12 =
−1.55168E−02
−1.94964E−02
−3.95892E−03
A13 =
A14 =
1.12350E−03
2.28758E−04
TABLE 9
Embodiment
Embodiment
Embodiment
Embodiment
1
2
3
4
f
3.67
3.36
3.34
3.75
Fno
2.8
2.5
2.5
2.8
HFOV
33.0
35.5
35.8
32.5
V2
23.4
23.4
30.2
23.4
V1-V2
32.5
32.5
25.7
32.5
N1
1.544
1.544
1.544
1.544
(T12/f) * 100
2.0
8.5
11.1
1.3
(T23/f) * 100
18.6
13.2
14.9
17.8
|f/f3|
0.05
0.10
0.05
0.10
R3/R4
14.52
0.50
0.65
17.87
R5/R6
1.16
1.24
1.13
1.22
R7/R8
1.22
1.21
1.18
1.23
TTL/ImgH
1.76
1.66
1.63
1.75
In the present optical lens system for taking image, the lens elements can be made of glass or plastic. If the lens elements are made of glass, the freedom of distributing the refractive power of the optical lens system will be improved. If the lens elements are made of plastic, the cost will be effectively reduced.
It is to be noted that the tables 1-8 show different data from the different embodiments, however, the data of the different embodiments is obtained from experiments. Therefore, any product of the same structure is deemed to be within the scope of the present invention even if it uses different data. Table 9 lists the relevant data for the various embodiments of the present invention.
While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. | An optical lens system for taking image comprises, in order from the object side to the image side: a first lens element with positive refractive power; a second lens element with negative refractive power; a third lens element with negative refractive power having a convex object-side surface and a concave image-side surface; a fourth lens element with negative refractive power being provided with at least one aspheric surface. In the optical lens system for taking image, the number of lens elements with refractive power is limited to four. Such arrangements can reduce the volume and the sensitivity of the optical lens system while providing higher resolution. | 6 |
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/261,713 filed Nov. 16, 2009, the entirety of which is incorporated by reference, as if fully set forth herein, including all Paris Convention priority rights.
BACKGROUND
[0002] 1. Field
[0003] This disclosure relates to gift packaging and management tools.
[0004] 2. General Background
[0005] The present disclosure is directed to gift packaging and management tools. Specially, the present disclosure is directed to an apparatus designed for clasping material to a presentation device in order to enhance a user's overall sensory perception of at least one of the material, the apparatus, and/or a collateral branding theme. For many years, the gift and novelty industry has provided consumers with options for affixing visually-appealing objects to gift material. Cards, live flowers, and wrapping paper are among the most common embodiments of such options. However, most gift delivery mechanisms such as wrappings and containers have at least partially, if not entirely, enveloped and covered the gift material enclosed therein. Most gift delivery mechanisms have been relegated to such covering apparatuses due to (1) ease in manufacturing, (2) user acceptance, (3) universal fitting of gift material, and (4) inability to reuse the gift delivery mechanism.
[0006] It is also important to note that promotional items are often gifted, in whole or in part, to potential customers or existing customers. Yet another desideration is fulfilled by aspect of the instant teaching being used to these ends, as explained below and claimed herein.
[0007] Notably, the attachment of gift material to an un-containerized or external presentation device has been hampered by the lack of a universal clasping or fitting apparatus able to secure heterogeneously-shaped and -sized gift material to said presentation devices. Common solutions to this dilemma include stapling, gluing, and taping. However, these solutions are each plagued by limitations in their dexterity, aestheticism, and reusability. That is, prior to the advent of the instant teaching.
[0008] It is desirable to have an apparatus for clasping or otherwise attaching one or more gift materials to a delivery device when the delivery device improves the aestheticism and user approval of the combination of said delivery device and gift material. The combination of the delivery device and gift material may illicit a heightened response from the recipient if the delivery device visually, comically, or otherwise enhances their joint presentation, especially when the gift material is wholly or partially revealed. The most desirable attributes of such a delivery device include its appealing aesthetics, compatibility with different shapes and sizes of gift materials, reusability, ease and cost of manufacture, and transportability.
SUMMARY
[0009] Briefly stated, a novel, reusable apparatus for affixing gift material to a presentation device. The apparatus comprises a dynamic fastener for clasping or holding a gift material, allowing for the transportation, packaging, and delivery of the combination of the apparatus and the gift material. The fastener uses one or more prongs to exert force upon the gift material towards the vertical axis of the fastener, thereby retaining said gift material. The fastener is connected to the presentation device in order to create an overall arrangement that is pleasing to the many senses of the user and recipient. Embodiments leverage known materials, themes and branding to enhance or achieve a commercial objective. Green, or sustainable aspect of the instant teachings facilitate efforts to conserve.
DRAWINGS
[0010] The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
[0011] FIG. 1 is a schematic depiction of apparatus according to the present invention.
DETAILED DESCRIPTION
[0012] The present invention contributes to the progress of science and the useful arts by enabling those who usually give flowers to receive a substantially identical kind of gift and appreciate it. The fastener is designed to be one-piece, constructed out of one of any metals, plastics, rubbers, composites, and biodegradable substances. The fastener is generally reusable and interchangeable among various presentation device attachments.
[0013] Referring to FIG. 1 , fastener 100 is at least one of unitary and modular and further includes at least one prong 102 . Fastener 100 is metal/plastic/rubber, may be coated, painted, processed/stamped, molded, bent or twisted; likewise, additional prongs 113 , 116 often are helpful in securing target material (not shown-see Appendix for Examples, e.g. mini-liquor bottles)
[0014] Retaining surface 104 is located on the inside of prong 102 (and each of additional prongs 113 / 116 ) and presentation-device 103 may be in the shape of a branch, and/or be a branch, stem or other aspect of a flower/plant natural or artificial. Supplemental extension 111 , appear to be a branchette (sub branch), or leaf sporting branch in this example.
[0015] Those skilled in the art understand that inherent in any prong 102 / 113 / 116 etc . . . , is a concave section protruding toward central axis of fastener 100 . Also, gripping or detent means 107 , 109 allow for bracingly engaging any desired material. Ventral surface 101 of prong 102 (and prongs 113 / 116 etc . . . ) may sport colors, paint, logos, advertising or whatever else is needed to make the article visually compelling.
[0016] Presentation device 103 attaches as known to artisans by adhesion, adherence, molding or other glue-mechanisms, or by clamping. The schematic example here may be hybridized with real or artificial flower-elements and prototypes have housed material (not shown) ranging from small bottles of liquor (see appendix) to motorcycle parts, assorted items that may or may not relate to the theme, or branding scheme of the subject apparatus 122 . Articles embodying these descriptions are available from at least one source (See the Manflower® from Creative Concepts of Oceanside, Calif. 92056).
[0017] The fastener may contain one or more prongs 102 / 113 / 116 . The prongs are aligned towards one of the two ends of the base of the fastener. Said prongs 102 / 113 / 116 , in their preferred embodiment, are shaped in a curved fashion, having both outwardly convex and inwardly concave slopes, the many prongs creating varied inner diameter as measured from the fastener's central axis. The many prongs are constructed of one of many substances having properties of pliability and resistance suitable for the retention of gift materials to be clasped by said prongs. See Appendix for prototypes, as discussed.
[0018] In one embodiment, a series of four prongs are constructed of a continuous sheet of stamped steel, wherein each of the four prongs are curved towards one end of the fastener, shaped in a fashion that both outwardly convex and inwardly concave slopes are present in each of the many prongs, the inner portion of said prongs creating a varied inner diameter as measured from the fastener's central axis, wherein the smallest inner diameter is present at approximately the middle of the fastener's vertical axis, and wherein the inward slopes of the many prongs above this smallest inner diameter point, act to apply an increasing amount of resistance towards the central axis when a cylindrical gift material is inserted into the fastener's inner diameter along the centrals axis. Said resistance will reach a maximum force of any given diameter of the inserted gift material when the many prong's curve defined as the smallest inner diameter is activated. At this point of maximum resistance, the inserted gift material will be generally affixed to the fastener, allowing for the packaging, transportation, and delivery of the combination fastener, gift material, and presentation device. Upon its receipt, or at any other time, a user may apply a pressure upon the gift material while the fastener is stationary, along the general vertical axis of the fastener, in a direction towards the formerly open diameter end of the fastener, in order to overcome the maximum resistance of the many prong, thereby separating the gift material from the fastener.
[0019] In another embodiment, the fastener has only one prong. Said prong is an uninterrupted cylinder from the portion of the prong's base to approximately two thirds of the prong's length, at which point the cylinder shape of the prong is interrupted by ornamental or functional design features, the smallest inner diameter of said prong occurring before the cylinder is interrupted by said features, and the challis-shaped end of the prong and base is capable of retaining various liquids in addition to retaining materials having a cylindrical or other profile fitting within the opening diameter of the open end of the fastener.
[0020] In a further embodiment, the inner retaining surface of each or one prong that comes into contact with the inserted material at or near the smallest inner diameter of the fastener has one or more protrusions jutting into the general direction central axis of the fastener. Said protrusions may be convex moldings of the same or different substance as the fastener or its respective prong(s). In one embodiment, said protrusions are rubber nodules affixed to the inner retaining surface of one or more prongs. Said rubber nodules act as a further contacting surface and especially assist with the retention of glass, plastic, or composite materials, especially glass containers of beer and wine bottles.
[0021] In yet a further embodiment, the fastener is capable of being attached to a presentation device, by means of one of many methods including male and female threads, Velcro, glue, epoxy, clamping, molding, soldering, welding, and snap fittings, wherein the presentation device is shaped and decorated as a stem and leaf or leaves of a rose or other flower, and the fastener is shaped and decorated as a flower or the many petals of a rose or other flower.
[0022] While the method and agent have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims.
[0023] It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. They still fall within the scope of this invention. It should be understood that this disclosure is intended to yield a patent covering numerous aspects of the invention both independently and as an overall system and in both method and apparatus modes.
[0024] Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of an embodiment of any apparatus embodiment, a method or process embodiment, or even merely a variation of any element of these.
[0025] Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms or method terms—even if only the function or result is the same.
[0026] Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled.
[0027] It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.
[0028] Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates.
[0029] Any patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in at least one of a standard technical dictionary recognized by artisans and the Random House Webster's Unabridged Dictionary, latest edition are hereby incorporated by reference.
[0030] Finally, all referenced listed in the Information Disclosure Statement or other information statement filed with the application are hereby appended and hereby incorporated by reference; however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these invention(s), such statements are expressly not to be considered as made by the applicant(s).
[0031] In this regard it should be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant has presented claims with initial dependencies only.
[0032] Support should be understood to exist to the degree required under new matter laws—including but not limited to United States Patent Law 35 USC 132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept.
[0033] To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular embodiment, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative embodiments.
[0034] Further, the use of the transitional phrase “comprising” is used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “compromise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.
[0035] Such terms should be interpreted in their most expansive forms so as to afford the applicant the broadest coverage legally permissible. | A novel, reusable apparatus for affixing gift material to a presentation device. The apparatus comprises a dynamic fastener for clasping or holding a gift material, allowing for the transportation, packaging, and delivery of the combination of the apparatus and the gift material. The fastener uses one or more prongs to exert force upon the gift material towards the vertical axis of the fastener, thereby retaining said gift material. The fastener is connected to the presentation device in order to create an overall arrangement that is pleasing to the many senses of the user and recipient. Embodiments leverage known materials, themes and branding to enhance or achieve a commercial objective. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/400,192 filed Apr. 10, 2006, which is a continuation of U.S. patent application Ser. No. 10/923,780 filed Aug. 24, 2004, now U.S. Pat. No. 7,055,290, which is a continuation of U.S. patent application Ser. No. 10/395,162 filed Mar. 25, 2003, now U.S. Pat. No. 6,931,811, which is a continuation of patent application Ser. No. 09/878,212, filed Jun. 12, 2001, abandoned.
FIELD OF THE INVENTION
[0002] This invention relates to a floor covering, more particularly of the type consisting of hard panels, as well as to floor panels for forming such floor covering, and a method for realizing such floor panels.
[0003] In particular, it relates to a floor covering formed of laminated panels, also called laminated parquet.
BACKGROUND
[0004] It is known that with such laminated parquet, the appearance of wood is imitated by providing the floor panels at their upper surface with a decorative layer printed with a wood pattern, on top of which a transparent layer of synthetic material is provided.
[0005] Mostly, the printed decorative layer consists of printed paper. Usually, the layer of synthetic material consists of a synthetic resin or one or more transparent or translucent material layers soaked in synthetic resin, in which possibly products can be worked in, in order to enhance, for example, the wear and tear resistance of the final surface.
[0006] The printed decorative layer and the layer of synthetic material are provided on an underlying basic layer, which can be realized according to different techniques.
[0007] So, for example, this is possible by soaking the decorative layer in resin and bringing it, after hardening, together with said layer of synthetic material, which then preferably also consists of a thin transparent paper layer also soaked in resin, and together with a basic layer and possible other layers, into a press and compressing it, under the supply of heat, to one hardened whole. This technique is known under the denomination of DPL (Direct Pressure Laminate).
[0008] Of course, other techniques are possible, too. So, for example, first a top layer may be formed which, amongst others, comprises the aforementioned decorative layer and the layer of synthetic material present thereupon, after which this top layer is attached on a basic layer or basic structure.
[0009] Also, said basic layer may consist of different materials or material layers. A material often used to this end is MDF (Medium Density Fibre board), HDF (High Density Fibre board), respectively.
[0010] It is also known that impressions can be realized in the transparent layer of synthetic material, this in order to obtain an imitation of wood pores and other unevennesses which can be present at the surface of real wood. With the known embodiments, this is performed by simply providing a series of impressions in the floor panels, which impressions substantially extend according to one and the same direction. Notwithstanding the use of such impressions, the known embodiments show the disadvantage that the imitation effect still is not optimum. So, for example, they show the disadvantage that if one looks at such floor panels at a relatively small angle, a light refraction at the transparent layer of synthetic matter is created, as a result of which only a glossy surface can be seen, without any visible effect of the actual print being perceived.
SUMMARY
[0011] The invention aims at a floor covering, and more particularly at floor panels, whereby the top layer has technical characteristics which contribute to a considerable improvement of the imitation of the wood pattern, or at least the visual perception of this wood pattern, and whereby the aforementioned disadvantages of the known embodiments are minimized.
[0012] To this aim, the invention thus relates to a floor covering, consisting of hard panels, with a laminated structure, whereby at least at the upper surface a printed decorative layer with a wood pattern is present, with thereupon a transparent layer of synthetic material in which impressions are formed, with as a characteristic that the impressions substantially follow the wood pattern, with which it is meant that they substantially are provided in function of the wood pattern. Hereby, it is preferred that the impressions follow the wood pattern substantially in longitudinal direction as well as substantially in transverse direction and in directions situated in between.
[0013] Thereby, a technical solution is offered for letting the printed pattern seem more real, without the necessity of refining the printing technique itself in an expensive manner, which is very important with laminated panels provided with such printed pattern. By having the impressions run not only substantially according to one well-defined direction, then, when a person moves over the floor covering, an effect is obtained that the light incidence moves, as a result of which, so to speak, a living light effect is created. Also, a better depth effect is obtained, and the colours of the printed pattern are better perceptible.
[0014] As usual with the known laminated parquet panels, the printed decorative layer preferably consists of paper, however, other materials, either on the basis of cellulose or not, are not excluded. Moreover, this decorative layer can be processed in different manners, for example, previous to the application thereof on the underlying basic layer, soaked in synthetic resin or such.
[0015] The aforementioned layer of synthetic material, which, according to the invention, is situated on top of the decorative layer, can be composed in any manner. By “transparent layer of synthetic material”, it is meant that this layer comprises synthetic material, as well as, in applied condition, is sufficiently transparent for perceiving the printed wood pattern. This layer of synthetic material itself may comprise other materials than synthetic material, as well as be composed of several sublayers.
[0016] Preferably, this transparent layer of synthetic material, as usual with known laminated parquet panels, consists of a synthetic resin or one or more transparent or translucent material layers soaked in synthetic resin, for example, very thin transparent layers of paper.
[0017] In the layer of synthetic material, substances may be present by which the wear and tear resistance of the surface is enhanced.
[0018] Although the invention aims at impressions which substantially follow the printed wood pattern, it is evident that this inventive idea can be realized in different ways.
[0019] So, for example, impressions can be applied which are bent or curved and which follow the bent shapes of the wood pattern.
[0020] Also, opposite to the known embodiments, whereby mostly relatively short impressions are applied, now longer impressions can be applied, for example, with lengths of 3 cm or more, or even over the entire length of a wood nerve.
[0021] It is noted that by the term “wood pattern”, different aspects of such wood pattern can be understood. So, for example, may the impressions, or at least a number of the impressions, be provided in function of the course of the wood nerves of the printed wood pattern, however, according to a variant, which either can be combined with the preceding or not, impressions are provided which are applied in function, and more particularly at the location, of the so-called wood pores of the printed wood pattern. Wood pores mostly are dark, often strip-shaped specks in wood, which up to now have been particularly difficult to imitate. In the first place, this problem is pertinent when imitating oak, where often less nerves are present, however, the wood pores are very important. By providing, according to the invention, impressions at the location of these wood pores, the imitated specks will almost have the look or real pores.
[0022] In the most preferred forms of embodiment, the floor covering, and more particularly each floor panel concerned, will be provided with impressions which are obtained by means of a pressing mould, more particularly pressing plate, the relief of which was realized by means of image-processing technology, starting from a wood pattern, either an image of a wood pattern or a real wood pattern. Hereby, one starts from the same wood pattern than the one of the print of the decorative layer.
[0023] Of course, the invention also relates to floor panels for realizing the floor covering described in the aforegoing.
[0024] Further, the invention also relates to a method for realizing such floor panel, which method is characterized in that the aforementioned impressions are applied in said layer of synthetic material by means of a pressing mould, more particularly a pressing plate. Of course, the pressing plate is provided with a relief, more particularly protruding parts, such that impressions are formed which, as aforementioned, follow the printed wood pattern and/or are realized in function of this wood pattern.
[0025] Preferably, hereby use is made of a pressing mould, more particularly a pressing plate, the relief of which was realized by means of image-processing technology, starting from a wood pattern, either an image of a wood pattern or a real wood pattern. By realizing said relief by means of image-processing, a true copy is obtained. More particularly, for forming, on one hand, the pressing plate and, on the other hand, the patterns to be printed, it is started from one and the same wood pattern, with the advantage that the relief and the printed pattern can be perfectly attuned to each other.
[0026] Of course, the results obtained by image-processing can be processed further.
[0027] It is also not excluded to determine the locations where the impressions have to be realized and therefore also the relief of the pressing plate in other ways, for example, by starting from an image of a wood pattern, to determine the locations and shapes of the desired impressions, either by means of or with the support of a computer program.
[0028] According to the invention, during image-processing, preferably a separation is performed, on one hand, for forming one or more image layers and, on the other hand, for forming one or more structural layers. A separation for image layers already is a known technique and is necessary for being able to print the different colours. According to the invention, now still an additional separation is performed for the aforementioned structural layers, in other words, for forming said relief at the pressing plate or such. To this end, an image of the wood pattern is made and, by means of image-processing technology, an image is formed therefrom which determines the position, and possibly also the depth and the size, of the impressions, after which, by means thereof, a pressing plate is realized, for example, by means of etching techniques or any other technique. It is evident that for the image processing for creating, starting from, for example, the pattern of a real piece of wood, an image which is suitable for forming the relief, different image-processing programs, possibly especially designed to this aim can be applied.
[0029] Preferably, the floor panels are realized according to the classical technique which is applied for forming DPL (Direct Pressure Laminate), with the only difference that a pressure mould, more particularly, a pressing plate is applied in the usual production press which is provided with a relief by which impressions, such as mentioned in the aforegoing, are formed. As usual, the floor panels hereby are formed from larger plates. These plates are formed by bringing a basic layer, more particularly a base plate, together with the decorative layer and the layer of synthetic material, and possible other layers, in a heated press and compressing them to a whole, whereby said synthetic resins provide for adhesion and hardening. Simultaneously to pressing, the impressions are applied, as the press, at the surface of the pressing part which comes into contact with the upper side of the aforementioned plate, is provided with said pressing plate comprising the relief which is necessary for applying impressions in accordance with the invention.
[0030] Preceding the pressing, according to the present invention, preferably a positioning is performed between, on one hand, the decorative layer and, on the other hand, the applied pressing plate, in order to position the printed pattern on the decorative layer and the pattern present at the pressing plate over each other.
[0031] Practically, the positioning preferably is performed by shifting the base plate, together with the decorative layer and the layer of synthetic material present thereupon, until they obtain the desired position.
[0032] The aforementioned positioning may be performed in different manners, however, it can be realized in a particular manner by performing such positioning by means of one or more marks provided on the decorative layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, several preferred forms of embodiment are described, with reference to the accompanying drawings, wherein:
[0034] FIG. 1 schematically represents a part of a floor covering which is composed of panels according to the invention;
[0035] FIG. 2 represents a panel of the floor covering from FIG. 1 in plan view;
[0036] FIGS. 3 and 4 represent cross-sections according to lines III-III and IV-IV in FIG. 2 , respectively;
[0037] FIG. 5 , at a larger scale, represents a cross-section according to line V-V in FIG. 1 ;
[0038] FIG. 6 , at a larger scale, represents a cross-section according to line VI-VI in FIG. 1 ;
[0039] FIG. 7 , at a larger scale, represents the part indicated by F 7 in FIG. 6 ;
[0040] FIG. 8 represents a view analogous as in FIG. 7 , but whereby the panels are shifted towards each other substantially in one and the same plane;
[0041] FIG. 9 , in cross-section, represents another panel according to the invention, with bevels provided with a print;
[0042] FIG. 10 , schematically represents how the print in the embodiment of FIG. 9 can be provided;
[0043] FIG. 11 schematically represents a cross-section according to line XI-XI in FIG. 10 ;
[0044] FIG. 12 , at a larger scale, represents the upper surface of a floor panel according to the invention, in particular the part indicated by F 12 in FIG. 2 ;
[0045] FIG. 13 represents a cross-section according to line XIII-XIII in FIG. 12 ;
[0046] FIG. 14 schematically represents how plates can be realized from which floor panels according to the invention can be formed.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] As represented in FIGS. 1 and 2 , the invention relates to a floor covering 1 , as well as to hard panels, more particularly floor panels 2 , from which such floor covering 1 is assembled, whereby these floor panels 2 , at their top side 3 or decorative side, are provided with a top layer 4 with a printed wood pattern 5 .
[0048] In the represented example, the floor panels 2 are rectangular, however, it is clear that they, according to not-represented variants, also can have another shape, for example, can be square or polygonal.
[0049] Preferably, the floor panels 2 , at least at two opposite edges 6 - 7 , and even better, as represented in FIGS. 2 to 8 , at both pairs of edges 6 - 7 , 8 - 9 , respectively, are provided with coupling means 10 , by means of which several of such floor panels 2 mutually can be coupled, such that these coupling means 10 provide for a locking according to a direction R 1 perpendicular to the plane of the floor covering 1 , as well as in a direction R 2 perpendicular to the edges 6 - 7 and/or 8 - 9 concerned and parallel to the plane of the floor covering 1 .
[0050] Hereby, such coupling means 10 can be realized such that the different floor panels 2 mutually can be coupled by means of translation movements T 1 and/or T 2 and/or pivoting movements W 1 , such as indicated in FIG. 1 , as well as made clear in FIGS. 6 to 8 .
[0051] Such coupling means 10 which allow a glue-free mutual coupling of the floor panels 2 , as well as an uncoupling thereof, are already known in themselves from the international patent application WO 97/47834.
[0052] It is noted that the present invention, however, is not limited to floor parts with coupling means 10 which provide for a mechanical locking in the directions R 1 and R 2 , but in fact also can relate to floor panels which are provided with other coupling means, for example, with a classical tongue and groove which can be glued into each other, or even to floor panels comprising no coupling means at all.
[0053] Besides, the floor panels 2 either can be provided with additional particularities or not, such as bevels 11 at the upper edges, for example, such as represented in FIGS. 3 to 10 , on which, as specifically illustrated in FIGS. 9 to 10 , either a decorative layer 12 is provided or not, for example, by means of transfer printing, whereby, such as schematically represented in FIGS. 10 and 11 , a print layer 13 , which is present on a carrier, is transferred to the surface of the bevels 11 , for example, by means of a heated pressing roll 15 .
[0054] The actual invention to which the present application is relating, is represented schematically in FIGS. 12 and 13 .
[0055] The particularity thereby consists in that at the top side of the floor panels 2 , a decorative layer 16 is present, with thereover a transparent layer of synthetic material 17 , in which impressions 18 A- 18 B- 18 C are formed. Hereby, the decorative layer 16 and the layer of synthetic material 17 are of the kind as described in the introduction and together form the top layer 4 indicated schematically in FIGS. 3 to 10 .
[0056] According to the invention, the impressions 18 A- 18 B- 18 C follow the printed wood pattern 5 , preferably substantially in longitudinal direction as well as substantially in transverse direction and in directions situated in between.
[0057] As represented in FIG. 13 , the impressions 18 A- 18 B- 18 C preferably only extend up to such a depth that they are situated above the printed decorative layer 16 .
[0058] As indicated by 18 A and 18 C, the impressions may consist of successive short impressions, or, as represented by 18 B, of longer, uninterrupted, possibly bent impressions. Of course, other designs are not excluded. However, it is important that the location and/or shape of the impressions is in function of the wood pattern 5 , with which it is meant in the first place that these impressions are realized in function of the wood nerves and/or in function of the wood pores.
[0059] In the case of short impressions, these, such as indicated by 18 A, can be directed with their length according to the printed wood nerve 19 or, as indicated by 18 C, also be directed with their longitudinal direction otherwise, however, positioned such that their configuration globally follows the wood nerve 19 .
[0060] It is noted that the three possibilities of impressions 18 A- 18 B- 18 C represented in FIG. 12 are not limitative. Also, these will normally not be applied in combination with each other, but one well-defined type 18 A or 18 B or 18 C or another configuration will be used.
[0061] According to a variant, the impressions, instead of at the wood nerve 19 itself, also can be situated in the zones formed therebetween, and/or at the transitions between the wood nerve 19 and the zones situated therebetween and/or at locations where so-called wood pores are depicted.
[0062] In FIG. 14 , a form of embodiment of the method of realizing said floor panels 2 , described in the introduction, is represented schematically.
[0063] As represented, the impressions concerned, for example 18 A and/or 18 B and/or 18 C, hereby are formed by using a pressing mould, more particularly a pressing plate 20 , which, at the side intended for coming into contact with the products to be treated, is provided with a suitable relief 21 .
[0064] First, during production, large plates are manufactured, from which several floor panels 2 can be formed, more particularly can be sawn therefrom, which subsequently can be provided with coupling means 10 , for example, by means of a milling treatment.
[0065] For forming said plates, as schematically represented in FIG. 14 , at least a printed decorative layer 16 and a layer of synthetic material 17 are provided on a base plate 22 , such in a press 23 , after which the whole is compressed by means of the pressing plate 20 , preferably while supplying heat.
[0066] According to the invention, previous to pressing, a positioning is performed between, on one hand, the decorative layer 16 and, on the other hand, the applied pressing plate 20 , in order to position the printed pattern on the decorative layer 16 and the pattern present at the pressing plate 20 over each other.
[0067] In the example, this positioning is performed by shifting the base plate 22 , together with the decorative layer 16 and layer of synthetic material 17 present thereon, until the desired position is achieved. This positioning is realized by means of one or more adjustable stops 24 against which the base plate 22 , with the decorative layer 16 and layer of synthetic material 17 present thereupon, and possible other layers, is positioned, possibly by means of marks which are applied on the decorative layer 16 , which are perceived by means of one or more sensors 25 , and whereby, by means of control means 26 and in function of the signals obtained from the sensors, it is provided for the control of driving means 27 of the movable stops 24 .
[0068] Obviously, the positioning can be achieved in the two directions of the plane of the base plate 22 .
[0069] It is evident that, according to a variant, the layer of synthetic material and the decorative layer, already before their application on the base plate, may consist of a single layer, for example, in that the decorative layer is soaked such that sufficient synthetic material is present thereupon in order to form impressions therein. It is also not excluded to start from a layer of synthetic material which is provided with a decorative layer at the underside, which layer is exclusively formed by a print. The term print must be interpreted in the broadest sense, and thereby any technique is intended with which an image of a wood pattern can be realized.
[0070] Also, other layers may be taken up in the top layer, such as, for example, a layer of white paper, also impregnated with resin, which is provided under the decorative layer, which has the purpose of forming a neutral underground.
[0071] The present invention is in no way limited to the forms of embodiment described as an example and represented in the figures, on the contrary may such floor covering, and more particularly said panels, as well as said method, be realized in different variants without leaving the scope of the invention. | A floor covering includes hard panels having a laminated structure. The panels have an upper surface with a printed decorative layer including a wood pattern. A transparent layer of a synthetic material extends over the printed decorative layer and includes a plurality impressions. The impressions substantially follow the wood pattern. | 8 |
FIELD OF THE INVENTION
[0001] The present invention is related to a method of supplying fuel, and, more specifically, to a method of supplying fuel to fuel cells, wherein, during the reaction of the fuel cells, the operating characteristics of the fuel cells, such as potential, current or power, are monitored and measured, whereby the fuel supply are controlled for maintaining performance without any installation of fuel concentration sensors in the fuel cells' operating system.
BACKGROUND OF THE INVENTION
[0002] Fuel cell is a kind of power generating device that transforms from chemical energy to electrical energy through electrochemical reaction. With a continuous feeding of the fuel, the fuel cell can react to generate power of electricity persistently. Since the production of the fuel cell is water, it will not contaminate the environment. With the merits of lower pollution and higher efficiency, the development and improvement of the fuel cells are now becoming the main stream in the power generation field.
[0003] Among the fuel cells, a direct methanol fuel cell or so called DMFC is a promising candidate for portable applications in recently years. The difference between DMFC and other power generating devices, such as PEMFC, is that the DMFC takes methanol as fuel in substitution for hydrogen. Because of utilizing liquid methanol as fuel for reaction, the DMFC eliminates the on board H 2 storage problem so that the risk of explosion in the use of fuel cells is avoided, which substantially enhances the convenience and safety of fuel cells and makes DMFC more adaptable to portable electronic appliances such as Laptop, PDA, GPS and etc, in the future.
[0004] During the electrochemical reaction occurred in the fuel cell, the fuel concentration is a vital parameter affecting the performance of the liquid feed fuel cell system. However, DMFC suffers from a problem that is well known to those skilled in the art: methanol cross-over from anode to cathode through the membrane of electrolyte, which causes significant loss in efficiency. It is important to regulate the supplying of fuel appropriately to keep methanol concentration in a predetermined range whereby DMFCs system can operate optimally. For example, a fuel sensor, such as methanol concentration sensor disclosed in the prior art, is utilized to detect the concentration of methanol so as to provide information for controlling system to judge a suitable timing to supply methanol. Although the foregoing method is capable of controlling the concentration of the fuel, it still has the drawbacks of increasing the complexity and cost of the fuel cells system. And a lot of experimental effort like calibration is necessary through the use of concentration sensor.
[0005] In order to reduce the cost and complexity caused by the additional concentration sensor in the prior arts, a couple of sensorless control for DMFCs approaches have been disclosed to decrease the cost and complexity of the fuel cells system and improve the stability of fuel cell operation by monitoring one or more of the fuel cells' operating characteristics. For instance, in U.S. Pat. No. 6,589,679, a change of methanol concentration is introduced by periodically reducing or interrupting the amount of methanol supplied to fuel cell and the rate of the potential drop can be used; or the potential difference between the inlet and outlet of the methanol flow can be used; or the load is periodically disconnected from the fuel cell and the open-circuit potential can be used to adjust the methanol concentration. Moreover, a prior art, disclosed in U.S. Pat. No. 6,824,899, provides a method to optimize the concentration of methanol by detecting the short circuit current. However, since periodically short circuit to detect the current is necessary, it is easily to damage the fuel cells itself so as to affect the stability of the fuel cells system. Meanwhile, in U.S. Pat. No. 6,698,278, the way to control the concentration of methanol is to calculate methanol concentration in the fuel stream based on the measurement of the temperature of the fuel stream entering the fuel cell stack, the fuel cell stack operating temperature, and the load current. However, the foregoing disclosing methods are based on the predetermined calibration of the fuel cells system and on empirical models. The monitoring and control of the methanol concentration are loose due to the complexity of fuel cells operation and MEA degradation.
[0006] According to the drawbacks of the prior arts described above, it deserves to provide a method for supplying fuel to fuel cells to solve the problem of the prior arts.
SUMMARY OF THE INVENTION
[0007] A primary object of the present invention is to provide a method of supplying fuel to fuel cells, wherein operating characteristics of the fuel cell, such as potential, electric current or power, during reaction are measured so that numerical calculation and correlation can be processed to determine the appropriate timing for fuel supplying so as to achieve the object of optimizing the output of the fuel cells.
[0008] A further object of the present invention is to provide a method of supplying fuel to fuel cells, wherein operating characteristics of the fuel cells during reaction are measured and correlated to control the fuel supplying without any setting of methanol concentration sensor so as to achieve the object of low cost, accurate and precise control.
[0009] For achieving the objects described above, the present invention provides a method of supplying fuel to fuel cells, comprising steps of: feeding a specific amount of a fuel into a fuel cell; obtaining a first characteristic value of the fuel cell within a monitoring time period; obtaining a second characteristic value of the fuel cell while the monitoring time period is over; and comparing the second characteristic value to the first characteristic value and enabling the fuel to be fed into the fuel cell while the second characteristic value is smaller than the first characteristic value.
[0010] More preferably, the first characteristic value is a value selected from the group consisting of a minimum voltage value, a minimum current value, and a minimum power value, each of which is measured over the monitoring time period. Besides, the first characteristic value may also be a value selected from the group consisting of a moving average value of measured characteristic of the fuel cell over the monitoring time period and a root mean square value of measured characteristic of the fuel cell over the monitoring time period.
[0011] More preferably, the monitoring time period is a duration that a specific power is generated to sustain a specific load through the specific amount of fuel, wherein the specific power is a maximum power in a polarization curve generated from the fuel cell to the load during the reaction of the specific amount of the fuel or is a smaller value prior to the maximum power in a polarization curve generated from the fuel cell.
[0012] More preferably, the method further comprises the steps of: if the second characteristic value is larger than the first characteristic value then obtaining a third characteristic value in a time point after the monitoring time period; obtaining a fourth characteristic value of the fuel cell before the time point; and comparing the third characteristic value to the fourth value, if the third characteristic value is smaller than the fourth characteristic value then feeding the fuel into the fuel cell. The fourth characteristic value may be a value selected from the group consisting of a moving average value of measured characteristic values of the fuel cell over a time interval before the time point or a root mean square value of measured characteristic values of the fuel cell over a time interval before the time point.
[0013] More preferable, the fuel is substantially a hydrogen-rich liquid fuel.
[0014] For achieving the objects described above, the present invention further provides a method of supplying fuel to a fuel cell, comprising steps of: (a) feeding a specific amount of a fuel into a fuel cell; (b) obtaining a first characteristic value of the fuel cell within a monitoring time period; (c)obtaining a second characteristic value of the fuel cell while the monitoring time period is over; (d) repeating the step (a) while the second characteristic value is smaller than the first characteristic value; (e) obtaining a third characteristic value in a time point after the monitoring time period; (f) obtaining a fourth characteristic value of the fuel cell before the time point; and (g) repeating the step (a) while the third characteristic value is smaller than the fourth characteristic value.
[0015] More preferably, the method further comprises the step of repeating the step (e) while the third characteristic value is larger than the fourth characteristic value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The drawings, incorporated into and form a part of the disclosure, illustrate the embodiments and method related to this invention and will assist in explaining the detail of the invention.
[0017] FIG. 1 is a flow chart illustrating the preferred embodiment according to the present invention.
[0018] FIG. 2 is a flow chart illustrating another preferred embodiment according to the present invention.
[0019] FIG. 3 is a schematic illustration of polarization curve during the reaction of the fuel cell after receiving a specific amount of fuel.
[0020] FIG. 4 is a schematic illustration depicting the relationship of voltage and time of the fuel cell during reaction.
[0021] FIG. 5A is a schematic illustration of the fuel cell connecting to a load.
[0022] FIG. 5B is a schematic illustration depicting the way sensing the electric current of the load.
[0023] FIG. 6 is a schematic illustration of the way for data acquiring in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Please refer to FIG. 1 which is a flow chart illustrating the preferred embodiment according to the present invention. The method is described in the following. Firstly, as illustrated in step 10 , a specific amount of a fuel is fed into a fuel cell. Then, as illustrated in step 11 , a second characteristic value is obtained at a time point that locates at the last of a monitor time interval wherein the characteristic value can be a value like potential, current, or power output of the fuel cell. Next, following step 12 , measuring characters of the fuel cell over the monitoring time interval before the second characteristic value for obtaining a first characteristic value. The character refers to an operating characteristic of the fuel cell, such as potential, current, or power output, for example. Finally, as shown in step 13 , the first characteristic value is compared to the second characteristic value for enabling the fuel to be fed into the fuel cell while the second characteristic value is smaller than the first characteristic value. The first characteristic value may be a minimum voltage value, a minimum current value, or a minimum power value of the measured character over the time interval. In addition, the first characteristic value may also be a moving average value of the measured characters of the fuel cell over the time interval or a root mean square value of the measured characters of the fuel cell over the monitoring time interval.
[0025] Please refer to FIG. 2 which is a flow chart illustrating another preferred embodiment according to the present invention. The method of supplying fuel for a fuel cell is started at step 20 to determine a monitoring time period. Please refer to FIG. 3 , which is a schematic illustration of polarization curve during the reaction of the fuel cell after receiving a specific amount of fuel and which is taken to be an illustration explaining the way to determine the monitoring time period. The polarization curve depicts the relationship between voltage and current density when the fuel cell is connected to a load and fed a specific amount of fuel; meanwhile a power curve corresponding to the polarization curve is also illustrated in the FIG. 3 . The power curve has a maximum power P max . Therefore, the monitoring time period can be determined to be a duration that the fuel cell can output the maximum power P max during the reaction within the injection of specific amount of fuel. In addition, in order to avoid overload, it is selected a power value P ref , smaller than P max shown in FIG. 3 , to be a suggested value for deciding the length of the monitoring time period as well. In another words, the monitoring time period can be determined to be a time period that the fuel cell can output power P ref during the reaction within the injection of specific amount of fuel. Of course, the value of power value, either P max or P ref , is dependent on the load required; hence, the determination of P max or P ref disclosed in this embodiment should not be a limitation of the present invention.
[0026] After the determination of the monitoring time period in step 20 , the step 21 is processed to feed a specific amount of fuel in the fuel cell so that the fuel cell starts to generate power through the electrochemical reaction. The fuel according the present invention is substantially a hydrogen-rich liquid fuel such as methanol, ethanol and etc. Please refer to FIG. 5A , which is a schematic illustration of the fuel cell connecting to a load. The fuel cell 4 , basically, comprise inlets for transporting methanol into anode 41 and transporting oxygen into cathode 40 of the fuel cell, while the fuel cell also comprises outlets for product water from cathode 40 and carbon dioxide from anode 41 . The anode 41 and cathode 40 are disposed inside the middle location of the fuel cell 4 , while a membrane of electrolyte 42 is disposed between the anode 41 and cathode 40 . A load 5 is connected to the anode 41 and cathode 40 to form an electric circuit. A measuring device 6 is connected to the load 5 so as to measure a characteristic value, such as voltage or current, of the load. In this embodiment, the measuring device 6 is a potential measuring device that is electrically connected in parallel with the load 5 . Alternatively, as shown in FIG. 5B , the measuring device 6 is capable of being a current measuring device that is connected in series with the load 5 .
[0027] Step 22 is proceeded after step 21 , wherein the potential measuring device 6 , shown in FIG. 5A , measures the characteristic values of the load 5 over the monitoring time period and then sends those data to a controller unit 7 . Please refer to FIG. 4 , wherein a curve 30 represents the relationship of characteristic value over time of the fuel cell during reaction while the fuel cell receives the specific amount of fuel. The controller unit 7 will determine a first characteristic value 301 , which is a minimum value among those measured characteristic values measured by the measuring device 6 over the monitoring time period T inv1 . Alternatively, the first characteristic value 301 may be replaced by a moving average value of the measured characteristic values of the fuel cell over the monitoring time period T inv1 , or a root mean square value of the measured characteristic values of voltage of the fuel cells over the monitoring time period T inv1 . In addition, the first characteristic value 301 may also be a minimum current value or a minimum power value, which depends on the type and configuration of system device. Next, in the step 23 , the measuring device 6 measures a second characteristic value 302 at a point of time when the monitoring time period T inv1 , is just over. After that, in step 24 , the controller unit 7 compares the first characteristic value 301 to the second characteristic value 302 , and if the second characteristic value 302 is smaller than the first characteristic value then back to step 21 so that the controller unit 7 will signal the fuel feeding unit 8 to inject fuel in the fuel cell 4 and then repeat to keep monitoring.
[0028] If the second characteristic value of voltage 302 is larger than the first characteristic value 301 , then the flow is processed to step 25 which is a step for obtaining a third characteristic value of voltage 303 at a time point T 1 . Then, as shown in step 26 , a time interval T inv2 before the time point T 1 is decided so as to calculate a fourth characteristic value 305 which is a moving average value of the measured characteristics among the time interval T inv2 . In addition to the moving average value, the fourth characteristic value 305 can be a root mean square value, or the minimum voltage value over the time interval T inv2 .
[0029] After step 26 , a step 27 is processed to determine whether controller unit 7 should feed fuel to the fuel cell 4 or not. If the third characteristic value 303 is smaller than the fourth characteristic value 305 , it goes back to step 21 , and the controller unit 7 signals the fuel feeding unit 8 to inject fuel to the fuel cell 4 . If the third characteristic value of voltage 303 is larger than the fourth characteristic value 305 , which is just the case shown in FIG. 4 , then it goes back to step 25 to find another time point T 2 , shown in FIG. 4 , to obtain another third characteristic value 304 . Then repeat step 26 to determine another time interval T inv3 for determining another fourth characteristic value 306 , which is a moving average value of measured characteristic value over the time interval T inv3 . Then the third characteristic value 304 is compared to the fourth characteristic value 306 ; in this case, the third characteristic value 304 is smaller than the fourth characteristic value 306 so that the step of flow will return to step 21 to feed fuel to the fuel cells 4 and continue to process the whole flow repeatedly to monitor the operating status of the fuel cells 4 .
[0030] Please refer to FIG. 6 , which is a schematic illustration of the way for data acquisition in the present invention. Besides single measurement to obtain the characteristic value, such as voltage, current and so on, it may also measure a plurality data to form a characteristic value through averaging so as to increase accuracy. Taking the second characteristic value 303 as an example, as shown in FIG. 6 , it is possible to grab four data 3031 , 3032 , 3033 , and 3034 around the time point T 1 so that the controller unit 7 can calculate average of those four data 3031 , 3032 , 3033 , and 3034 to form the second characteristic value 303 . Of course the characteristic value 301 ˜ 306 shown in FIG. 4 can be calculated in such a way.
[0031] While the preferred embodiment of the invention has been set forth for the purpose of disclosure, modifications of the disclosed embodiment of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention. | The present invention relates a method of supplying fuel to a fuel cell, which comprises steps of: feeding a specific amount of a fuel into a fuel cell; obtaining a second characteristic value at a specific time point; detecting and measuring a character of the fuel cell at a time interval before the specific time point for obtaining a second characteristic value; comparing the second characteristic value to the first characteristic value for enabling the fuel to be fed into the fuel cell while the second characteristic value is smaller that the first characteristic value. By the aforesaid method, the supplying of fuel to the fuel cell can be effectively controlled for optimizing the performance of the fuel cell without the use of fuel sensor required thereby and thus reducing the cost and complexity of manufacturing the fuel cell system. | 8 |
ORIGIN OF THE INVENTION
The invention described herein was made by employees of the United States Government and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to structural resins and in particular to new polyimidazoles formed from the aromatic nucleophilic displacement reaction of novel di(hydroxyphenyl)imidazole monomers with activated aromatic dihalides or activated aromatic dinitro compounds, whereby economically produced, high molecular weight polyimidazoles useful as adhesives, coatings, films, membranes, moldings, and composite matrices are obtained.
2. Description of the Related Art
Polyimidazoles (PI) are heterocyclic polymers which were synthesized by the reaction of a bis(phenyl-α-diketone) with an aromatic dialdehyde in the presence of ammonia as represented below: ##STR1## where Ar is a divalent aromatic radical such as ##STR2## R is a divalent aromatic radical which may be ##STR3##
The synthesis and characterization of PI was first described in 1967 [V. B. Krieg and G. Manecke, Die Makromolekulare Chemie, 108,210 (1967)]. The polymers were of relatively low molecular weight, and only a few physical properties were determined. PI prepared by the reactin of bis(phenyl-α-diketone) with aromatic dialdehydes in the presence of ammonia generally are of low molecular weight, presumably due to side reactions. Therefore, there are relatively few reports concerning the preparation and characterization of these materials.
SUMMARY OF THE INVENTION
The present invention constitutes new compositions of matter and a new process to prepare polyimidazoles (PI). It concerns new PI, novel monomers, and the process for preparing the same.
Another object of the present invention is to provide new PI that are useful as adhesives, coatings, films, membranes, moldings, and composite matrices.
Another object of the present invention is to provide several new di(hydroxyphenyl)imidazole monomers.
According to the present invention the foregoing and additional objects are obtained by synthesizing PI by the nucleophilic displacement reaction of di(hydroxyphenyl)imidazole monomers with activated aromatic dihalides. The inherent viscosities (η inh ) of the PI ranged from 0.24 to 1.38 dL/g, and the glass transition temperatures (Tg) ranged from 230° C. to 318° C. Thermogravimetric analysis showed no weight loss occurring below 300° C. in air or nitrogen with a five percent weight loss occurring at about 400° C. in air and at about 495° C. in nitrogen.
The PI is a polyimidazole having the general structural formula: ##STR4## wherein the substitution of oxygen is selected from the group consisting of meta meta, para para, and para meta; wherein Ar is a radical selected from the group consisting of: ##STR5## wherein R is selected from the group consisting of: H, CH 3 , CF 3 , CH 2 CH 3 , OCH 3 , ##STR6## wherein Z is a radical selected from the group consisting of: CF 3 , F, Cl, Br, I, CH 3 , OCH 3 , CH 2 CH 3 , NO 2 , and Ph; and ##STR7## wherein Ar' is selected from the group consisting of: ##STR8## wherein G is not a substituent or is a substituent selected from the group consisting of: CH 2 , O, S, C═O, and SO 2 ; wherein X is a radical selected from the group consisting of: ##STR9## and wherein n is an integer between 4 and 100.
The synthesis of PI involved the use of di(hydroxyphenyl)imidazole monomers of two different types; those prepared from monoaldehydes as shown in Equation (1), and those prepared from dialdehydes as depicted in Equation (2). ##STR10## where R can be H, CH 2 CH 3 , OCH 3 , CH 3 , CF 3 , ##STR11## where Z can be CH 3 , CF 3 , OCH 3 , Ph, NO 2 , I, Cl, Br, F, and CH 2 CH 3 . The catenation of the hydroxy group may be meta meta, para para, or meta para.
The general reaction sequence for the preparation of the di(hydroxyphenyl)imidazoles prepared from dialdehydes is represented in Equation (2). ##STR12## Where Ar' is ##STR13## Where G is nil, CH 2 , O, S, C═O, SO 2 . The catenation of the hydroxy group may be meta meta, para para or meta para.
The general reaction sequence for the synthesis of PI is represented below: ##STR14## Where Y can be Cl, F, or NO 2 where R can be H, CH 3 , CH 2 CH 3 , OCH 3 , CF 3 ##STR15## Where Z can be CH 3 , CF 3 , OCH 3 , Ph, NO 2 , I, Cl, Br, F, CH 2 CH 3 , etc.
Where Ar' can be ##STR16## Where G can be nil, CH 2 , O, S, C═O, SO 2 .
The substitution of the hydroxy group may be meta meta, para para, or meta para, and X can be
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Having generally described the invention, a more complete understanding thereof can be obtained by reference to the following specific examples which are provided herein for purposes of illustration only and do not limit the invention.
EXAMPLES
Example 1
The following example illustrates the reaction sequence for the synthesis of a polyimidazole where R is a phenyl group and X is terephthaloyl and Y is F (see Equation (3)).
Monomer Synthesis
4,5-Bis(4-hydroxyphenyl)-2-phenylimidazole
Into a one liter three neck round bottom flask equipped with a mechanical stirrer, thermometer, nitrogen inlet and reflux condenser was placed 4,4'-dimethoxybenzil (13.53 g, 0.05 mol) and acetic acid (300 ml). The mixture was stirred with heating to give a yellow solution. Ammonium acetate (68.0 g, 0.88 mol) and benzaldehyde (26.0 g, 0.25 mol) were added along with additional acetic acid (100 ml). The solution was heated to reflux (about 120° C.) overnight under nitrogen. The orange solution was cooled and poured into water to give an off-white precipitate which was collected, washed repeatedly with water and dried at 125° C. Yield was 17.5 g (98%) of white solid. Recrystallization from ethanol/water (3:1) gave 15.8 g (89%) of white crystals, m.p. 198°-200° C.
4,5-Bis(4-methoxyphenyl)-2-phenylimidazole (15.8 g, 0.044 mol) was placed in a 250 ml three neck round bottom flask equipped with a mechanical stirrer, nitrogen inlet, thermometer, reflux condenser and hydrogen bromide gas trap along with acetic acid (75 ml) and 47-49% aqueous hydrogen bromide solution (130 ml). The mixture was heated to reflux for 16 hours, cooled, poured into water to give a white solid, which was neutralized with sodium hydroxide, collected, washed with water and dried at 100° C. Yield was 13.7 g of white solid. Recrystallization from ethanol/water (3:1) gave 11.5 g (79%) of white crystals, m.p. 327°-330° C. Anal. Calcd. for C 21 H 16 N 2 O 2 : C, 76.80%; H, 4.91%; N, 8.53%. Found: C, 76.50%; H, 5.00%; N, 8.44%.
Polyimidazole Synthesis
Into a 100 ml three neck round bottom flask equipped with a mechanical stirrer, thermometer, nitrogen inlet, moisture trap and reflux condenser was placed 4,5-bis(4-hydroxyphenyl)-2-phenylimidazole (2.4267 g, 7.5 mmol), 1,4-bis(4-fluorobenzoyl)benzene (2.4173 g, 7.5 mmol), pulverized anhydrous potassium carbonate (2.4 g, 17.0 mmol, 15% excess), dry N,N-dimethylacetamide (DMAc) (20 ml, 20% solids) and toluene (30 ml). The mixture was heated to about 135° C. for four hours and then heated to 155° C. overnight under nitrogen. The viscous dark red solution was diluted with DMAc (20 ml) and precipitated into water/acetic acid mixture, collected, washed successively in water and methanol and dried at 125° C. Yield was 4.4 g (97%) of yellow polymer with a glass transition temperature of 248° C. The inherent viscosity of a 0.5% solution in DMAc at 25° C. was 0.89 dL/g. Thin films cast from DMAc solution gave tensile strength, tensile modulus and elongation at 25° C. of 14,200 psi, 407,000 psi and 6.0%; at 177° C. of 8,200 psi, 306,000 psi and 6.0%; and at 200° C. of 6,600 psi, 273,500 psi and 7.5%.
Example 2
The following example illustrates the reaction sequence for the synthesis of the polyimidazole where R is a phenyl group, X is a carbonyl group, and Y is F (see Equation (3)).
Into a 100 ml three neck round bottom flask equipped with a mechanical stirrer, thermometer, nitrogen inlet, moisture trap and reflux condenser was placed 4,5-bis(4-hydroxyphenyl)-2-phenylimidazole (3.2836 g, 10.0 mmol), 4,4-difluorobenzophenone (2.1819 g, 10.0 mmol), pulverized anhydrous potassium carbonate (3.2 g, 23.0 mmol, 15% excess), dry DMAc (22 ml, 20% solids) and toluene (35 ml). The mixture was heated to about 135° C. for four hours and then heated to 155° C. overnight under nitrogen. The viscous dark red solution was diluted with DMAc (20 ml) and precipitated into water/acetic acid mixture, collected, washed successively in water and methanol and dried at 125° C. Yield was 5.0 g (99%) of off-white polymer with a glass transition temperature of 259° C. The inherent viscosity of a 0.5% solution in DMAc at 25° C. was 0.61 dL/g. Thin films cast from DMAc solution gave tensile strength, tensile modulus and elongation at 25° C. of 13,300 psi, 405,200 psi and 5.0% and at 177° C. of 9,500 psi, 400,500 psi and 3.4% respectively.
Example 3
The following example illustrates the reaction sequence for the synthesis of the polyimidazole where Ar' is 1,4-phenylene, X is isophthaloyl and Y is F (See Equation 3).
Monomer Synthesis
1,4-Bis[2-imidazolyl-4-(4-hydroxyphenyl)-5-(phenyl)]benzene
Into a 500 ml three neck round bottom flask equipped with a mechanical stirrer, thermometer, nitrogen inlet and reflux condenser was placed 4-hydroxybenzil (9.05 g, 0.04 mol) and acetic acid (100 ml). The mixture was stirred with heating to give a yellow solution. Terephthalaldehyde (2.68 g, 0.02 mol) was subsequently added along with ammonium acetate (43.1 g, 0.56 mol) and acetic acid (50 ml). The mixture was stirred with heating and within one hour a yellow precipitate formed. The mixture was then heated to reflux (about 120° C.) for six hours. The mixture was cooled and poured into ice water, and the yellow solid collected, washed with water, and dried at 100° C. Yield was 10.7 g (98%). The solid was recrystallized from N,N-dimethylformamide (100 ml) and water (25ml) using activated charcoal to give 8.6 g (79%) of yellow solid, m.p. about 390° C. Anal. Calcd. for C 36 H 26 N 4 O 2 : C, 79.10%; H, 4.79%; N, 10.25%. Found: C, 78.81%; H, 4.87%; N, 10.12%.
Polyimidazole Synthesis
Into a 100 ml three neck round bottom flask equipped with a mechanical stirrer, thermometer, nitrogen inlet, moisture trap and reflux condenser was placed 1,4-bis[2-imidazolyl-4-(4-hydroxyphenyl)-5-(phenyl)]benzene (2.7330 g, 0.005 mol), 1,3-bis(4-fluorobenzoyl)benzene (1.6115 g, 0.005 mol), pulverized anhydrous potassium carbonate (1.6 g, 0.0115 mol, 15% excess), dry DMAc (18 ml, 18% solids) and toluene (25 ml). The mixture was heated to about 135° C. for four hours, and then heated to 155° C. overnight under nitrogen. The viscous dark red solution was diluted with DMAc (20 ml) and precipitated into water/acetic acid mixture, collected, washed successively in water and methanol and dried at 125° C. Yield was 4.04 g (97%) of yellow polymer with a glass transition temperature of 273° C. The inherent viscosity of a 0.5% solution in DMAc at 25° C. was 1.38 dL/g. Thin films cast from m-cresol solution gave tensile strength, tensile modulus and elongation at 25° C. of 17,600 psi, 464,000 psi and 8.1%, at 93° C. of 15,300 psi, 402,000 psi and 5.6% and at 232° C. of 7400 psi, 285,300 psi and 4.8% respectively.
Polymer characterization is presented in Table 1, and thin film and adhesive properties are presented in Table 2 and Table 3, respectively.
TABLE 1__________________________________________________________________________POLYMER CHARACTERIZATION ##STR18## INHERENT.sup.1 GLASS TRANSITION.sup.2POLYMER X VISCOSITY, dL/g TEMPERATUIRE,__________________________________________________________________________ °C.P1 ##STR19## 0.24 318P2 SO.sub.2 0.41 277P3 CO 0.61 259P4 ##STR20## 0.53 258P5 ##STR21## 0.40 248P6 ##STR22## 0.89 248P7 ##STR23## 0.49 239P8 ##STR24## 0.58 231P9 ##STR25## 0.64 230 P10 ##STR26## 0.55 230__________________________________________________________________________
TABLE 2______________________________________THIN FILM PROPERTIES.sup.1 TEST TENSILE TENSILEPOLY- TEMP., STRENGTH, MODULUS, ELONG.,MER °C. KSI KSI %______________________________________P3 25 13.3 405.2 5.0 177 9.5 400.0 3.4P6 25 14.2 407.0 6.0 177 8.2 306.0 6.0 200 6.6 273.0 7.5P7 25 13.8 390.0 6.3 177 8.4 285.0 6.2 P10 25 12.0 362.4 4.0 177 8.3 336.4 3.8______________________________________ .sup.1 Tested according to ASTM D882, average of four specimens per test condition.
TABLE 3__________________________________________________________________________ADHESIVE PROPERTIES* ##STR27##BONDING TEST TI/TI TENSILE FAILURECONDITIONS TEMP., °C. SHEAR STRENGTH, PSI MODE__________________________________________________________________________300° C., 100 PSI, 1 HR 25 4660 50% COHESIVE300° C., 500 PSI, 1 HR 25 4120 20% COHESIVE300° C., 200 PSI, 1 HR 25 4810 75% COHESIVE" 93 3800 30% COHESIVE" 177 3700 40% COHESIVE" 200 3050 45% COHESIVE__________________________________________________________________________ *Tested according to ASTM D1002, average of four specimens per test. Inherent viscosity of polymer 0.57 dL/g, glass transition temperature 245° C. | Polyimidazoles (Pl) are prepared by the aromatic nucleophilic displacement reaction of di(hydroxyphenyl)imidazole monomers with activated aromatic dihalides or activated aromatic dinitro compounds. The reactions are carried out in polar aprotic solvents such as N,N-dimethylacetamide, sulfolane, N-methylpyrroldinone, dimethylsulfoxide, or diphenylsulfone using alkali metal bases such as potassium carbonate at elevated temperature under nitrogen. The di(hydroxyphenyl)imidazole monomers are prepared by reacting an aromatic aldehyde with a dimethoxybenzil or by reacting an aromatic dialdehyde with a methoxybenzil in the presence of ammonium acetate. The di(methoxyphenyl)imidazole is subsequently treated with aqueous hydrobromic acid to give the di(hydroxyphenyl)imidazole monomer. This synthetic route has provided high molecular weight Pl of new chemical structure, is economically and synthetically more favorable than other routes, and allows for facile chemical structure variation due to the availability of a large variety of activated aromatic dihalides and dinitro compounds. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to the following U.S. patent applications, incorporated herein by reference:
[0002] Ser. No. 09/887,939 filed Jun. 22, 2001;
[0003] Ser. No. 10/218,013 filed Aug. 13, 2002;
[0004] Ser. No. 10/610,449 filed Jun. 30, 2003; and
[0005] Ser. No. 10/945,704 filed Sep. 21, 2004.
BACKGROUND AND SUMMARY OF THE INVENTION
[0006] Hearing instruments, i.e., devices that assist the hearing impaired, designed for complete or partial insertion into the user's ear canal, have a shell or housing that holds various components. One such component is the receiver, the element that generates the sound heard by the instrument's user. The sound is carried from the receiver by a receiver tube affixed to a port on the receiver to an opening (the receiver tube hole) in the tip of the shell, the portion of the hearing instrument positioned in the ear canal towards the eardrum.
[0007] During assembly, the receiver and its receiver tube are inserted into the shell, receiver tube first, and the tube is passed through the receiver tube hole. Once the receiver is in place inside the shell, anchored by a support, any excess portion of the receiver tube protruding from the shell is removed.
[0008] During assembly, the receiver tube is inserted into the shell and aimed towards the receiver tube hole. Occasionally, the end of the tube misses the receiver tube hole and catches on the inside of the shell. In that instance, the receiver tube must be pulled out and reinserted in an attempt to pass the tube through the receiver hole.
[0009] An Improved Configuration for the Inside of the Shell
[0010] The problem mentioned above may be minimized by providing an inwardly-sloping contour inside the shell of the hearing instrument. In particular, the interior of at least a portion of the shell comprises a chamber having planar or conical surfaces or inwardly curving or convex surfaces that guide the receiver tube towards the tip of the shell and the receiver tube hole.
[0011] Depending on the size and length of the hearing instrument, the shell may contain more than one such chamber. For example, where there are two chambers, the receiver tube is inserted into and through the first chamber and the tube then passes through an optional interconnecting passage and into and through the second chamber. A stopper having dimensions greater than the interconnecting passage may be provided on the receiver tube. When the stopper meets the end of the first chamber, the tube will not travel further into the shell, fixing the location of the receiver in the shell. A stopper may also be provided for a shell having a single chamber.
[0012] The design discussed here will improve the assembly process. An additional benefit achieved by the configurations discussed here is that walls of the shell are reinforced, reducing any tendency of the walls to vibrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1 and 2 are partial cross-sectional views of hearing instrument shells comprising a single chamber;
[0014] FIGS. 3, 4 , 5 , and 6 are partial cross-sectional views of hearing instrument shells comprising two chambers;
[0015] FIG. 7 is a partial axial cross-sectional view of a chamber and a conforming stopper for a receiver tube; and
[0016] FIGS. 8 and 9 are partial cross-sectional views of a hearing instrument shell comprising a chamber having multiple angular profiles or contours.
DESCRIPTION OF THE INVENTION
[0017] FIG. 1 is a partial cross-sectional view of a hearing instrument shell or housing 10 , comprising a tip 12 to be inserted into the ear canal of the person wearing the hearing instrument. The other end of the shell 10 , on the right side of FIG. 1 , shown incomplete in this as well as the other figures, is where the faceplate 20 (shown schematically here) would be attached. The faceplate 20 is the portion of the hearing instrument that faces generally outwardly from the ear proper, and at least a portion of the faceplate 20 is typically visible in the outer ear. In addition to an opening to admit sound, the faceplate 20 may also contain a battery door and a volume control. The faceplate may be fabricated as an integral component of the housing or shell 10 or it may be a separate part attached to the housing or shell 10 during assembly.
[0018] A receiver assembly 100 is positioned in the interior 200 of the shell 10 and may be mounted there using anchors 16 such as those described in U.S. application Ser. No. 10/945,704 and schematically depicted here in FIG. 1 . A flexible receiver tube 300 , having a degree of resilience and compliance, conveys the sound generated by the receiver 100 to the outside of the instrument housing 10 . The receiver tube 300 is attached to the receiver assembly 100 and the end 302 of the receiver tube 300 passes through a receiver tube hole 14 in the tip 12 of the shell 10 .
[0019] At least a portion of the shell interior 200 is a forward chamber 210 located in the tip 12 of the hearing instrument shell 10 . As illustrated in FIG. 1 , the forward chamber 210 is oriented such that the narrow end 212 of the chamber 210 is near the tip 12 ; the wide end 214 of the chamber 210 is closer to the faceplate 20 . Depending on design and space considerations, the receiver 100 may reside at least partially within the forward chamber 210 .
[0020] In the configuration illustrated in FIG. 1 , the walls or surfaces 216 of the forward chamber 210 are depicted as straight lines. In such a case, those surfaces 216 may be conical or planar. The geometry of the chamber 210 would then be either conical or polyhedral, respectively, and may be truncated at the receiver tube hole 14 . Also, a chamber 210 comprising a polyhedral contour may have sides (i.e., portions of the walls 216 ) of equal or unequal dimensions. Alternatively, the walls or surfaces 216 may curve inwardly, defining convex surfaces such as a hyperboloid (technically, one-half of a hyperboloid), as illustrated in FIG. 2 .
[0021] The entire chamber 210 or a portion of the chamber 210 may exhibit the desired planar, conical, or convex shape. In FIG. 1 , however, only the portion of the chamber 210 closest to the tip 12 has this shape (i.e., planar or conical). The rear portion 202 of the shell interior 200 , where the bulk of the receiver 100 is positioned, follows the outer contour of the shell 10 to a greater or lesser degree. Similarly, only the portion of the chamber 210 illustrated in FIG. 2 adjacent to the tip 12 has a convex contour.
[0022] If desired, a stopper 310 may be provided for the receiver tube 300 , as shown in FIG. 1 . The stopper 310 may be an integral part of the receiver tube 300 or an added piece that sits on the outside of the tube 300 . As appropriate, the shape of the stopper 310 can be fashioned to conform to the shape of the walls 216 of the forward chamber 210 or it can assume the shape of a truncated cone (also known as a conical frustrum), a torus, a sphere, or some other suitable configuration.
[0023] An intermediate chamber 240 may also be provided behind the forward chamber 210 , as shown in FIG. 3 . The walls or surfaces 246 of the intermediate chamber 240 may be planar (or conical) as shown in FIG. 3 or curved inwardly, i.e., convex, as depicted in FIG. 4 , and the entire chamber 240 or a portion of the chamber 240 may exhibit this shape. In either case, the intermediate chamber 240 is oriented such that the narrow end 242 of the intermediate chamber 240 is closer to the tip 12 ; the wide end 244 of the chamber 240 is closer to the faceplate 20 . Again, a stopper 310 can be provided for the receiver tube. In this instance, it would be located in the intermediate chamber 240 , closer to the receiver 100 and further from the tip 12 of the shell 10 .
[0024] If desired, instead of an immediate transition from the intermediate chamber 240 to the forward chamber 210 , an interconnecting channel 250 (see FIG. 3 or 4 ) can be provided between the intermediate chamber 240 and the forward chamber 210 . In this arrangement, the receiver tube 300 passes through the intermediate chamber 240 , the interconnecting channel 250 , and then the forward chamber 210 . Alternatively, the intersection between the two chambers 210 and 240 can be abrupt, with no interconnecting passage.
[0025] Depending on the outer shape of the shell 10 , the forward and intermediate chambers 210 and 240 may be collinear, as illustrated in FIG. 5 and evidenced by the relatively straight receiver tube 300 (note the dashed line denoting the axis of the receiver 100 and the receiver tube 300 ), or they may lie on different axes as illustrated in FIGS. 3 and 4 (note the dashed lines representing the axes of the two chambers).
[0026] To accommodate the particular shape of the chambers, the stoppers 310 illustrated in FIGS. 1-5 conform to the taper of the walls ( 216 or 246 ). As an alternative, a recess 248 can be provided for the stopper 312 as shown in FIG. 6 at the narrow end 242 of the intermediate chamber 240 . Here, the recess 248 provides a conforming receptacle having a generally rectangular profile for a stopper 312 having a similarly non-tapered profile, such as a torus. As an additional refinement, the stopper may assume the form of a polyhedron, such as the stopper 314 illustrated in FIG. 7 . Here, the walls 246 of the shell 10 are planar, defining four of five surfaces of a pentahedral chamber. In this particular case, the stopper 314 must be positioned in one of four possible orientations (i.e., at 0, 90, 180, or 270 degrees), radially orienting the receiver 100 (not shown in this view). Alternatively or in addition, a locating spline and keyway (shown collectively in FIG. 7 in phantom as element 320 and described in U.S. application Ser. No. 10/218,013) could be provided on the receiver tube 300 and the interconnecting channel 250 , respectively, or on the stopper 312 and the recess 248 of FIG. 6 , respectively.
[0027] In FIGS. 1-6 , the chambers 210 and 240 assume a single shape or contour, whether the walls are planar or convex surfaces. In a particularly small hearing instrument, there may be a desire to move the receiver 100 as close as possible to the tip 12 to maximize the use of space within the shell interior 200 . This may be achieved by flaring a portion of the walls or surfaces of the chamber, either in the forward chamber 210 or the intermediate chamber 240 , or both, creating a second angular profile or contour, whether planar, conical, or convex, within the same chamber.
[0028] In FIG. 8 , the angular orientation of the walls 216 at the narrow end 212 of the chamber 210 with respect to the axis of the chamber 210 defines one angle or a first angular contour 218 , while the portion at the wide end 214 of the chamber 210 defines a greater angle or a second angular contour 220 (note the dashed lines). Similarly, in FIG. 9 , distinct inwardly curved (or, convex or hyperboloidal) contours or surfaces 222 and 224 , exhibiting different degrees of curvature relative to the axis of the chamber 210 , are illustrated for the narrow and wide ends 212 and 214 of the chamber 210 , respectively (again, note the dashed lines).
[0029] If desired, planar, conical, and convex walls could be used in combination for the multiple contours, e.g., one planar and one convex, or planar and conical, or convex and conical, within the same chamber. Additionally, the chambers 210 and 240 could be divided into more than two sections, such that there are three or more contours or shapes from one end of the chamber ( 210 or 240 ) to the other. Also, the walls or surfaces within the same section of the chamber could be a combination of planar and convex contours. Finally, a shell could have more than two chambers, e.g., a very long shell.
[0030] Assembly of the shells is enhanced with the configurations of FIGS. 1-9 . In each case, the free end 302 of the receiver tube 300 , i.e., the end not attached to the receiver 100 , is inserted into the intermediate chamber 240 , if one has been provided, through an interconnecting channel 250 if present, and then into the forward chamber 210 , and towards the receiver tube hole 14 , and then through the receiver tube hole 14 . The contours of the walls or surfaces in the forward and intermediate chambers 210 and 240 guide the free end 302 of the receiver tube 300 through the chamber 200 , without fear of having the end 302 catch against the inside of the shell 10 .
[0031] The receiver tube 300 and the stoppers 310 and 312 may be fabricated from a synthetic material such as an elastomer or any other suitable material. One such elastomer is marketed by DuPont Dow Elastomers, L.L.C. under the trademark Viton. | A portion of a hearing instrument housing or shell comprises one or more chambers having planar, conical, or convex walls. During assembly, this shape helps guide the receiver tube towards tip of the shell and the receiver tube hole. Additionally, it will reinforce the walls of the shell, decreasing the tendency of the shell to vibrate when the receiver is generating sound. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 12/126,476, filed May 23, 2008, the entire disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention are generally related to back flow preventors that interconnect to a water source. More particularly, devices that attach to a sill cock, or any other fluid source, to prevent back flow of fluids, that may contain contaminants into the fluid supply are provided.
BACKGROUND OF THE INVENTION
[0003] Almost all buildings include some type of exterior fluid delivery system. The most common outdoor fluid delivery system is comprised of a faucet with a handle for actuating a valve that initiates or ceases fluid flow from a fluid source through a sill cock of the faucet. In order to direct the exiting fluid, it is also well known to employ a hose that is threadingly interconnected to the sill cock. Fluid in the hose may, under certain conditions, enter the faucet and ultimately the fluid source. For example, if the fluid pressure in the hose is greater than the fluid supply pressure “back flow” will occur. Such back flow may be harmless. One skilled in the art will appreciate, however, that the fluid in the hose could be harmful and result in spoilage of the water supply or contamination of fluid dispensing apparatus often interconnected to the hose.
[0004] One source of contamination includes pesticides and/or fertilizers that are often associated with a delivery system that is interconnected to the open end of the hose. Fluid from the supply is used to dilute those harmful chemicals in the delivery system prior to being distributed. Most municipalities require that a one-way check valve be included in a fluid supply line that delivers water from a public water source to a dwelling so that contaminated water cannot enter the public water supply from the dwelling. Often, there is no requirement that dictates that similar precautions are taken with respect to an exterior fluid delivery system that is associated with a dwelling. It is entirely conceivable that contaminants entering a dwelling from an outside fluid source will affect individuals associated within the dwelling but not the public at large. Further, if the above-mentioned check valve is absent or malfunctioning contaminants could also enter the public water supply via the dwelling.
[0005] Another issue related to back flow is the harmful effects of freezing when supply pressure is reduced and/or flow is stopped wherein liquid accumulates within the faucet and/or related plumbing. When the ambient temperature drops, the trapped liquid may freeze potentially causing severe damage to the faucet interconnected check valve and/or associated plumbing. To address this freezing, draining features have been incorporated into prior art check valves, such as the A. W. Cash Valve Company Model VB-111, which includes a stem that must manually be actuated to allow drainage when a hose is not connected. This type of manually draining valve relies on an operator to drain the valve, and is thus not reliable. Self-draining check valves, however, are also known in the art and are disclosed in U.S. Pat. No. 4,712,575 to Lair (“Lair I”), which is incorporated by reference herein. Lair I discloses a self-draining, single valve back flow preventor. When a hose is detached, a spool succumbs to spring pressure and moves axially outwardly from the outlet end of the check valve. A valve, housed within the spool, is thus allowed to move axially from its sealing washer to permit drainage. When the hose is connected, the spool and the valve housed therein, are forced axially toward a sealing washer to create a seal that prevents back flow. Vent holes in the check valve prevent accumulation of back pressure within the valve. Sufficient water pressure during supply flow with the hose attached overcomes a spring used to seat the valve and deflects a vent sealing washer, thereby sealing the vent holes. One drawback of the Lair valve is that foreign material may lodge between the valve and the sealing washer, creating a passage through which back flow may occur.
[0006] One way to address the major drawback of Lair I is to provide a second check valve. U.S. Pat. No. 3,905,382 to Waterston (“Waterston”), which is incorporated herein, discloses a check valve with two normally closed spring biased valves, one inside an outlet, and the other located near an inlet. The central portion of the Waterston check valve has an externally-threaded vent outlet. When flow occurs, the supply pressure forces the inlet valve axially from its seat toward the outlet and seals the vent. As flow progresses to the outlet valve, the flow pressure compresses an outlet spring and fluid is free to flow from the check valve. When flow ceases and back flow pressure is sufficient to overcome the valve in the outlet, liquid accumulates in the sealed tube and is discharged through a vent.
[0007] The Waterston valve does not provide a draining feature that relieves accumulated liquid upstream from the check valve. In the event of freezing the accumulation of liquid upstream from the check valve can result in severe damage to the check valve and plumbing upstream of the check valve. In addition, contamination may collect in the internal portion of the check valve such that when a back flow condition occurs, the contamination trapped in the check valve may enter the fluid supply.
[0008] Another system that employs more than one check valve to prevent back flow of a liquid into a distribution system by eliminating pressure differentials that may occur between the faucet and interconnected hose, is the V-444 Valve (“V-444”) manufactured by A. W. Cash Valve Company. The V-444 is succinctly described in U.S. Pat. No. 5,228,470 to Lair et al. (“Lair II”). The V-444 employs three separate valves enclosed in a housing that allows drainage of the sill cock after the hose is removed and also prevents backflow into the structure. The V-444 includes an outer housing with an internally situated movable spool. The spool includes an o-ring positioned on an angled upper surface thereof that cooperates with an angled inner surface of the housing to define a first valve that selectively opens and closes an outer passage that allows trapped fluid in the sill cock to drain from a plurality of vent holes. The V-444 also includes an inlet check valve and an outlet valve that controls fluid through the valve and that prevents backflow.
[0009] In a first mode of use, wherein no hose is connected and supply pressure is absent, the V-444 is self-draining A spring forces the spool downwardly to open a fluid path that drains fluid from the sill cock through the plurality of vent holes. Fluid trapped within the inlet and outlet check valves also drains from the outlet of the valve.
[0010] In a second mode of use, wherein the V-444 is exposed to supply pressure without a hose interconnected, the spring will force the spool downwardly, thereby creating a path for water to flow through the vents of the check valve. The supply pressure will also deflect the inlet check valve and the outlet check valve so that fluid will be able to exit the valve system.
[0011] In a third mode of operation, a hose is interconnected to the outlet portion of the V-444, but no supply pressure is provided. Any back pressure generated by fluid in the hose will force the outlet check valve to seat upon a surface provided by the spool. In this configuration, a hose forces the spool upward, thereby closing the first valve so that any fluid within the inlet check valve on the outlet valve can only travel out of the vents and not into the fluid supply.
[0012] In a fourth mode of operation, supply pressure is added to the V-444 with a blocked interconnected hose. Here, fluid from the fluid supply causes a seal to deflect, thereby blocking the vents. In addition, the outlet check valve is seated as described above, thereby preventing fluid from entering into the center of the V-444.
[0013] The V-444 includes a fifth mode of operation that is similar to the fourth mode wherein the hose is open to free flow. Again, since the hose is interconnected, the first valve is closed. Fluid pressure causes the inlet valve to transition downwardly to seat on the stem, thereby allowing fluid to flow through the center of the inlet check valve. The fluid pressure also pushes the outlet valve downwardly from its seat on the stem, which allows fluid to freely flow into the hose.
[0014] Among the major drawbacks of the V-444 are its size, weight, dimensions and inclusion of components that add to its complexity and expense, thereby rendering it unsuitable for use in various situations. More specifically, the V-444 check valve is approximately 2.2 inches in length and 1.9 inches in diameter and weighs about 200 grams. This size is attributed to the use of complex valving mechanisms and the provision of a first valve that includes a movable spool.
[0015] Other back flow preventors have been employed such as those similar to the backflow preventor shown and described in U.S. Pat. No. 7,013,910 to Tripp (“Tripp”), which is incorporated by reference herein. Tripp discloses an in-line backflow preventor that is used in fluid carbonation systems is interconnected between a fluid source and a mixing tank. The pressure in the mixing tank of these systems is often greater than the source pressure. Tripp is designed for either continuous down-steam pressure increases or intermittent down-stream pressure variations. Accordingly, Tripp does not have the capability of releasing pressure upstream of the valve outlet. Further, Tripp, due to its normally closed configuration, does not automatically drain or contain other similar features that are required for freeze prevention.
SUMMARY OF THE INVENTION
[0016] It is one aspect of the present invention to provide a double check valve for interconnection to a sill cock associated with an outside water source that prevents back flow into the water supply. Back flow can occur as a result of a siphon condition wherein a vacuum exists within the check valve, the sill cock or the water source that is apt to suction water in a hose, or in the interconnected check valve into the water supply. A back flow condition may also occur when the fluid pressure within the hose is greater than that of the water supply. For example, if the hose was taken to a roof of a building, the resulting head pressure may be greater than the supply pressure. In addition, a temporary loss or interruption in supply pressure may create a pressure differential that would create a back flow situation. The embodiments of the present invention also provide freeze protection wherein water inside the sill cock is allowed to freely drain from the double check valve after supply pressure is removed.
[0017] Embodiments of the present invention employ a valve body that includes an inlet check valve and an outlet check valve positioned within a valve body and a valve cap. The inlet check valve includes an inlet check seal and is biased from the outlet check valve via a spring (or other similar resiliently deflectable member). The inlet check seal cooperates with a main seal that is positioned between the valve body and the valve cap of the double check valve. The outlet check valve is comprised of an outlet check body with an outlet check seal that selectively engages a seat provided in the valve body. The outlet check body and the inlet check body are preferably selectively interconnected to each other, which will be described in further detail below. A hose plunger, which is adapted to selectively engage a hose, is preferably slidingly interconnected to the double check valve and is biased by a compressive member, such as a spring (or other similar resiliently deflectable member), that is associated with the seat of the valve body. The hose plunger includes a centralized hub that engages an outlet check spring (or other similar resiliently deflectable member) that is associated with the outlet check body. This combination of components is sufficient to prevent back flow and to provide self-draining (e.g. promote freeze resistance) without the need of a third check valve to control fluid flow through the vents. Detailed descriptions of the functionality of certain embodiments of the present invention will be provided below.
[0018] It is thus another aspect of the present invention to provide a check valve that omits or is devoid of components employed in prior art systems, thus rendering embodiments of the present invention easier and less expensive to manufacture, lighter, less complex, less prone to malfunction, and easier to repair. More specifically, embodiments of the present invention omit additional valves but continue to provide the same functionality of check valves of the prior art, such as the V-444 described above. That is, a system is provided that more effectively employs less than three valves and preferably two valves, thereby allowing size, weight and failure reduction. For example, it is contemplated that the double check valve of embodiments of the present invention are about ⅓ the size (preferably an about 70% reduction) of the V-444 check valve, which reduces bulk, weight and facilitates installation. Preferably, the check valve of one embodiment of the present invention is approximately 1.2 inches in length (an about 44% reduction) and approximately 1.4 inches in diameter an about 26% reduction) and weighs about 130 grams (an about 35% reduction). In one embodiment, this reduction in size and weight is attributed to the omission of a spool and a stem that controls flow out of the vents of the V-444 check valve. To achieve this, embodiments of the present invention allow for drainage from a point other than through vents in a valve body, for example, drainage from the outlet of the double check valve as opposed to primarily through vents provided in a valve body, as is done by the V-444 check valve. In addition, the present invention employs a fixed inlet valve and a fixed outlet valve as opposed to the complicated valving scheme employed by the V-444, wherein a movable spool alters the configuration of the internal volume of the valve depending on flow condition.
[0019] It is still yet another aspect of the present invention to provide a check valve that meets the American Society of Safety Engineers (ASSE) regulations. More specifically the check valve of embodiments of the present invention meets the requirements of ASSE 1052.
[0020] It is another aspect of the present invention to provide a valving system that is dual use. More specifically, embodiments of the present invention possess the capabilities of an in-line valve as disclosed in Tripp and the ability to provide automatic self draining when a hose is disconnected from the valve. The double check valve, preferably, employs normally opened inlet and outlet check valves, which allows for complete and automatic drainage. When a hose is interconnected to the dual check valve, the inlet and outlet check valves close, and will open when the faucet is turned on, for example. Normally opened (present invention) and normally closed (in-line) valves are different and are regulated separate ASSE standards. Normally opened check valves are regulated by ASSE 1052 and in-line valves are regulated by ASSE 1022. ASSE 1022 concerns backflow prevention devices that protect potable water supplies that serve beverage dispensing equipment. ASSE 1022 requires that two independently acting check valves be used that are biased to a normally closed position. Conversely, ASSE 1052 concerns basic performance requirements and test procedures for backflow preventors that are designed to interconnect to a hose. ASSE 1052 valving systems are designed to protect against backflow due to back siphonage and low-head backpressure, under the high hazard conditions present at a hose threaded outlet. ASSE 1052 also requires that the inlet and outlet check valves be biased closed. Embodiments of the present invention comply with ASSE 1052 when a hose is interconnected thereto and provide needed automatic drainage when the hose is disconnected, a technological advancement over the prior art and an improvement over prior art devices similar to Tripp.
[0021] Accordingly, it is one aspect of the present invention to provide a back flow prevention device for interconnection to a sill cock that includes a valve body with threads that are adapted to receive a hose, the valve body also having an inlet volume and an outlet volume separated by an internally-disposed wall, a lower surface of the wall defining a valve seat, the valve body further including a vent that provides a flow path between the outside of the valve body and the inlet volume; a seal positioned with the valve body in a volume located adjacent to the inlet volume, the seal adapted to selectively block the vent; a valve cap interconnected to the valve body that is positioned within the volume that maintains the seal against the valve body, the valve cap having threads for interconnection to a sill cock of a faucet; an inlet check valve comprising: an inlet check spring positioned within the inlet volume, wherein the spring contacts an upper surface of the wall, an inlet check body positioned within the inlet check spring, an inlet check seal interconnected to the inlet check body that is adapted to selectively engage the seal, thereby opening and closing an aperture of the seal to control fluid flow from the valve cap into the inlet volume; a drain spring positioned within the outlet volume that contacts the seat and a plunger that is adapted to engage a hose; an outlet check valve comprising: an outlet check body positioned within the drain spring, an outlet check seal interconnected to the outlet check body that is adapted to selectively engage the seat to either open a flow path between the inlet volume and outlet volume, or isolate the outlet volume from the inlet volume, thereby preventing fluid from flowing from an interconnected hose into the sill cock; and an outlet check spring positioned about the outlet check body that contacts a portion of the outlet check body and a hub of the plunger.
[0022] More generally, it is an aspect of the present invention to provide a back flow prevention device, that includes a valve body with a fixed inlet volume and a fixed outlet volume, the valve body also having a vent for allowing fluid from inside the valve body to escape; a valve cap; a seal positioned between the valve cap and the valve body; an inlet check valve positioned within the inlet volume; and an outlet check valve positioned within the outlet volume.
[0023] In addition, it is an aspect of the present invention to provide a back flow prevention device including a body with a fixed inlet volume and a fixed outlet volume, the body also having an aperture; a cap; a primary means for sealing positioned between the cap and the body; an inlet means for selectively preventing flow of fluid positioned within the inlet volume; and an outlet means for selectively preventing flow of fluid positioned within the outlet volume.
[0024] Further, one of skill in the art will appreciate upon review of this disclosure that it is another aspect of the present invention to provide a water delivery system including a faucet associated with a water supply; a valve associated with the faucet that is adapted to selectively control the flow of fluid from the water supply through the faucet; and a double check valve associated with the faucet that prevents fluid from entering the water supply and that allows fluid within the faucet to drain therefrom when the valve is in the off position, the double check valve comprising: a valve body with a fixed inlet volume and a fixed outlet volume, the valve body also having a vent for allowing fluid from inside the valve body to escape, a valve cap, a seal positioned between the valve cap and the valve body, an inlet check valve positioned within the inlet volume, and an outlet check valve positioned with the outlet volume.
[0025] It is also an aspect of the present invention to provide a back flow prevention device that employs a housing having a passageway configured for the transport of a fluid therethrough, the housing having an inlet and an outlet, the passageway encompassing a valve system consisting essentially of: a first check valve disposed in the passageway that allows fluid to flow through the passageway in the direction from the inlet to the outlet; and a second check valve disposed in the passageway that allows fluid to flow through the passageway in the direction from the inlet to the outlet; a diaphragm disposed in the passageway adapted to engage at least one of the first check valve and the second check valve; a vent in fluid communication with the passageway and located between the first and second check valves, the vent selectively isolated from the passageway by the diaphragm, the vent adapted to permit fluid located between the first and second check valves to exit the housing through the vent, whereby the back flow prevention device permits substantially all fluid to drain completely from the device.
[0026] It is still yet an aspect of the present invention to provide a back flow prevention device that includes a housing having first and second ends and including a means for connecting to a fluid inlet line at the first end and for connecting a fluid outlet line to the second end; a central cavity within the housing; wherein the housing includes a valve system consisting essentially of first and second drain valves and is devoid of a third drain valve, the first drain valve located within the housing between the central cavity and the fluid inlet line to permit drainage of fluid from the fluid inlet line to the fluid outlet line end of the housing when the fluid outlet line is not connected thereto, and the second valve located within the housing between the central cavity and the fluid inlet line to control flow between the fluid inlet line and the central cavity, whereby the back flow prevention device permits substantially all fluid to drain completely from the device.
[0027] The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
[0029] FIG. 1 is a perspective view of a double check valve of one embodiment of the present invention;
[0030] FIG. 1A is a partial cross-sectional view of the double check valve of one embodiment of the present invention associated with a faucet;
[0031] FIG. 2 is an exploded perspective view of the double check valve shown in FIG. 1 ;
[0032] FIG. 3 is a cross-sectional view of FIG. 2 ;
[0033] FIG. 4 is a cross-sectional view of FIG. 1 showing an open flow configuration wherein the double check valve is interconnected on one end to a sill cock and opened on the other end;
[0034] FIG. 5 is a cross-sectional view of FIG. 1 showing a no flow configuration wherein the double check valve is interconnected to a sill cock and a hose;
[0035] FIG. 6 is a cross-sectional view of FIG. 1 showing a closed flow configuration wherein the double check valve is interconnected to a sill cock and a hose;
[0036] FIG. 7 is a cross-sectional view of FIG. 1 showing a double check valve in a siphon condition;
[0037] FIG. 8 is a cross-sectional view of FIG. 1 showing the double check valve exposed to back siphonage;
[0038] FIG. 9 is a cross-sectional view of FIG. 1 showing the double check valve subsequent to hose removal;
[0039] FIG. 10 is a cross-sectional view of FIG. 1 showing the double check valve during testing;
[0040] FIG. 11 is a valve cap of an alternate embodiment of the present invention; and
[0041] FIG. 12 is a valve cap of an alternate embodiment of the present invention.
[0042] To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:
[0000]
#
Components
2
Double check valve
4
Hose
6
Inlet check valve
10
Outlet check valve
14
Valve body
18
Valve cap
22
Vent
26
Outlet
30
Inlet
34
Main seal
38
Inlet check seal
42
Threads
46
Knurls
50
Hose plunger
51
Faucet
52
Valve
54
O-ring
58
Wrench flats
62
Annular jut
66
Inlet check body
70
Hooked surface
74
Inlet check spring
78
Seat
80
Passage
82
Drain spring
86
Outlet check body
90
Hollow portion
94
Slot
98
Stop
102
Outlet check seal
104
Outlet check spring
108
Cylindrical portion
112
Protrusion
116
Hub
118
Upper surface
120
Lip
124
Stop
128
Thumb screw hole
132
Hose washer
134
Fluid
136
Ring
140
Groove
[0043] It should be understood that the drawings are not necessarily to scale, although particular perspective dimensions may be relied upon to define the present invention. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0044] Referring now to FIGS. 1-12 , a double check valve 2 is provided that includes an inlet check valve 6 and an outlet check valve 10 positioned in a valve body 14 . The valve body 14 receives a valve cap 18 that is adapted for interconnection to a sill cock of a faucet, for example. The valve body 14 also includes a plurality of vents 22 that allow for drainage of fluids from the sill cock, the inlet check valve 6 and/or outlet check valve 10 depending on the pressure gradient within the double check valve 2 . Embodiments of the present invention thus allow fluid within the sill cock to drain from the double check valve to prevent freezing. Back flow is prevented such that when pressure at an outlet 26 of the double check valve is greater than the pressure at the inlet 30 , which is in communication with a fluid supply, a main seal 34 (or diaphragm) will cooperate with an inlet check seal 38 to prevent back flow from entering the fluid supply. Excess water then will be trapped within the inlet check valve 6 or outlet check valve 10 (when a hose is interconnected to the check valve), or be drained from the vents 22 . If no hose is interconnected, trapped fluid is able to drain from the inlet and outlet valves as well.
[0045] Referring now to FIGS. 1 and 1A , a double check valve 2 of one embodiment of the present invention is shown. Preferably, the components of double check valve 2 , which will be described in further detail below, are constructed of a rigid material commonly used in the plumbing arts, such as brass. However, one skilled in the art will appreciate other suitable materials may be utilized without deviating from the scope of the invention. The double check valve 2 includes a valve body 14 that is interconnected to a valve cap 18 . The valve cap 18 is the inlet 30 of the double check valve 2 and employs a plurality of threads 42 (or a bayonet fitting), positioned on its outer and/or inner surface thereof, for interconnection to a sill cock of a faucet. The valve body 14 is preferably a cylindrical member that may include a knurled 46 outer surface that aids in the interconnection of the double check valve 2 to a fluid source. The double check valve 2 also includes a plurality of vents 22 that allow fluid and/or air to escape from the internal volume thereof. The valve body 14 also includes a plurality of threads 42 positioned about an outlet 26 of the double check valve 2 . A hose plunger 50 is selectively interconnected to the valve body 14 and is designed to coincide with the outlet 26 of the double check valve 2 when a hose 4 is interconnected thereto. FIG. 1 A illustrates an embodiment of the double check valve 2 in association with a faucet 51 , also referred to as a sill cock. The faucet 51 employs a valve 52 to control the flow of water.
[0046] Referring now to FIGS. 2 and 3 , exploded views of one embodiment of the present invention are provided. An o-ring 54 is positioned within the valve cap 18 . One of skill in the art will appreciate the sealing function provided by the o-ring 54 may be performed by a flat seal or any other sealing member, or combination thereof, without departing from the scope of the invention. The valve cap 18 may also include a plurality of wrench flats 58 for securely interconnecting the double check valve 2 to a sill cock, for example. The valve cap 18 also includes an annular jut 62 that interfaces with the main seal 34 of the double check valve 2 . Between the main seal 34 and the valve body 14 resides an inlet check body 66 that includes a lower end with a protruding, or hooked surface 70 . The inlet check body 66 receives the inlet check seal 38 on one end and an inlet check spring 74 on the other end. The inlet check spring 74 rests on an internal wall, or seat 78 , provided within the valve body 14 . Alternatively, the inlet check spring 74 may contact and outlet check body 86 . The seat 78 defines a passage 80 that allows fluid to flow from the inlet check valve 6 to the outlet check valve 10 . The valve body 14 also includes threads 42 that receive a hose.
[0047] The seat 78 is also associated with a drain spring 82 that is positioned about the outlet check body 86 . The outlet check body 86 includes a hollow portion 90 having a slot 94 bounded by a stop 98 . The stop 98 cooperates with the hooked surface 70 of the inlet check body 66 , thereby operably interconnecting the inlet check body 66 and the outlet check body 86 . The outlet check body 86 includes an outlet check seal 102 and an outlet check spring 104 positioned about a cylindrical portion 108 thereof. Finally, the outlet check body 86 includes a lower protrusion 112 that is snap fit within a hub 116 of the hose plunger 50 .
[0048] An upper surface 118 of the hose plunger 50 is engaged to the drain spring 82 wherein its lower portion is adapted to contact a hose. The hose plunger 50 also includes a lip that engages an inner surface of the valve body 14 when a hose is interconnected thereto that prevents further insertion of the hose plunger 50 into the double check valve when the hose is interconnected. The hose plunger 50 of one embodiment of the present invention is a snap fit within the valve body 14 such that the lip 120 of the hose plunger 50 engages a stop 124 provided adjacent to the outlet of the valve body 14 when a hose is not interconnected to the valve body 14 .
[0049] Referring now to FIG. 4 , the double check valve 2 of one embodiment is shown during an open flow condition. Here, the valve cap 18 is shown interconnected to the valve body 14 . The valve cap 18 may include a thumbscrew aperture 128 to receive a thumbscrew that allows a user to tightly (an often permanently) affix the double check valve 2 onto a sill cock. A main seal 34 is positioned between the annular jut 62 of the valve cap 18 and the valve body 14 . Embodiments of the present invention interference fit the valve cap 18 onto the valve body 14 . One skilled in the art, however, will appreciate that the valve cap 18 may be screwed, welded or otherwise interconnected to the valve body 14 . An o-ring 54 resides within the valve cap 18 and is adapted to provide a seal between the sill cock and the valve cap 18 .
[0050] FIG. 4 shows an open flow condition wherein the supply pressure exists but no hose is interconnected to the double check valve 2 . The hose plunger 50 is biased by the drain spring 82 such that the lip 120 of the hose plunger 50 contacts the stop 124 of the valve body 14 . Supply pressure forces the main seal 34 to deflect downwardly, which blocks fluid flow through the vents 22 . This configuration is substantially different from the V-444 configuration described above. During an open flow condition with no interconnected hose, the V-444 valve will allow fluid to escape out of the vents that wastes water. Supply pressure also forces the inlet check body 66 downwardly, which compresses the inlet check spring 74 . The supply pressure in this configuration is sufficient enough to transition the outlet check seal 102 downwardly and to compress the outlet check spring 104 to separate the outlet check seal 102 and seat 78 .
[0051] Referring now to FIG. 5 , the double check valve 2 is shown with the hose 4 interconnected during a non-flow condition. In this configuration, connection of the hose 4 , which includes a hose washer 132 , forces the hose plunger 50 , and thus the hub 116 thereof, axially upward. The upward motion of the hose plunger 50 compresses the outlet check spring 104 , which forces the outlet check body 86 upwardly such that the outlet check seal 102 engages the seat 78 . Thus, interconnection of the hose 4 completely isolates the outlet check valve 10 from the inlet check valve 6 . If any back flow causing pressure rise in the hose 4 occurs, the seal between the outlet check seal 102 and its seat 78 will prevent fluid from entering the fluid source, unless those components have failed (for example, debris lodged between the outlet check seal 102 and the seat 7 that allows for fluid infiltration). Since there is no flow from the fluid supply, the inlet check spring 74 and the inlet check body 66 will be positioned upwardly so that the inlet check seal 38 is engaged to the main seal 34 . Thus, the inlet check valve 6 is isolated from the valve cap 18 that is interconnected to the fluid source. The inlet check valve 6 is, however, in fluidic communication with the vents 22 wherein any fluid pressurized by the transitioning outlet check body 86 will exit therethrough.
[0052] Referring now to FIG. 6 , a closed flow condition is shown wherein the hose (not shown) is interconnected to the valve body 14 and the fluid supply has been opened. Here, supply pressure deflects the inner diameter of the main seal 34 downwardly such that the main seal 34 blocks the vents 22 . Supply pressure also acts on the inlet check seal 38 to force it downwardly which compresses the inlet check spring 74 . As described above, since the hose is interconnected to the valve body 14 , the hose plunger and the outlet check body 86 will be shifted upwardly. The inlet check body, however, will contact the outlet check body 86 and force it downwardly, thereby counteracting the outlet check seal and opening the passage 80 between the inlet check valve 6 and the outlet check valve 10 .
[0053] Referring now to FIG. 7 , a non-flow configuration wherein a siphon has occurred is shown subsequent to the removal of supply pressure with the hose (not shown) interconnected to the valve body 14 . A siphon condition may be caused when gravity-induced flow of the water in the hose pulls a vacuum after the supply pressure has been shut off. The vacuum within the inlet check valve 6 and the outlet check valve causes the main seal 34 and the outlet check body 86 to deflect towards the outlet of the double check valve 2 . The outlet check body 86 translates downwardly until it contacts the hub 116 of the hose plunger 50 . The inlet check spring 74 pushes the inlet check body 66 upwardly. However, the hooked surface 70 of the inlet check body 66 will engage with the stop 98 of the outlet check body 86 , thereby limiting the range of motion of the inlet check body 66 and preventing the inlet check seal 38 from closing the main seal 34 . That is, during a siphoning condition, the inlet check seal 38 will not be able to fully flatten the main seal 34 . As a result, the deflected main seal 34 will be prevented from completely blocking the vents 22 . A path between the inlet check seal 38 and the internal surface of the inlet check valve 6 will allow air from the outside of the double check valve 2 to enter through the vents 22 to break the vacuum which allows the outlet check spring 104 to relax and engage the outlet check valve 10 on the seat 78 . This in turn will allow the inlet check body 66 to transition upwardly to engage the inlet check seal 38 onto the main seal 34 to isolate the inlet check valve 6 and the outlet check valve 10 from the valve cap 18 as shown in FIG. 5 .
[0054] Referring now to FIG. 8 , a back siphonage situation is shown. Here, the hose (not shown) is interconnected to the valve body 14 and a vacuum has occurred at fluid supply that could cause contaminated fluid from the hose or double check valve 2 to enter the fluid supply. In operation, the hose forces the hose plunger 50 upwardly that compresses the drain spring 82 . The hub 116 of the hose plunger 50 also moves upwardly and forces, via the outlet check spring 104 , the outlet valve check body 86 to move upwardly so that outlet check seal 102 engages the seat 78 . The vacuum in the valve cap 18 pulls the inlet check seal upwardly to engage the main seal 34 . Thus the outlet check valve 10 is isolated from the inlet check valve 6 and the inlet check valve 6 is isolated from the cap valve 18 which is interconnected to the fluid supply, and no fluid from the hose and/or the double check valve can enter the fluid supply.
[0055] Referring now to FIG. 9 , draining of the double check valve 2 is illustrated. After the hose is removed, the drain spring 82 expands and forces the hose plunger 50 downwardly such that the lip 120 of the hose plunger 50 contacts the stop 124 of the valve body 14 . The hub 116 of the hose plunger 50 will also contact the protrusion 112 of the outlet check body 86 and pull the outlet valve body 86 downwardly, which removes the outlet check seal 102 from the outlet check seat 78 . The stop 98 of the outlet check body 86 will contact the hooked surface 70 of the inlet check body 66 and pull the inlet check seal 38 from the main seal 34 . Thus, a free flow path from the inlet check valve 6 into the outlet check valve 10 and out of the hose plunger 50 is provided. Water in the sill cock will also be able to flow through the valve cap 18 and through the inlet check valve 6 , the outlet check valve 10 and out of the hose plunger 50 . Fluid may also drain through the plurality of vents provided.
[0056] Referring now to FIG. 10 , the double check valve 2 is shown during a test. More specifically, it is one aspect of the present invention that the double check valve 2 of embodiments of the present invention can be easily tested in the field to ensure that it is in proper working condition. Here, the hose (not shown) is interconnected to the threads 42 of the valve body 14 that forces the hose plunger 50 upwardly and compresses the drain spring 82 . The hub 116 is also forced upwardly which compresses the outlet check spring 104 and forces the outlet check seal 102 against seat 78 . If the double check valve 2 is working properly the outlet check valve 10 should be isolated from the vents 22 . Fluid 134 is then added via the hose and into the outlet 26 of the double check valve 2 . If the integrity of the outlet check valve 102 and the seat 78 are adequate, no fluid will enter the inlet check valve 6 . Conversely, if the integrity between the outlet check seal 102 and the seat 78 is broken, fluid 134 will fill the inlet check valve 6 , and will exit from the plurality of vents 22 . The inlet check spring 74 will force the inlet check body 66 upwardly to place the inlet check seal 38 in contact with the main seal 34 to prevent any fluid from entering the water source during this test.
[0057] Referring now to FIGS. 11 and 12 , valve caps 18 of alternate embodiments of the present invention are provided. Here, the annular jut 62 , which interfaces with the main seal 34 and ring 136 , which interfaces with a groove 140 provided on the valve body 14 are substantially the same as those described above. However, the inlet portion 30 of the valve cap 18 includes a plurality of exterior threads 42 for threading onto sill cocks and have inwardly threads 42 . Inspection of FIGS. 11 and 12 will show that the inlets 30 of these valve caps 18 are of different diameters, thereby succinctly illustrating the scalability of the present invention.
[0058] One of skill in the art will appreciate that the valve described and shown herein may be interconnected to the sill cock via a bendable or telescoping member to provide the ability to selectively locate the valve. Alternatively, or in addition, valves as described may possess telescoping functionality as shown in U.S. Design Pat. No. D491,253 to Hansle. The valve may also employ a timer, flow regulation capabilities, etc. to control the flow of fluid therefrom. The valve may employ more than one outlet, which each may include valving as described, and may employ a combination of materials as described in Tripp. Further, the valve may be directly integrated into the sill cock instead of interconnected thereto. The system described herein may include a visual or audible alarm to notify the instance of a valve failure.
[0059] While various embodiments of the present invention have been described in detail, it will be apparent that modifications and alterations of those embodiments are also intended to be encompassed by this description. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. For example, aspects of inventions disclosed in U.S. Patent and Published Patent Application Nos. 5632303, 5590679, 7100637, 5813428, and 20060196561, all of which are incorporated herein by this reference, which generally concern back flow prevention, may be incorporated into embodiments of the present invention. Aspects of inventions disclosed in U.S. Pat. Nos. 5,701,925 and 5,246,028, all of which are incorporated herein by this reference, which generally concern sanitary hydrants, may be incorporated into embodiments of the present invention. Aspects of inventions disclosed in U.S. Pat. Nos. 6,532,986, 6,805,154, 6,135,359, 6,769,446, 6,830,063, RE39235, 6,206,039, 6,883,534, 6,857,442 and 6,142,172, all of which are incorporated herein by this reference, which generally concern freeze-proof hydrants, may be incorporated into embodiments of the present invention. Aspects of inventions disclosed in U.S. Patent and Published patent application Nos. D521113, D470915, U.S. Pat. No. 7,234,732, 7,059,937, 6,679,473, 6,431,204, 7,111,875, D482431, 6,631,623, 6,948,518, 6,948,509, 20070044840, 20070044838, 20070039649, 20060254647 and 20060108804, all of which are incorporated herein by this reference, which generally concern general hydrant technology, may be incorporated into embodiments of the present invention. | A double check valve is provided that includes an in-line inlet check valve and an outlet check valve that cooperate to prevent back flow of fluid through the valve. The check valve also includes at least one vent that allows for fluid trapped within the check valve to drain, thereby preventing freezing of the check valve and hydrant to which it is interconnected. The check valve provided omits many superfluous components and thus is smaller and easier to install than check valves of the prior art. | 5 |
FIELD OF THE INVENTION
This invention is directed to an implantable neurostimulator having improved efficacy in treating epilepsy and other neurological disorders and to processes of using that neurostimulator. The neurostimulator itself generally involves two modes of electrical stimulation: the first involves delivering a non-responsive electrical stimulation signal which is applied to the central nervous system to reduce the likelihood of a seizure or other undesirable neurological even from occurring, and a second mode that involves delivering electrical stimulation signal or signals when epileptiform waveforms are impending or extant.
The responsive electrical stimulation signal or signals are intended to terminate epileptiform activity, e.g., to desynchronize abnormally synchronous brain electrical activity.
Alternatively, the second mode may be used to deliver sensory stimulation, e.g., a scalp or sound stimulation, to the patient rather than deliver electrical stimulation to the patient.
Finally, the neurostimulator may be used by a physician to induce epileptiform activity and then verify the effectiveness of the parameters of the first and second neurostimulation signal or signals.
BACKGROUND OF THE INVENTION
Epileptic seizures are characterized by excessive or abnormally synchronous neuronal activity. Neurologists recognize a wide variety of seizures. Partial onset seizures begin in one part of the brain; general onset seizures arise throughout the entire brain simultaneously. When partial onset seizures progress to involve much of the brain, they are said to have “secondarily generalized.” Some seizures result in the loss of conscious awareness and are termed “complex” seizures. So-called “simple” seizures may involve other symptoms, but consciousness is unimpaired. Seizure symptoms may include sensory distortions, involuntary movements, or loss of muscle tone. The behavioral features of a seizures often reflect a function of the cortex where the abnormal electrical activity is found.
Physicians have been able to treat epilepsy by resecting certain brain areas by surgery and by medication. Brain surgery is irreversible, and is ineffective or is associated with neural morbidity in a sizable percentage of cases. Medication is the most prevalent treatment for epilepsy. It is effective in over half of patients, but in the reminder of the patients, the medication is either ineffective in controlling seizures, or the patients suffer from debilitating side effects. A more promising method of treating patients having epileptic seizures is by electrical stimulation of the brain.
Since the early 1970's, electrical brain stimulators have been used which provide more or less constant stimulation, the stimulation largely being unrelated to detected electrical activity.
Electrical stimulation of the nervous system has been used to suppress seizures. A device is described in Cooper et al. for stimulation of the cerebellum. See, “The Effect of Chronic Stimulation of Cerebellar Cortex on Epilepsy and Man,” I. S. Cooper et al in The Cerebellum, Epilepsy and Behavior, Cooper, Riklan and Snyder Edition, Pleman Press, New York 1974. Others have utilized devices which stimulated the centro median nucleus of the thalamus. See, “Electrical Stimulation of the Centro Median Thalamic Nucleous in Control of Seizures: Long Term Studies.” F. Valasco et al, Epilepsia, 36 (1): 63-71, 1995. Chaos Theory has been used to apply stimulation to a seizure focus in vitro to abort the seizure. See, S. Schiff et al, “Controlling Chaos in the Brain,” Nature, Volume 370, Aug. 25, 1994.
Non responsive electrical stimulation devices have been used for significant periods. The devices and procedures did not constitute a panacea, however. For instance, a 17 year follow-up study shown in Davis et al. (“Cerebellar Stimulation for Seizure Control 17 Year Study,” Proceedings of the Meeting of the American Society for Stereotactic and Functional Neurosurgery, Pittsburgh, Pa., Jun. 16-19, 1991 and in Stereotact. Funct. Neurosurg. 1992; 58; 200-208) showed that less than one-half of the patients became seizure free, even though 85% showed some benefit.
In contrast, responsive stimulation, specifically electrical stimulation, that is applied to the brain, has not yet been used to treat patients in long-term studies. This is true even though there are algorithms suitable for detection of the onset of an epileptic seizure. For instance, Qu et al provide an algorithm said to recognize patterns of electrical activity similar to those developed while recording an actual epileptic seizure. See, Qu et al., “A Seizure Warning System for Long-Term Epilepsy Monitoring, Neurology,” 1995; 45:2250-2254. Similarly, Osario, et al. have suggested an algorithm applied to signals from intracranial electrodes with good results. See Osario, et al. “A Method For Accurate Automated Real-Time Seizure Detection,” Epilepsia, Vol. 35, supplement 4, 1995.
None of the cited documents describes procedures in which a non-responsive electrical stimulation signal is applied to the brain in a first mode and, upon detection of impending or of extant epileptiform electrical activity, a second responsive mode of stimulation is applied to the brain either with or without cessation of non-responsive stimulation.
SUMMARY OF THE INVENTION
The invention is an implantable neurostimulator having improved efficacy in treating epilepsy and other neurological disorders and processes of using that neurostimulator. The method generally includes three or more steps. Initially, a non-responsive electrical stimulation signal is applied to the brain in a non-responsive mode. Secondly, some brain electrical activity is detected either during the non-responsive stimulation signal or after the non-responsive stimulation signal is paused. Third, when that detected electrical activity shows an impending or existing epileptiform brain electrical activity, a second electrical stimulation signal is applied to the brain. Alternatively, a sensory stimulation, e.g., sound or scalp twitch, may be directed to the patient in place of or in addition to the second electrical stimulation signal.
The first or non-responsive electrical stimulation signal, may or may not be paused during the second phase as desired. The non-responsive stimulation may be diurnally varied or varied on some other schedule as desired. The brain electrical activity may be detected in a variety of ways including scalp electrodes, cortical electrodes, or the electrical activity may be monitored at a depth within the brain. The responsive electrical stimulation signal may be applied to one or more electrodes placed on or about the brain. If multiple electrodes are chosen, either for measurement of the brain electrical activity or application of the responsive stimulation, the electrodes may be chosen so that they are independently selectable if so desired. The responsive stimulation (and the non-responsive stimulation) may be defined by parameters such as the electrode or electrodes selected, pulse width, interpulse interval, pulse amplitude, pulse morphology, the number of pulses in the burst, the number of bursts, and the intervals between bursts. Each of these parameters for either the responsive or the non-responsive stimulation may be changed or left static during a mode of the process.
The procedure may include a pause of the responsive stimulation for detection of or measurement of brain electrical activity. This may then be followed by either re-commencement of the non-responsive stimulation, or, if the desired cessation of epileptiform activity has not been achieved, by a continuation of the responsive stimulation.
The procedure may also include the step of using the implanted neurostimulator to apply electrical stimulation to the brain under physician control to cause epileptiform activity and a second step of using the implanted neurostimulator to apply a responsive stimulation signal which terminates that epileptiform activity. This permits the neurostimulator to be used to test the effectiveness of the parameters selected for responsive stimulation. The testing may be done before, during, or anytime after implantation of the inventive neurostimulator to assess functionality. in addition, the testing may be used to verify the effectiveness of the non-responsive stimulation parameters by assessing the relative ease or difficulty in initiating epileptiform activity.
In general, the implantable neuro-stimulator includes at least a first brain electrical activity sensor near or in contact with the brain, at least a first stimulator electrode for providing a non-responsive stimulation to the brain and optionally for providing the responsive stimulation, a non-responsive signal source for the first stimulation electrode, one or more (optional) second stimulator electrodes for providing the responsive stimulation, and a responsive stimulation source. The non-responsive and responsive sources may be integrated into a single source if so desired.
Desirably there may be two brain electrodes: the first used for non-responsive stimulation and positioned in or on the cerebellum or in a deep brain structure such as the thalamus, hippocampus or amygdala, the second used for responsive stimulation and placed on or near the seizure focus or a neural pathway involved in sustaining or propagating the epileptiform activity. In some instances there may be only one electrode that is used for both purposes. Conversely, in some variation of the invention, the patient will benefit from a larger number of electrodes being used.
This invention has the following advantages:
1. improved ability to terminate epileptiform activity,
2. less likely to generalize ongoing epileptiform activity,
3. optimally controls seizures by lowering the incidence of seizures as well as treating instances of breakthrough epileptiform activity, and
4. provides for optimization of stimulation parameters programmed into the implanted neurostimulator.
A BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a time graph of typical first and second modes and the operation of a blanking operation as used in the inventive process.
FIG. 1B shows a circuit useful in blanking input to a measurement step as shown in FIG. 1 A.
FIGS. 2A and 2B show a time graph of alternative methods for detecting electrical activity in the brain by pausing the responsive and non-responsive stimulation of the inventive process.
FIG. 3 shows a graph of conventions used in describing pulse and burst parameters.
FIGS. 4A-4F show time graphs of exempletive changes in pulse and burst parameters useful in the inventive process.
FIG. 5 is a depiction of one variation of the inventive neurostimulator having multiple electrodes.
DESCRIPTION OF THE INVENTION
As noted elsewhere, this invention includes a neurostimulation method and devices for practicing that method.
Neurostimulation Methods
In one variation of the invention, the neurostimulation process includes at least two modes. The first mode involves application of a generally “non-responsive” electrical stimulation (or stimulation signal) to the brain. The second mode involves the application of a “responsive” electrical stimulation to the brain or a sensory stimulation elsewhere to the body. Optionally, the process includes steps for detection of electrical activity of the brain, analysis of that activity for impending or existent epileptiform activity, and decision-making steps relating whether to initiate responsive stimulation or to change the parameters of that stimulation.
As used herein, “non-responsive” stimulation refers to the application of electrical therapy intended to lower the probability of a seizure occuring. The parameters (electrode or electrodes used, number of pulses, amplitude, pulse to pulse interval, duration of pulses, etc.) of the non-responsive stimulation, or the application of the non-responsive stimulation may be set or varied as a result of the detection of signals from the patient's body including the nervous system and brain. The parameters of non-responsive stimulation may also be set by a physician. In general, however, and unless the context of the term indicates otherwise, a non-responsive stimulation is one in which the parameters of that stimulation are not controlled or modified in the implantable neurostimulator as a result of the detection of an existing or impending epileptiform event unless done so in conjunction with the use of the response stimulation.
As used herein, “responsive” stimulation refers to the application of electrical therapy in response to the detection of an electrographic (or some other) event indicating an impending or existent seizure. The electrographic event may be the beginning of an electrographic seizure, epileptiform activity, or other features of the EEG that typically occur prior to a seizure. Other events may include motion detection, or external triggering.
As used herein, “seizure” may represent a behavioral seizure wherein clinical evidence of functional or cognitive manifestations of the seizure may be elucidated by testing the patient; or electrographic seizure which refers to abnormalities detectable on the EEG (whether from brain, scalp or other electrodes).
By “stimulation”, we mean an electrical signal applied to brain tissue or some type of sensory input applied to the patient to elicit a response. The latter may include such physical motions such as vibration, other electrical signals not to brain tissue (for example a scalp twitch), light flashes, sound pulses, etc.
The term “epileptiform activity” refers to the manifestation on an EEG (cortical, depth, or scalp) of abnormal brain activity whether associated with clinical manifestations or not.
“Electrical stimulation” means the application of an electric field or electric current to biological tissue, “stimulation” means electrical or sensory stimulation.
The brain's electrical activity is detected and analyzed to detect epileptiform activity or to detect such impending activity. If the epileptiform activity is present or impending, the second mode of responsive stimulation is initiated. The results of the analysis of the epileptiform activity may also be used to modify the parameters of the non-responsive stimulation to optimize the suppression of seizures of other undesirable neurological events.
The parameters (electrode or electrodes used, number of pulses, amplitude, frequency, duration of pulses, etc.) of the responsive stimulation may be varied. The variation of the parameters may be based either upon a preprogrammed sequence or based upon some characteristic of the detected epileptiform activity. Additionally, the parameters of the responsive stimulation may be advantageously varied between different episodes of spontaneous epileptiform activity to minimize the tendency of the stimulation itself to predispose the brain to epileptogenesis (also known as “kindling”). Application of the responsive stimulation may be temporally paused or the amplifier blanked during responsive stimulation to allow analysis of the electrical activity of the brain to determine whether the stimulation has had its desired effect. Readjustment of the parameters of the responsive stimulation in the second mode may be repeated as long as it is advantageous in terminating the undesirable epileptiform activity.
This inventive procedure provides for multimodal therapies to be delivered not only to terminate impending or existent epileptiform activity, but also to diminish the likelihood that native seizures will occur. In addition to providing for responsive stimulation delivered upon detecting an indication of epileptiform activity, this invention includes the additional first mode of operation for decreasing the incidence of seizures using non-responsive stimulation. The use of non-responsive stimulation in conjunction with responsive stimulation optimizes the control of seizures by providing a multimodal device that reduces the incidence of seizures, and is also effective at terminating any breakthrough seizures which may occur.
In addition, a testing mode is provided in the implanted device that can be used in conjunction with the responsive and non-responsive modes of operation mentioned above. Once the implantable neurostimulator has been connected to the patient, the testing mode allows for non-invasive verification of the functionality and appropriate programmed settings of the parameters for the responsive and non-responsive modes of operation.
First Mode Stimulation
In its most basic variation, the procedure and device provides neurostimulation in a first mode that is believed to modulate neurotransmitter levels or provide neural desynchronization in the brain resulting in a reduction of seizure incidence. Appropriate use of the non-responsive mode may also be used to reduce the risk of kindling, a phenomenon whereby stimulation may make the neural tissue more prone to epileptogenesis. In addition, any epileptiform electrical activity that may occur is terminated by responsive stimulation in the second mode. As will be discussed below, the first mode (non-responsive) stimulation and the second mode (responsive) stimulation may be delivered from the same electrode, but preferably are delivered from separate electrodes connected to the same implantable neurostimulator. The location of the electrode for the second mode (responsive) stimulation is preferably near the epileptogenic focus. The electrode for first mode (non-responsive) stimulation is preferably in a deep brain structure such as the thalamus, hippocampus, amygdala or is in contact with the cerebellum.
The first mode (non-responsive) stimulation typically is made up of low intensity, short duration pulses delivered at about a 20 to 150 Hz rate. To reduce the likelihood of kindling, pulse to pulse intervals of as much as a second or more may be used for typically 15 minutes or more. The parameters for application of the non-responsive stimulation may be varied according to circadian rhythms. In particular, for some patients, it will be advantageous to alter the stimulation patterns before or during normal sleep times to avoid disrupting sleep patterns, particularly REM sleep.
Responsive Stimulation
As noted above, the responsive stimulation is initiated when an analysis of the brain's electrical activity shows an impending or existent neurological event, such as epileptiform activity. To detect such activity reliably while the first (non-responsive) mode of stimulation is in progress often presents challenges. In some cases, the level of non-responsive stimulation is set at a low enough level, and the sensing electrodes are physically far enough away, that the stimulation does not interfere with detection of brain activity. The use of closely spaced electrodes for either non-responsive stimulation and detection, or both, is helpful in this regard. Often however, it is necessary to take measures to keep the non-responsive stimulation from interfering with detection of brain activity. One method for doing that is to “blank” the detection amplifier (or other detecting circuit component) during the pulse output of the non-responsive stimulation. If that is not effective in eliminating the interference, it may be necessary to periodically pause application of the non-responsive stimulation to allow detection of brain activity.
FIG. 1A shows the known concept of “blanking” in this inventive procedure. We show in the uppermost portion in the drawing a representative non-responsive stimulation signal ( 100 ) as a function of time. The pulse width of each stimulation pulse is exaggerated for clarity. In practice, a typical pulse width of 0.2 msec could be used, and the pulse to pulse interval would be about 20 msec. Similarly, just below the non-responsive stimulation ( 100 ) is a representative responsive stimulation ( 102 ) which has been initiated as the result of detected electrical neurological activity. During the period just before and during each of the stimuli, the input to some component of the detecting function, typically an amplifier, is “blanked” to prevent detecting the stimuli as if they were signals generated by the brain. The blanking is terminated a short period after the pulse ceases. For instance, although the entire stimulation pulse duration is about 0.2 msec, the entire blanking period per pulse might be about 1.0 msec. For a pulse-to-pulse interval of 20 msec, 95% of the time remains available for detecting brain activity. The blanking signal ( 104 ) shows the gating time (not to scale) which is used to prevent the sensors from passing information to the related sensing and detecting equipment during the time the stimulation is imposed. Curve ( 104 ) shows the “on-off” states for the blanking. The dashed lines from the non-responsive stimulation ( 100 ) and a responsive stimulation ( 102 ) depict how the blanking periods are formed.
The typical stimulation pulses shown in FIG. 1A are biphasic and typically have a duration of 0.025 to 0.50 milliseconds per phase. The blanking signal ( 104 ) slightly precedes and lasts longer than the stimulation pulses to assure that no stimulation artifact disturbs the measurement. The overall duration of the blanking time desirably is typically 1 to 5 milliseconds.
FIG. 1B shows a conceptual circuit which may be used to cause blanking as shown in FIG. 1 A. The differential amplifier ( 118 ) which detects brain activity has two electrodes ( 120 ) and ( 122 ). One electrode ( 122 ) may be connected to a ground reference ( 124 ), which ground reference ( 124 ) may be either in the brain or elsewhere in or on the patient's body. The electrical signal detected from the brain is amplified by a differential amplifier ( 118 ) before getting additional filtering and amplification by amplifier ( 126 ). Blanking switch ( 128 ) interposed between differential amplifier ( 118 ) and amplifier ( 126 ) is usually closed allowing the signal from the brain to be amplified and filtered. During stimulation, the blanking switch ( 128 ) is momentarily opened to keep the electrical artifact from the various stimulation pulses from corrupting the output of amplifier ( 126 ). When the blanking switch ( 128 ) is opened, capacitor ( 130 ) keeps the input of amplifier ( 126 ) stable in a “track-and-hold” fashion until blanking switch ( 128 ) is closed.
In some cases it may be advantageous to add gain reduction to the first ampifier stage and/or autozeroing to further minimize the effect of transients caused by stimulation.
As noted above, another variation of the step for detecting the electrical activity of the brain amidst intermittent instances of stimulation is depicted in FIGS. 2A and 2B. In this variation, instead of blanking the input to the amplifier, the various electrical stimulation signals are paused or stopped for a discrete period, during which the measurement of neuroelectrical activity may be made.
FIG. 2A shows a situation in which non-responsive stimulation ( 140 ) (shown here with an exaggerated pulse width for clarity) has been applied to the patient and continues to a first quiet or quiescent period ( 142 ) during which monitoring of brain electrical activity is performed. In this variation, whether or not epileptiform activity is found to be approaching or is existing during this initial monitoring period ( 142 ), the non-responsive stimulation ( 140 ) is restarted ( 144 ).
In any event, returning to the first variation shown in FIG. 2A, in this example, pending or existent epileptiform electrical activity is detected in some part of the brain during the initial monitoring period ( 142 ) and the responsive stimulation ( 146 ) is initiated. In this variation, the non-responsive stimulation ( 144 ) continues. Later, both the non-responsive stimulation ( 144 ) and the responsive stimulation ( 146 ) are then temporally paused for monitoring during the subsequent monitoring period ( 148 ) to determine whether epileptiform activity has ceased. The responsive stimulation ( 146 ) and non-responsive stimulation ( 144 ) may be paused simultaneously, or one may cease before the other. In the instance depicted in FIG. 2A, the epileptiform activity was terminated and the responsive stimulation ( 146 ) is not re-initiated after the subsequent monitoring period ( 148 ). Of course, as is discussed below, the responsive stimulation ( 146 ) is re-initiated, it may be re-initiated either with or without being modified in some fashion.
There are several methods of predicting an impending seizure. The methods include monitoring or detection of EEG synchronization from multiple brain sites and a shift in the energy spectrum. A preferred monitoring scheme is detection of a shift in phase-space parameters. When such a shift occurs, it indicates that a seizure is likely to occur soon, e.g., within the next two to sixty minutes. Under such circumstances, the inventive neurostimulation process may both modify the non-responsive parameters of stimulation and initiate the stimulation. The stimulation changes the underlying dynamics of the brain which results in a reduced likelihood of the impending seizure occurring. Of course, if a seizure occurs, or if the monitoring scheme determines that a seizure is imminent in less than a minute, the responsive mode of stimulation is applied to terminate it.
FIG. 2B shows essentially the same scheme as that shown in FIG. 2A with the major exception that the variation found in FIG. 2B eliminates the non-responsive stimulation signal ( 144 in FIG. 2A) after the initial monitoring period ( 142 ). This variation can be determined either by the decision-making devices of this invention or by pre-programming.
The second electrical stimulation signals in each of FIGS. 1A, 1 B, 2 A, and 2 B are depicted as trains of biphasic pulses. FIG. 3 depicts the terminology used in discussing those signals.
In FIG. 3 is shown a burst ( 158 ) of three pulses ( 160 , 162 , and 164 ). The first two pulses ( 160 , 162 ) are of low amplitude—the term “amplitude” ( 166 ) and the physical meaning may be seen in FIG. 3 . Amplitude may refer to peak amplitude or average amplitude for non-square pulses. It may refer to any phase of a pulse if the pulse is multiphasic. Amplitude may also be used to describe either the voltage or current for an electrical pulse. The “pulse duration” ( 168 ) or time-length of the pulse is depicted as well. Finally, the “pulse-to-pulse interval” ( 170 ) of the pulses is the time between pulses.
As noted above, it is within the scope of this invention to vary the electrode used and the parameters of the pulses or of the burst, as shown in FIG. 3, for both the responsive and non-responsive modes of stimulation.
FIGS. 4A to 4 F show a number of variations of the pulse and burst makeup, which pulse and parameters may be varied either during a responsive electrical stimulation or may be varied from burst to burst.
FIG. 4A shows a simple sequence of bursts having pulses of the same frequency and amplitude in each pulse.
FIG. 4B shows a burst of three pulses in which the duration of the pulses varies as a function of time.
FIG. 4C shows a pair of bursts in which the amplitude of the pulses varies during each burst.
FIG. 4D shows a pair of bursts in which the amplitude of the pulses is increased during the second pulse.
FIG. 4E shows a variation in which the pulse to pulse interval is varied within a burst. This variation is highly desirable in de-synchronizing neuronal activity. The range of pulse to pulse intervals may be varied randomly or changed in a systematic fashion, such as incrementing or decrementing the pulse to pulse interval within a burst.
FIG. 4F depicts another variation of the invention which desynchronizes brain activity to terminate epileptiform activity by spatially desynchronizing activity in the vicinity of the stimulation electrode. To accomplish this, various individual pulse parameters, e.g., pulse spacing, duration or width, and amplitude, within a burst may be varied, particularly in a random, pseudo-random, or fractal fashion. Shorter duration pulses (on the order of 50 to 150 microseconds) tend to directly depolarize smaller diameter nerve cells. Longer pulses (100 to 500 microseconds) depolarize larger diameter nerve cells. By varying pulse amplitude, the individual pulses may be tailored directly to depolarize different neural tissue. Lower amplitude pulses directly depolarize tissue in the immediate vicinity of the electrode; higher amplitude pulses directly depolarize tissue both near the electrode and at some distance from the electrode. By varying the amplitude of the pulses within a burst, local tissue can be depolarized at a higher rate than tissue somewhat distant from the electrode.
Since the tissue disposed near an electrode may have highly variable anatomy, it is anticipated that any or all of the parameters described (pulse to pulse interval, pulse amplitude, the use of hyperpolarizing pulses, pulse width, etc.) may be varied alone or in combination to optimize the ability of a burst to terminate epileptiform activity in the brain while improving the safety of the burst by reducing the likelihood of inducing epileptiform activity or generalizing such pre-existing activity.
In addition to producing bursts having pulse intervals having pre-set or absolute time increments, this inventive procedure includes the improvement of setting the pulse to pulse interval based upon the detected temporal interval of the epileptiform activity as sensed by the electrodes detecting the brain electrical activity. In this mode of operation, the rate of the sensed epileptiform activity is detected and measured. The rate of the detected activity is used to modulate the rate, or the average rate, of the burst used to terminate the epileptiform activity perhaps as depicted in FIG. 4 F.
It is highly desirable to synchronize initiation of a responsive stimulation burst with certain parameters of the sensed EEG. As is described with greater particularity in Ser. No. 09/543,264 the entirety of which is incorporated by reference) the initiation of the responsive stimulation burst may be delayed for a calculated period that varies from 0 to 100% of the detected EEG interval.
For the purposes of this invention, a burst (in this variation and in each of the others described herein) may be any number of pulses, but typically is in the range from 1 to 100 pulses. After the burst is delivered, the EEG is re-examined, and if the epileptiform activity was not terminated, a subsequent burst is delivered. As was the case above, the subsequent burst may have the same signal parameters as the first burst, may re-adapt to the changing EEG rate, or may have new parameters to more aggressively attempt to terminate the epileptiform activity, e.g., higher pulse or burst rate, more pulses, higher amplitude, or modified pulse to pulse intervals, such are shown in FIGS. 4A to 4 F.
Determination of Threshold Values
The following inventive procedures may be used to verify the effectiveness of the implanted neurostimulator and to determine various stimulation parameters for responsive and non-responsive stimulation.
For instance, to verify pulse parameters for effective termination of epileptiform activity after the neurostimulator has been implanted, the following procedure may be used. An epileptiform-inducing stimulation is introduced into the brain under physician control using the implanted neurostimulator thereby initiating epileptiform activity. A responsive stimulation described by the stimulation signal parameters outlined above, e.g., selected electrode, pulse width, pulse-to-pulse interval, pulse amplitude, number of pulses in a burst, etc., is applied to the brain. The stimulation signal parameters are varied until the epileptiform activity ceases.
The steps of initiating epileptiform activity using the implanted neurostimulator, varying stimulation parameters, checking for stimulation effectiveness, and incrementing stimulation parameters may be repeated until a satisfactory cessation of the epileptiform activity is achieved.
Similarly, the efficacy or threshold values associated with operation of the non-responsive mode may be determined. The efficacy of the non-responsive mode is determined by the physician providing increasingly more severe epileptiform-causing stimulation using the implanted neurostimulator until epileptiform activity begins. The more difficult it is to induce the epileptiform activity, the better the non-responsive mode is functioning. By increasing the length of the burst, and/or the amplitude of the pulses within a burst, it is possible for the physician to determine the ease or difficulty with which epileptiform activity may be induced. By comparing how resistant the brain is to the induction of epileptiform activity when the non-responsive stimulation is either activated or not, or with differing burst parameters for the non-responsive stimulation the physician can optimally set the parameters of the non-responsive stimulation.
Implantable Neurostimulator
This inventive device includes a neurostimulator central unit and at least one electrode. The neurostimulator central unit includes the necessary circuitry, e.g., A/D converters, filters, central processing unit(s), digital processing circuits, blanking circuits, power supplies, batteries, signal generators, etc., and programming configured and adapted to perform the steps listed above. Specifically the neurostimulator central unit ( 200 ) desirably is as shown in FIG. 6 and is shaped in such a way that it conforms to the shape of the skull, although it need not be so. The neurostimulator central unit should at least contain a non-responsive electrical stimulation source, a responsive stimulation source, (where both sources may be the same circuit operated in two modes), and devices for detecting epileptiform activity and for initiating and for terminating the various non-responsive and responsive electrical stimulation. The neurostimulator assembly should also include at least a first brain electrical activity sensor ( 202 ), at least a non-responsive neurostimulator electrode ( 202 ), and a responsive electrical neurostimulator electrode ( 204 ). A detailed embodiment of this structure may be found in U.S. Pat. No. 6,016,449. The various necessary connectors, leads, and supporting components are also included. The various sensor and neurostimulator functions may be incorporated into one or more electrodes as shown in FIG. 5, however. The various components perform the functions outlined above.
A highly desirable aspect of the inventive device is the use of multiple brain electrodes to provide therapy. The detecting electrodes are preferable in contact with the brain, but, as discussed above, may be scalp electrodes or within the brain tissue. Multiple therapy electrodes enhance the ability of electrical stimulation to desynchronize brain activity in terminating epileptiform activity. Although the same burst may be delivered from a multiplicity of electrodes in the vicinity of the epileptogenic focus, we prefer introducing bursts having different signal parameters, particularly pulse to pulse timing, to the brain from different electrodes to achieve a greater degree of spatial heterogeneity of neural activity and most effectively desynchronize brain activity.
We contemplate that this method of terminating epileptiform activity provides a substantial added benefit in that the lower current densities at the electrodes may be used to affect a larger amount of brain tissue than if a single electrode were used.
The application of multiple electrodes to different parts or regions of the brain also provides a way to treat epilepsy having more than one focus. Electrodes may be placed on or near the various epileptogenic foci. The inventive neurostimulator senses and stimulates independently from each electrode. Optional amplifier blanking eliminates cross talk, and logical flow in the device's software keeps the device from erroneously detecting its own output as epileptiform activity.
This inventive device may utilize independently actuatable, spatially separated electrodes so that those epilepsies having many epileptogenic foci or for which the focus is so diffuse the seizure arises from a large portion of the brain, may be treated. In such a case, it is desirable to place one electrode deep in the brain, preferably in the area of the hippocampus. Additional electrodes may be placed on the surface of the cortex. When epileptiform activity is detected, the device stimulates from the hippocampal region to take advantage of the large number of neural pathways emanating from that area into the cortex. Electrodes on the cortex provide additional electrical access to the brain allowing electrical stimulation to terminate epileptiform activity having a greater spatial extent.
Although preferred embodiments of the invention have been described herein, it will be recognized that a variety of changes and modifications can be made without departing from the spirit of the invention as found in the appended claims. | This is directed to an implantable multimodal neurostimulator having improved efficacy in treating epilepsy and other neurological disorders and to processes of using that neurostimulator. The neurostimulator itself generally has two modes of electrical stimulation: the first involves delivering a non-responsive electrical stimulation signal which is applied to the central nervous system to reduce the likelihood of a seizure or other undesirable neurological even from occurring, and a second mode that involves delivering electrical stimulation signal or signals when epileptiform waveforms are impending or extant. The responsive electrical stimulation signal or signals are intended to terminate epileptiform activity, e.g., to desynchronize abnormally synchronous brain electrical activity. Alternatively, the second mode may be used to deliver sensory stimulation, e.g., a scalp or sound stimulation, to the patient rather than deliver electrical stimulation to the patient. Finally, the implanted neurostimulator may be used by a physician to induce epileptiform activity and then verify the effectiveness of the parameters of the first and second neurostimulation signal or signals. | 0 |
TECHNICAL FIELD
The invention presented here involves a process for the distribution of one or more liquid(s) contained in one or more container(s), in quantities measured by weight, in the use of which each dose is delivered with a great degree of precision, on the order of 0.5 milligrams, as well as a distribution device and a system for the distribution of one or more liquids to one or more recipient(s).
BACKGROUND ART
For a large number of activities, among which the following can be cited, without the list being restrictive: perfumes, aromas, cosmetics, fine chemistry, pharmaceutics, coloring agents, dyes and paints, food processing, wines and spirits, etc. it is necessary to make “compositions”, as much in the laboratory for tests or sampling, as in production. These compositions are mixtures of liquid or solid raw materials, according to a formula in a precise dosage. The traditional manual creation of these compositions is long and can rise to many manufacturing errors. Moreover, it is difficult to achieve accuracies on the order of a half-milligram.
SUMMARY OF THE INVENTION
The invention presented here makes it possible to correct for these disadvantages for compositions of liquid raw materials. It also makes it possible to deliver precise quantities of a unique liquid into many containers.
For this purpose, the process for distribution of dosed quantities of a liquid contained in a storage container, connected to a distribution conduit equipped with a nozzle for the discharge of liquid to a container connected to a gauge component that delivers, in the form of a signal, a representative value of the quantity of liquid present in the container, where the conduit, at a distance from the nozzle, is connected to a valve component that, upon command, blocks or opens the passage of the liquid through the conduit, from the container towards the distribution nozzle. The diameter of the distribution nozzle is such that the liquid column in the portion of the conduit between the nozzle and the valve component, when the valve component is blocking the passage of liquid, can be immobilized there under the action, in particular, of surface tension forces. The process is characterized essentially in that it consists in the following functional steps, given in chronological order:
a)—open the passage of liquid between the container and the nozzle by acting on the valve component, in a manner such that the liquid can fill the portion of the conduit between the valve component and the distribution nozzle,
b)—block the passage of liquid by acting on the valve component, in order to cut off the flow of the liquid,
c)—apply on the liquid column, located between the valve component and the distribution nozzle, at least one mechanical impulse having a calibrated amplitude and/or intensity, in order to expel a micro-quantity of liquid from the liquid column, through the distribution nozzle, towards the container,
d)—compare the value given by the gauge component to a pre-set reference value C1, representative of the value of the dose to be delivered, a tolerance value ΔC1 associated with the value C1,
e) and to repeat the steps c) and d) if the value given by the gauge component is not contained in the tolerance range associated with the reference value C1.
According to the preferred embodiment form, the gauge component gives a signal representing the weight of the quantity of liquid in the container.
It is necessary to be able to distribute in the container a relatively sizable quantity of liquid while maintaining a precision on the order of a half-milligram. Thus, according to another characteristic of the process according to the invention, during the step a), during which the passage of the liquid between the container and the nozzle is opened and the liquid is also discharged into the container, the value given by the gauge component is continuously compared to a reference value C0, less than the reference value C1, and close to this reference value C1, and the step b) of the process is begun when the value given by the gauge component is equal to the reference value C0, the steps c), d) and e) then being started successively.
This device makes it possible to ensure both the speed of the dosage and its precision.
According to another characteristic of the invention, the mechanical impulses that must be communicated to the liquid column are applied via the conduit.
According to another characteristic of the invention, the mechanical impulses that must be communicated to the liquid column are applied directly to the liquid column.
The invention also has the object of a distribution device for the delivery of a liquid in dosed quantities, characterized in that it consists of:
a storage container containing the liquid to be distributed,
a distribution conduit connected to the container and provided with a nozzle for the discharge of the liquid towards a container connected to a gauge component that delivers, in the form of a signal, a value representing the quantity of the liquid present in the container,
a valve component connected to the conduit and placed at a distance from the nozzle, blocking or opening upon command the passage of liquid between the container and the nozzle, the area of the section of passage that determines the nozzle being such that when the valve component blocks the passage, the liquid column present in the portion of the conduit between the nozzle and the valve component is immobilized in this portion, under the notable effect of surface tension forces,
an impulse mechanism, located between the valve component and the nozzle for the deliverance of the liquid, in order to communicate to the liquid located between the valve component and the distribution nozzle, at least one mechanically calibrated impulse, under the effect of which a micro-quantity of liquid is expelled from the liquid column.
According to one of the embodiment forms, the distribution device consists of a rigid structure consisting of a first drill hole that goes all the way through, into which the conduit enters with a functionally reduced play, this rigid structure consisting of a second drill hole, is preferably straight, opening up on the one side, into the first drill hole that goes all the way through, and on the other side, on one of the sides of the rigid structure, the second drill hole receiving the pulse mechanism. According to this embodiment form, the pulse mechanism acts on the conduit and this conduit, according to another aspect of the invention, is elastically deformable at least in the first drill hole of the rigid structure.
According to another characteristic of the invention, the pulse mechanism consists of a pushrod that can be moved crosswise relative to the conduit and mounted to slide in the second drill hole at least by its front part, in order to make it possible to act by the free end of the front part, by pushing on the conduit This pushrod can be manually maneuvered, but preferably, in a manner so that the impulses communicated can be perfectly calibrated, the impulse mechanism also consists of an operating mechanism fitted to move the pushrod by a brief movement of translation towards the conduit, and this is done according to a specified and perfectly controlled amplitude and acceleration. This operating mechanism, designed to act together with the free end of the rear part of the shaft, can be integrated with the structure of the device, but according to an advantageous aspect of the invention leading to a simplification, this mechanism for operating the pushrod is external to the structure and is independent of it.
The valve component can be arranged over the portion of the conduit located between the structure and the container or even be connected to the nozzle discharge of the container, but according to an advantageous aspect of the invention, the structure of the distributor device, upstream from the second drill hole considering the direction of flow of the liquid in the conduit, is provided with a third drill hole, preferably straight, opening on the one side into the first drill hole that goes through and on the other side, on one of the sides of the rigid structure, the third drill hole receiving the valve component.
According to another characteristic of the invention, the valve component consists of a mounted shaft, at least with its front part in the third drill hole, coming into blocking position with the open end of its front part pinching the soft conduit. The internal passage of the conduit thus becomes blocked by the flattening of the wall of the conduit on itself.
The operation of the shaft can be done manually, but preferably according to another aspect of the invention, the valve component consists of a mechanism for operating the shaft designed to cooperate with the rear part of this shaft, this operating mechanism being preferably outside of the rigid structure.
Preferably, according to another aspect of the invention, the shaft is threaded and the third drill hole is tapped in order to receive the shaft when it is screwed in. In screwing the shaft for adjustment of the degree of recess of the shaft in the tapped hole and in the conduit, it is possible to adjust the degree of throttling of the conduit by the shaft, and thus the section of the passage at the level of the valve component, and as a result, the flow rate of the liquid.
For its manipulation by the operating mechanism, the shaft, along the open end of its rear part, is equipped with a keyway, which acts together with the formed fitting and the torque transmission and the rotating movement, the drive endpiece in rotational, motorized drive with the operating mechanism. According to a preferred embodiment form, the operating mechanism of the shaft of the valve component is equipped with a drive instrument at the output shaft of which the drive endpiece is coupled.
In the embodiment form described above, the impulse mechanism and the valve component act on the wall of the conduit.
According to another embodiment form, the distribution device according to the invention is remarkable notably in that the conduit consists of an upstream section connected to the storage container and a downstream section having an open end from which the distribution nozzle is formed and that the valve component is a slide valve of a normally closed type, to which is connected on one side the upstream section of the conduit and on the other side, the downstream section of the conduit, the aforementioned valve consisting of a valve body in which a housing is formed that consists of an upstream section and a downstream section which are in communication with each other via an intermediate section having a cylindrical form, at the opening of which, in the upstream part of the housing, a valve seat is formed, against which a valve that is mounted so that it is mobile in the upstream part of the housing, can rest in a blocking position. This upstream part of the housing is in contact with the upstream section of the conduit by a drill hole formed in the valve body. The downstream section of the conduit is in turn in contact with the intermediate part of the housing through a second drill hole formed in the valve body. The valve body is provided with a third drill hole that passes through it along an axis perpendicular to the valve seat and opening into the downstream part of the housing, where in this drill hole a shaft for operating the valve is placed. The shaft is connected to an operating mechanism and the valve is connected to an impulse mechanism.
According to another characteristic of the invention, the material constituting the seat has a greater hardness than that of the constituent material of the valve seat. This makes it possible to perform the automatic run-in of the valve seat and to improve impermeability.
According to another characteristic of the invention, an aspiration mechanism is provided to bring back, by aspiration into the upstream part of the conduit, the drops of liquid present at the level of the distribution nozzle and in particular, before the application of impulses on a liquid column. This device, in preventing the liquid drops from falling inadvertently into the container, guarantees dosages that are precise and can be reproduced with the same degree of precision.
In the preferred embodiment form, the aspiration mechanism consists of a piston mounted in a cylinder bore made in the valve body. The cylinder bore being in communication with the upstream part of the housing and the piston being connected to an operating mechanism. Advantageously, according to another aspect of the invention, the piston and the operating mechanism constitute the impulse mechanism.
According to a particularly advantageous embodiment form, the piston is formed around the activation shaft of the valve and is fixed to this shaft; the operating mechanism of the piston constitutes the operating mechanism of the shaft; the shaft and the valve are not bound to each other and the shaft is mobilized by its operating mechanism in a resting position such that it is isolated from the valve in one of its operating positions where, in operating by pushing on the valve, it supports this valve in isolation from its seat, the value of the isolation between the valve and the seat is thus the value of the flow rate of the liquid, depending on the operating position obtained by the operating shaft.
Thus, in selecting the operating position that the shaft must reach, and in controlling this position, it is possible to select the value of the flow rate of the liquid across the slide valve and to perfectly control this value.
According to another characteristic of the invention, the operating mechanism of the impulse and actuation mechanism of the valve component consists of a cam and of a driving instrument for driving the cam, this cam being fixed on the rotating output shaft of the drive instrument.
The invention presented here also has as an object, a system for delivering in an automatic manner, precise quantities of one or more liquids to one or more container(s) characterized essentially in that it is equipped with at least one distribution device as previously defined.
According to another characteristic, the system according to the invention consists of a first support assembly on which are mounted several distribution devices and a second support assembly, on which the driving instrument(s) of the operating mechanisms is or are mounted, the aforementioned system consisting of more or less one container for liquid(s), at least one gauge component showing the quantity of liquid in this container, this component is fitted to emit a signal representative of this quantity to another programmable unit for the calculation and control, according to the data of a pre-set program, of the drive instrument(s) of the operating mechanism(s) of the valve component and the impulse mechanism of each distribution device.
According to another characteristic of the invention, the support assemblies are mobile relative to each other and at least one of the two support assemblies is mobilized relative to the other by a driving instrument controlled by a control and command unit in order to be positioned relative to each other, the driving instrument(s), and the operating shafts of the selected distribution device.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages, goals and characteristics of the invention appear in reading the description of a preferred embodiment form, given as an guideline example, in referring to the attached drawings in which:
FIG. 1 is a longitudinal sectional view of a distribution device according to a first embodiment form,
FIG. 2 is a longitudinal sectional view of a distribution device according to a second embodiment form,
FIG. 3 is a sectional view, according to a vertical plane, of a system equipped with distribution devices according to the preferred embodiment form,
FIG. 4 is a sectional view along the line AA of FIG. 3,
FIG. 5 is a sectional view along a vertical plane, of a system equipped with the distribution devices according to the second embodiment form,
FIGS. 6 and 7 are views of a system according to an embodiment form.
DETAILED DESCRIPTION OF THE INVENTION
As shown in the distribution device 1 , 2 according to the invention, a storage container 3 contains liquid to be distributed in dosed quantities, consisting of a nozzle for discharging a liquid, to which a distribution conduit 4 is attached in any known way. The distribution conduit 4 is provided at its free end with a nozzle 5 for the discharge of the liquid to a container 6 connected to a gauge component 7 which transmits in the form of a signal, a representative value of the quantity of liquid present in the container 6 . The distribution device consists of, in addition, a valve component 8 connected to the conduit and placed at a distance from the nozzle 5 , blocking or opening the passage of liquid into the conduit between the container 3 and the nozzle 5 on command. This nozzle, having a circular form, determines a circular passage section whose clearance area value is equal to or less than the value necessary in order to ensure that when the valve component is in position blocking the passage liquid, the immobilization of the liquid column in the portion of the conduit includes between the nozzle and the valve component. This immobilization is essentially due to the surface tension forces. The diameter of the nozzle will be a function of the physical characteristics of the liquid to be distributed and thus notably a function of its viscosity. Between the valve component and the nozzle for discharging the liquid, the distribution device is equipped with an impulse mechanism 9 in order to communicate to the liquid column located between the valve component 8 and the distribution nozzle 5 , at least one mechanical impulse calibrated under the effect of which a micro-quantity of liquid is expelled from the liquid column. This impulse mechanism is only activated after the closing of the section of the liquid passage by the valve component 8 . For a dosage of a determined quantity of liquid, the functioning of the device is the following: the valve component 8 is placed first in the open position of the internal passage of the conduit in a manner so that the liquid can flow from the container 3 to the container 6 . The quantity of liquid required being reached to within a drop or a fraction of a drop, and the valve being placed in the blocking position of the internal passage of the conduit, the shocks or impulses, transmitted by the impulse mechanism 9 directly or indirectly to the liquid column contained between the valve component 8 and the nozzle 5 , make it possible to expel micro-quantities of the liquid contained in this column. As a function of the liquid viscosity, of the size of the discharge nozzle 5 , and of the impulse energy, the quantity delivered by these impacts can be precisely determined, and in a repeatable manner by calibration. Thus, the quantity required can be precisely obtained.
The liquid container 3 , the valve component 8 , the impulse mechanism 9 , the gauge component 7 and the container 6 are carried by the appropriate supports.
The container 3 for liquid storage, of a known type, can be located at a distance from the valve component or even near to it. This container will be provided with a cover for blocking and protecting the internal volume that it contains. This container can be placed to a higher height level with regard to the one of the valve component 8 to allow a gravitational flow of liquid or even at a level lower in connection with a mechanism for propulsion of the liquid towards the valve component 8 . This mechanism can consist of a volume of compressed gas introduced in the upper part of the container in order to exert a pressure on the liquid contents. In the case of the drawing, the cover will ensure a perfect impermeable closing and will be provided with a drill hole that goes through, in which will be fixed a connection nozzle of a conduit connected to a source of gas under pressure. This gas is to be selected in a manner such that a chemical reaction can not occur with the liquid contained in the container.
The gauge component 7 , according to the preferred embodiment form, is of the type of those that are fitted to transmit a signal representing a weight value. The gauge component will be or will consist of a weight sensor placed under the container to give a signal representing the weight value of the container and the quantity of liquid contained in the container. Judiciously, the signal emitted will be an electric signal of the analog or digital type in order to allow the treatment of the signal by a command and control unit 10 that can be connected to distribution device 1 , 2 in order to command and control the functioning according to the instructions of a pre-set program based on the user's requirements. The gauge component 7 in the preferred embodiment form is a precision scale suited to produce the signal mentioned above and to transmit it to the command and control unit 10 to which it is connected by an appropriate electrical line. This precision scale can be provided with a display component in a form understandable to the user, having the weight value of the liquid introduced into the container. This scale will be provided with a horizontal support on which the container will rest for the purpose of measuring the weight of the liquid contained in it.
As a variation, the gauge component will be one of the type of those fitted to directly deliver a signal representing the height of the liquid in the container then convertible by the unit 10 into the weight value or volumetric value.
In FIG. 1, a distribution device according to a first embodiment form.
This device consists of a rigid structure 11 , having a parallelepiped shape, attached to an appropriate support. This structure consists of, between its two horizontal upper and lower sides, a first drill hole going through, vertically, having a diameter that is equal to or slightly greater than that of the conduit. The conduit 4 is placed in the drill hole and the drill hole preferably only covers a part of the length of the conduit. The rigid structure 11 is preferably located at a distance from the two ends of the conduit. The wall of the part of the conduit located in the first drill hole is elastically deformable. For reasons of simplification of the embodiment, the assembly of the conduit 4 is made of an elastically deformable material but you could provide a conduit in three sections joined by an impermeable material. The two lateral sections could be made of a rigid material, for example, of metal while the middle section, the section to be placed in the first drill hole, could be made in an elastically deformable material.
Thus the part of the conduit housed in the vertical drill hole can deform onto itself, under the action of outside forces, in a non-permanent manner, this deformation being done against internal elastic forces due to the natural elasticity of the material constituting its wall. When these forces are removed, the conduit can resume its initial shape because of these internal elastic forces. The dynamic pressure of the liquid exerted on the inner side of the conduit also contributes to returning the conduit to its initial shape.
According to the preferred embodiment, the material used to create the conduit 4 has a base of tetrafluoroethylene as is known under the commercial name “TEFLON”, because of the resistance of this material to chemical agents and to corrosion.
Perpendicularly to the first drill hole and in a secant manner to it, the structure of the lower part consists of a second drill hole and in an upper part, of a third drill hole. These second and third horizontal drill holes, opening on one side into the first drill hole and on the other side on a same small lateral vertical side of the structure. In the upper drill hole, the valve component is placed while in the lower drill hole, the impulse mechanism is placed.
The valve component consists of a shaft 12 mounted at least by its front part in the third drill hole. This shaft, in blocking position, by the free end of its front part, comes to pinch the flexible conduit and flatten the wall of this conduit onto itself, which leads to blocking the internal passage of the liquid The end of the front part of the shaft 12 is rounded in order to prevent damaging the conduit. In the preferred embodiment form at least the lower part of the shaft is threaded and the upper drill hole, along all of its length, is tapped in order to receive the threaded front part of the shaft 12 when it is screwed in. The rear part of the shaft 12 , outside of the rigid structure 11 , is provided with a head 13 , which when manipulated, allows the adjustment of the degree of recess of the free end of the rear part of the shaft 12 in the conduit 4 . Thus, by this arrangement, between a position of full opening in which the conduit 4 is not deformed by the shaft and a position of complete closing, in which the wall of the conduit is flattened on itself by the shaft, it is possible to pull in and to support the free end of the front part of the shaft in an intermediate position according to the desired degree of throttling and thus the flow rate of the liquid obtained.
At the level of the valve component, the continuous opening of the inner section of the passage, by unscrewing the shaft 12 , makes it possible to vary the flow rate in a continuous manner, from a drop-by-drop very slow, to a maximum flow rate, which is a function of the section of the conduit and that of the nozzle 5 , of the liquid viscosity, and of the difference of the height between the level of the liquid in the container and the output nozzle or even of the value of the excess pressure in the container, in the case where this container receives a compressed gas in order to propel the liquid.
The head, which forms an annular swelling on the shaft, allows the manual manipulation of the shaft. In addition, the head of the shaft can form a stop for the progression of the shaft in the coming conduit, in a completely closed position, against the rigid structure 11 .
Thus, in this position, the shaft will not be able to penetrate any further into the wall of the conduit which eliminates the risks of the perforation of this wall.
According to a preferred embodiment form, the valve component also contains a mechanism 13 for an automated activation of the aforementioned shaft 12 . This mechanism 13 is outside of the rigid structure 11 and contains a drive instrument 13 a , for example, a step-by-step electric motor, at the output shaft of which a male drive endpiece 13 b is coupled which acts together by interlocking of shape and transmission of the couple and the rotational movement with a keyway engraved on the free end of the rear part of the shaft 12 in the axis of the shaft. The drive instrument 13 a will be driven by the control and command unit 10 and for this purpose, will be connected by a suitable electric line to the unit.
As mentioned above, the horizontal lower drill hole receives the impulse mechanism 9 . This impulse mechanism contains a pushrod 14 mounted to slide in the lower drill hole in order to be able to act by pushing radially on the conduit and in this way to communicate a mechanical impulse to the liquid column. The impulse mechanism contains, in addition, outside of the rigid structure 11 , an operating mechanism 15 fitted to move the pushrod 14 along a brief translational movement towards the conduit 4 . The pushrod 14 is mounted by its rear part in the lower drill hole and by its rear part comes outside of the rigid structure 11 . The free end of the front part is rounded in a manner to eliminate any risk of perforation of the conduit under the action of the impulses received. In addition, the amplitude of the path of the pushrod is limited to a value lower than the diameter of the inside passage of the conduit in a manner so that the pushrod can not crush the conduit 4 ; this value can also be less than that of the radius of this passage.
In order to limit the amplitude of its path, the pushrod 14 contains, between its front part and its rear part, a flanged form 16 that forms a stop and is placed with this flanged form in a countersinking formed in the rear part of the drill hole. The flanged form 16 , coming to stop against the countersunk base, limits the movement of the drive of the pushrod in the conduit 4 .
Here it is noted that the internal elastic forces on the part of the conduit housed in the vertical drill hole are sufficiently sizable in order to push back the pushrod 14 towards its initial position when the impulse has stopped. However, if need be, an elastic return movement instrument, in the form of a spring having non-abutting spirals, can be placed under tension between the flanged form and the countersunk base.
In the preferred embodiment form, the operating mechanism 15 is made of a drive instrument of the pneumatic or hydraulic valve type, arranged by its shaft relative to the pushrod 14 in axial alignment with the pushrod. This valve, single or double action, is connected to a source of liquid under pressure (air or oil depending on the valve type), through a solenoid valve piloted by the command and control unit 10 . For this purpose, this solenoid valve is connected to the unit 10 by an appropriate electric line. This valve 15 is mounted on an appropriate support. By the end of its shaft, this valve when it is activated in the direction of the movement out of the shaft, will communicate to the pushrod a mechanical impulse axial, under the action of which this pushrod can be displaced by sliding in the lower drill hole and comes to act by pushing radially on the conduit. Immediately afterwards, the valve is activated in the direction of retraction of its shaft. The shaft of the valve can be fixed to the pushrod by a sleeve tube or an articulation but preferably these two components are not connected to each other.
As a variation, the operating mechanism can be made of a cam in the form of an eccentric, and by a drive instrument having a rotating output shaft to which the cam is coupled. This motor, which can be a step-by-step electric motor will be positioned on a fitted support of the type having its output shaft vertical and having the cam in the form of an eccentric positioned relative to free end of the rear part of the pushrod 14 . The cam is, in the form of a thick, circular disk, provided along its depth with a drill hole passing through, set eccentrically, by which it will be mounted in fixed attachment on the output shaft of the motor. By its cylindrical surface, in the process of rotation, the cam comes to act by pushing on the pushrod 14 . The drive instrument will be operated by the command and control unit 10 and will be connected to this unit by a suitable electrical line.
In FIG. 2, a distribution device 2 is shown according to a second embodiment form.
According to this embodiment form, the conduit 4 has an upstream section 4 a connected to the storage container 3 and a downstream section 4 b on the free end of which the distribution nozzle 5 is formed. The valve component 8 consists of a slide valve of the normally closed type to which, on one side the upstream section 4 a of the conduit is connected, and on the other side, the downstream section 4 b of the conduit is connected.
The valve component consists of a valve body in a parallelepiped form, made of a material that is low in its susceptibility to corrosion and suited to resist chemical agents A stainless steel can be used or preferably a synthetic material based on tetrafluoroethylene such as is known under the commercial name “TEFLON”.
In the body of the valve, a horizontal, cylindrical housing that goes through it is formed, consisting of an upstream part 17 and a downstream part 18 each in communication with each other by an intermediate part 19 having a cylindrical form, at the opening of which, in the upstream part 17 of the housing, a seat 20 of the valve is formed. The upstream part of the housing is blocked in an impermeable manner by a stopper 22 . This stopper consists of a head extended axially by a threaded cylindrical part placed so that it screws into a female threading formed in the cylindrical part upstream 17 from the housing. By the head, the stopper is moved under pressure towards the side corresponding to the body of the valve.
Against the seat 20 of the valve, a valve 21 , that is mounted so that it can move in the upstream part 17 of the cylindrical housing, rests in the blocking position. Advantageously, the valve is made up of a ball made of stainless steel having a polished surface. This ball has a diameter that is slightly less than the diameter of the upstream part 17 of the housing in order to be able to slide freely in the housing while being perfectly guided. To the valve 2 l, is joined an elastic instrument for return-movement 21 a which fixes its bearing against the seat 20 in blocking position of the valve. This elastic instrument for return-movement 21 a consists of a spring having non-abutting spirals, mounted in the upstream part 17 , under tension between the blocking ball 21 and the stopper 22 .
The upstream part 17 , by a drill hole 23 made in the valve body perpendicularly to the drill hole passing through, is connected to the upstream section 4 a of the conduit, this conduit being placed by force into the drill hole 23 while the downstream section 4 b of the conduit is itself connected to the intermediate part 19 of the housing through a second drill hole 24 made in the valve body, in a manner perpendicular to the drill hole going through. The section upstream from the conduit will be placed by force into the drill hole 4 b.
The opening of the drill hole 23 , in the upstream part 17 , is positioned so that it is only partially blocked by the ball when the ball is resting on its seat. By this arrangement, the pressure of the liquid in the upstream part 17 , when the valve is in the blocking position, ensures, in combination with the spring 21 a , the support of the ball against its seat. In addition, this arrangement ensures the communication of the drill hole 23 with the intermediate part 19 of the housing and this as soon as the ball 21 is lifted off its seat 20 .
The valve body, along an axis perpendicular to the seat of the valve, in the axis of the drill hole passing through, is provided with a drill hole passing through, opening into the downstream part of the housing, in which a cylindrical shaft 25 engages for operating the valve 21 . According to a preferred embodiment form, this drill hole passing through is made in a blocking stopper 26 placed by screwing into a threaded cylindrical part that it contains in a female threading made in the downstream part 18 of the housing. This blocking stopper 26 contains a head by which it is moved under pressure against the lateral side corresponding to the valve body. Some impermeable seals in a toroidal shape are arranged around the shaft, in the drill hole passing through the stopper.
Outside of the valve body, the shaft 25 acts together with an operating mechanism made up of, for example, a cam 27 in the form of an eccentric and by a drive mechanism 28 for driving the cam, having a rotating output shaft on which the cam 27 is supported. The motor 28 which can be a step-by-step electric motor is positioned on a fitted support of the type such that its output shaft is vertical and that the cam 27 is positioned relative to the free end of the rear part of the shaft 25 . The cam, in the case of a vertical configuration of the output shaft of the motor, has in the form of a thick circular disc, provided along its depth, a drill hole going through it eccentrically, by which it is mounted in fixed attachment to the output shaft of the motor 27 . By its cylindrical surface, during its rotation, the can comes to act by pushing on the shaft 25 in a manner so as to lift the valve from its seat against the action exerted by the elastic mechanism 21 a . The shape of the cam ensures the continuity of the opening of the valve and thus the continuous variation of the flow rate of the liquid and this is done from a drop-by-drop very slowly, to a maximum flow rate. In addition, in order to assure the bearing of the cam in a fixed angular position, it is possible to regulate the level of the flow rate of the liquid through the valve and to maintain this flow rate constant.
As a variation, the motor will be positioned such that its output shaft is horizontal. In this configuration, the cam has a cam surface that expands in an oblique manner relative to the axis of rotation.
The drive instrument will be controlled by the command and control unit 10 and will be connected to this unit by a suitable electric line.
It is noted here that when there is a power cutoff, the return-movement spring 21 a is sufficiently powerful to push back the assembly made up of the valve, the shaft 25 and the cam, and to move the valve to its seat. Thus, a power cutoff of the drive instrument turns into a closing of the valve.
Connected to this device is an aspiration mechanism for moving the liquid drops present at the level of the distribution nozzle 5 by aspiration in the upstream part of the conduit 4 b , and this is notably done before the application of the impulses on the column of liquid. According to the preferred embodiment form, this aspiration mechanism consists of a piston 29 formed around the actuation shaft 25 and attached to the shaft. This piston is mounted to slide in the downstream part 18 , where this part 18 is bored. In this embodiment form, the actuation shaft 25 is not fixed to the valve and an elastic instrument 30 is planned for moving back, as soon as the valve has returned to its seat, of the shaft and the piston to a resting position, i.e. the position the furthest from the seat of the valve. According to this position, the shaft 25 is removed from the valve. In the resting position, the piston 29 , by a conical door 29 a that it has in its rear part, comes to support against a conical seat 26 a arranged in the stopper 26 around the drill hole passing through. This arrangement promotes impermeability of the assembly. The elastic instrument 30 is mounted in the downstream part ( 18 ) of the housing, under tension between the piston ( 29 ) and a shoulder ( 19 a ) formed between the part ( 18 ) and the intermediate part ( 19 ). The return movement of the shaft and the piston is done continuously during the return of the cam to an initial angular position where it no longer acts on the shaft 25 . During this return movement to the resting position, the valve being support on its seat, the volume of the encapsulation formed in front of the piston increases continuously and the liquid contained in the section of the conduit 4 b is aspired to the part 19 of the housing and towards the upstream part 18 . Thus, the liquid drops present at the level of the nozzle 5 are brought back into the section of the conduit 4 b.
In this embodiment form, the piston 29 and the actuation mechanism of the shaft of the valve consisting of the impulse mechanism 9 , it is noted that the maximum amplitude value of the movement of the shaft, when the impulses are communicated by the piston to the column of liquid present in the conduit section 4 b is less than the value of the difference between the shaft and the valve 21 , measured when the valve is resting on its seat and the shaft is in the resting position. Thus, during the application of the impulses on the liquid column, the shaft can not come into contact with the valve 21 which eliminates risks of opening the valve unexpectedly during micro-dosage.
It is noted here that the mechanism which is being described presents two zones to know one zone of elevated pressure concerning section 4 a of the conduit, the drill hole 23 and the upper part 17 of the housing and a lower pressure zone involving the section of the conduit 4 b , the intermediate part 19 of the housing, and the downstream part 18 of the housing. It is noted also that the impermeability of this assembly is primarily ensured in the lowest pressure zone, which is a notable advantage for the reliability of the device.
The container 3 of this device can be placed at a distance from the valve body or even immediately adjacent to the valve body, in order to reduce the length of the conduit section and thus the size of the storage volumes. This device is notably applied when the liquid is costly and/or when it must be distributed in a very low quantity. The container 3 can also be directly fitted in the drill hole 23 by its nozzle.
The distribution device 2 as has been described can be used in a large number of applications from micro-dosage in the laboratory to the dosage of large quantities of liquid. For production applications, the size of section 4 a , 4 b of the conduit can reach without difficulty diameters of 50 mm, or even more. The size of the valve will of course be proportional to the size of the conduit.
In FIGS. 3 to 7 , various embodiment forms of a system provided with at least one distribution device 1 , 2 are shown, as have been described above. This system is designed to deliver in an automatic manner, precise quantities of one or more liquids to one or more container(s) 6 in order to form, for example, mixtures of various liquid products.
The installation consists of a first assembly support 31 on which several distribution devices 1 , 2 are mounted and a second assembly support on which the drive instrument(s) 13 a , 15 , 27 , 28 of the actuation mechanisms is or are mounted. Connected to this system are at least one container 6 of liquid(s), at least one gauge component 7 of the quantity of liquid in the container 3 , which is fitted to transmit a signal that is representative of this quantity to the calculation and command unit 10 , programmably fitted to command and control according to the data of its program, the drive instrument(s) of the actuation mechanism(s) of the valve component and of the impulse mechanism of each distribution device.
According to a first embodiment form, the support assemblies 31 , 32 are mobile relative to each other and at least one of the two support assemblies is mobilized relative to the other by a drive instrument controlled by the calculation and command unit 10 in order to be positioned in relation to the other ones, the drive instruments of the actuation mechanisms and the actuation shaft(s) of the distributor device selected.
Always depending on the preferred embodiment form, the distribution devices 1 , 2 are placed on the first assembly support 31 at a constant interval along a circle circumference and in a radial manner relative to the circle circumference in a manner so as to form a crown. As a variation, these devices can be placed at a constant interval along a straight line or even along a curve if the geometrical restrictions of the implantation and installation site require such a configuration. With a configuration in a straight line, the second assembly support will be movable and will be constituted by a shifted carriage so much in height as to be parallel to the alignment formed by the distribution devices. The movements of this carriage with respect to the distribution devices, as well as its position relative to the distributor selected are steered and controlled by the command and control unit 10 .
The distribution devices could also be arranged at a non-constant interval from each other.
In the embodiment forms shown in FIGS. 3 to 5 , the second assembly support 32 is arranged in the first one and the shaft(s) 12 , 14 , 25 of the actuation mechanism(s) of each distribution component 1 , 2 is or are horizontal and radial to the crown formed by the distribution devices.
Preferably, the first assembly support 31 is fixed and the second is mobilized by the drive instrument. You could, however, provide an inverse device i.e. a second fixed assembly support and a first assembly support that is mobile and activated by the drive instrument.
In FIGS. 3 and 4, a system equipped with the distribution device 1 according to the first embodiment form is shown. The first assembly support 31 consists of a continuous wall 33 , defining a cylindrical volume in which the second assembly support 32 is housed. This continuous wall receives an upper wall 34 in the form of the circular disk and a lower wall 35 in the form of a circular disk. These upper and lower walls block partly above and partly below the cylindrical volume which delimits the continuous wall 33 . The enclosure formed by the walls 33 , 34 , and 35 is supported by a suitable underframe, not shown. On the outside cylindrical side of the continuous wall 33 , attached by any mechanism known to the professional, is the rigid structure 11 of each distributor device 1 equipping the system. At the level of each distributor device 1 , the continuous wall 33 is equipped with two drill holes that go through it radially. In one of these drill holes, the shaft 12 of the valve component 8 is placed and in the other one, the pushrod 14 of the impulse mechanism 9 .
The second assembly support 32 consists of an enclosure 32 a forming a parallelepiped caisson, provided with an upper horizontal wall 36 and a lower horizontal wall 37 each equipped along a vertical common axis with a drill hole going through, in which a rotational guide bearing is mounted on a vertical shaft 38 that forms a single piece with the first assembly support 31 , and more precisely, with the walls 33 and 34 of the assembly support 31 . This caisson is arranged in a manner centered relative to the crown formed by the distributor devices 1 . The two upper and lower walls 37 , 38 are joined to each other by at least two lateral walls 39 , 40 , diametrically opposed, perpendicular to a same axis secant and perpendicular to the longitudinal axis of the guide shaft 38 . The first of these walls, the wall 39 , along a horizontal axis radial to the guide shaft 38 and radial to the first assembly 31 , is equipped with a drill hole passing through in which a collar is placed that is provided with a bore going through the right polygonal section and expanding along a radial horizontal axis to the guide shaft and radially to the crown formed by the distribution devices. In this bore, a sheath 41 is placed, parallelepiped in shape, that makes up a case having upper 41 a and lower 41 b walls, each one provided relative to the other with an opening 41 c going through the passage of the vertical guide shaft 38 . This shaft receives by attachment, in the sheath 41 , a fixed toothed crown 42 with which it is designed to act together in engaging a toothed pinion 43 supported on the horizontal output shaft of a drive instrument for driving in rotation the second assembly support 32 around the guide shaft 38 . This drive instrument is a single piece with the sheath and is fixed in front of this sheath by any mechanism known to the professional. This drive instrument consists for example of a step-by-step electric motor controlled by the command and control unit 10 .
Advantageously, this drive instrument is made of the drive instrument 13 a of the actuation mechanism 13 . For this purpose, this motor contains a shaft that goes through in order to receive along one of its ends the pinion 43 and along the other end, outside of the enclosure, and relative to the distribution devices, the endpiece 13 b for coupling to the shaft 12 .
The sheath 41 carries outside of the enclosure 32 a and relative to the distribution devices, the drive instrument 13 a with the endpiece 13 b for coupling the valve component 8 while the enclosure 32 a under the actuation instrument cited above, carries the drive instrument 15 of the actuation mechanism of the impulse mechanism 9 .
The drive instrument 13 a for driving in rotation the second assembly support is steered by the unit 10 so as to displace the actuation mechanisms towards the distribution device selected and to temporarily immobilize them in the axis of the shaft 12 and pushrod 14 .
Advantageously to the axis going through the drive instrument 13 a , a coder is connected, of a known type, connected by an appropriate electric line to the control and command unit in order to deliver to the control and command unit a signal representing the angular position of the second assembly in the first.
The sheath 41 is mounted to slide in the bore going through the collar, and the openings 41 c going through, made in the lower and upper walls of the sheath 41 are in an oblong form and oriented in a manner so that their longitudinal axis expands in a manner radially and secant to the longitudinal axis of symmetry of the guide shaft 38 . In addition, at the rear wall of the sheath and at the wall of the enclosure 32 a , an activation instrument 41 d is attached, of a valve type, under the action of which the sheath 41 is displaced in the bore of the collar either towards the distribution device 2 selected so that the coupling endpiece 13 b that is carried by the drive instrument 13 a is coupled to the shaft 12 a of the valve component 8 and the pinion 43 is uncoupled from the crown 42 , or in the inverse direction so that the coupling endpiece 13 b is uncoupled from the shaft 12 of the valve component 8 and the pinion 43 is coupled to the toothed crown 42 .
Also depending on this type of embodiment, the container 6 and the gauge component 7 of the liquid quantity in this container are fixed with respect to the first assembly support 31 and occupy a lower position coaxial with respect to the crown that forms the distribution devices 1 . The conduits of these devices in the lower part are bent in a manner so as to come to be located by their discharge nozzle 5 above the container 6 . It is noted that the conduit through their lower parts have equal dimensions and are bent along the same angle. This characteristic permits the improvement of the repeatability of the resulting quantities.
The system as described can also be use distribution devices 2 according to the second embodiment form.
In FIG. 5, a system is shown equipped with distribution devices 2 according to the second embodiment form.
The first assembly support 31 consists of a horizontal plate 45 carried by and in a three-dimensional structure formed by the assembly of uprights and traverses arranged according to the edges of a rectangular parallelepiped. This structure receives the fixed walls of the cover defining a parallelepiped volume in which the second assembly support is placed. This volume is provided with an access opening to which a mobile screen, a seal, or even a flap is connected. The horizontal plate 45 receives in attachment the valve body of each distribution device 2 equipping the system. As indicated previously, the valve bodies are arranged at regular interval relative to each other along the circle circumference in a manner so as to form a circular crown and are oriented so that their actuation shaft 25 is radial to the crown formed and is oriented towards the center of this crown and towards the second assembly support 32 .
The second support assembly 32 consists of a vertical shaft 46 to which a support arm 47 , is attached in a radial manner. The support arm 47 carries at a distance the shaft 46 , the drive instrument 28 with cam 27 of the impulse mechanism 9 and actuation mechanism of the valve component 8 . The arm extends on both sides of the shaft and carries, in the opposite direction of the motor component 28 , a balance weight. The vertical shaft 46 is placed at its lower end in a guide plate in rotation, fixed to a lower plate 48 that is in one single piece with the first support component 31 and is coupled at its upper end to the vertical output shaft of a drive instrument 49 for driving in rotation, which is fixed by its case to a mount that is a single piece with the first assembly support. This drive instrument, made, for example, by a step-by-step electric motor is connected by an electric line fitted to the control and command unit 10 so that it is steered by the unit 10 and positions as desired the arm 47 and the drive instrument 28 with cam 27 relative to the distribution device selected for distribution of the required amount of liquid in the container 6 . In order to immobilize the arm 47 and the shaft 46 for the time of the distribution of the required quantity of liquid, the body of each distribution device is equipped with an obstructed drill hole open on its upper horizontal side and a pneumatic vertical valve is provided, carried by the arm of the side of its balance weight and intended when it is activated to penetrate by its shaft in the obstructed drill hole of the distributor body diametrically opposed to the one selected.
The shaft 46 between the support arm 47 and its upper end is placed in a guide bearing mounted in the drill hole going through the horizontal plate 45 of the first support assembly 31 . The shaft 46 is centered relative to the crown that forms the valve body of the distributors that are oriented so that their shaft 25 expands in a radial manner to the shaft 46 and is turned towards the shaft.
The section down from the conduit of each distribution device is fitted in a drill hole going through the support plate ( 45 ) so as to come to be the upstream section ( 4 b ) of the conduit of each distribution device ( 2 ) being placed in a drill hole going through the support plate ( 45 ) so as to come be located, by the distribution nozzle ( 5 ), located, by the distribution nozzle ( 5 ), above a second horizontal support plate 50 placed under the first one and at a distance from the first one, this second support plate being rigidly attached to the drive shaft 46 in a manner to be driven in rotation with the support arm 47 , the container 6 and the gauge component 7 of the liquid quantity in the container being installed on the second plate. The container is positioned with its opening on this plate so that it is in the axis, i.e. is below the discharge nozzle 5 of the distributor device selected to discharge a dosed quantity of liquid contained in the container connected to this distribution device. Advantageously, the position of the plate 50 is adjustable along the axis in order to be able to receive containers having different heights.
Preferably, the sections of the conduits 4 b are all rectilinear, vertical and of equal lengths. These devices make it possible to improve the repeatability of the results of the dosages.
Between the plate 50 and the plate 45 , the second assembly support is equipped with a protection plate 51 horizontally fixed to the drive shaft 46 . This plate has a raised peripheral edge and has projecting on its upper side a projection. This projection and the plate have passing straight through them a single vertical drill hole. This drill hole, by rotation of the shaft is carried into the axis of the nozzle 5 of the distributing device selected and allows the flow of the liquid from the nozzle 5 to the container.
This plate 51 has the purpose of recovering and holding by its raised edge the residual flows of the liquid and of preventing these flows from coming to contaminate the composition made, or even in the course of its creation and to damage the dosage.
Preferably, to the rotating shaft 46 a coder is connected of a known type, connected by an appropriate electric line, to the control and command unit in order to deliver to this unit a signal representing the angular position of the second assembly in the first one.
According to another embodiment form of the invention, as can be seen in FIGS. 6 and 7, the two support assemblies 31 , 32 are fixed relative to each other and the first assembly support receives in attachment to at least one group of two distribution devices 2 , the two distribution devices of the group being arranged in a manner parallel and symmetrical relative to a geometrical vertical plane P and are oriented so that their actuation shafts 25 are turned in the same direction. To this group of distribution devices is connected an actuation mechanism which is appropriate to it, fixed on the second assembly support and consisting of a drive instrument 52 on the output shaft of which a cam 53 is supported. The output shaft of the drive instrument 52 of the actuation mechanism is placed in a vertical manner and the geometrical axis of rotation of this output shaft is placed in the vertical geometrical plane of symmetry P. The cam, supported in rotation on the motor shaft, is intended to be led by one of its cam surfaces by the drive instrument under pressure against the actuation shaft of the impulse mechanism and of the valve of one of the two devices, and by the other cam surface, against the other device. In FIG. 6, you can see that the system consists of several groups of distribution devices and that the two distribution devices of each group are placed side by side. In the case of the figure, the surfaces of the cams are placed according to two vertical planes forming an angle between them. In FIG. 7, you can notice that the installation does not have a single group of distribution devices. These distribution devices are isolated from each other and the surfaces of the cam used are parallel to each other. With one or the other form of the embodiment object of the FIGS. 6 and 7, several containers could be used that are mounted in an immobile manner on a mobile support driven by a drive instrument steered by the command and control unit so as to lead the containers under the discharge nozzles of the distribution devices. To this mobile support, for example, in rotation, a gauge device is connected. These mobile containers can be test tubes, sample tubes, and other containers in which several liquid products are introduced successively.
As a variation, a gauge indicator 7 and a container 6 are connected to each group of the system from FIG. 6 .
Of course, the invention presented here can receive any adjustments and variations in the range of equivalent techniques, without leaving the frame defined by the following claims. | The method for dispensing dosed amounts of a liquid contained in a storage reservoir connected to a dispensing duct provided with a nozzle for delivering the liquid into a receptacle associated with an indicator, delivering in the form of a signal representative of the value of the amount of liquid present in the receptacle and said duct distant from the nozzle, being associated with a closing mechanism which, by command, closes or releases the passage of the liquid through the duct, including the following steps: a) releasing the passage of the liquid between the reservoir and the nozzle by operating the closing mechanism, so that the liquid can fill the portion of the duct between the closing element and the dispensing nozzle; b) closing the passage of the liquid by operating the closing mechanism to interrupt the liquid flow; c) applying on the liquid column between the closing mechanism and the dispensing nozzle, at least a mechanical pulse of calibrated amplitude and/or intensity, for expelling from the liquid column, a micro-amount of liquid; d) comparing the value shown by the indicator and a predetermined index value C1; e) and repeating steps c) and d). | 1 |
RELATED APPLICATION
[0001] This patent application is related to concurrently filed U.S. patent application Serial No. ______ (attorney docket 042390.P6877), titled “Voltage Regulator,” by M. Beck, filed on , assigned to the assignee of the present invention and herein incorporated by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention is related to high speed signal transmission or communications, such as, for example, in a computing or computer system.
[0004] 2. Background Information
[0005] As is well-known, in a computer system, for signal communication to occur between, for example, the computer peripheral and the host computer, today signals are transmitted that comply with a predetermined specification or protocol. This is desirable because it enhances the interoperability between devices manufactured by different entities, for example. One such specification is the well-known Universal Serial Bus specification, version 1.0, available from USB-IF, 2111 NE 25 th Ave., MS-JF2-51, Hillsboro, Oreg. 97124,(hereinafter referred to as “Standard USB”). The current version of the specification refers to signals that communicate at a low speed, 1.5 megabits per second, and at full speed, 12 megabits per second. However, with increases in the speed of microprocessors, and the number and speed of the peripherals, it has become desirable that signal transmission occur at even higher signal rates. In addition to this desire for high speed signaling, it is also desirable that new computing or computer systems include the capability to comprehend or communicate with legacy systems that operate at the preexisting or lower speed signaling rates. Therefore, it is desirable to have a process or technique for communicating at high speeds when that capability exists, while retaining the capability to communicate at low or state-of-the art speeds to maintain backward compatibility.
SUMMARY
[0006] Briefly, in accordance with one embodiment of the invention, an integrated circuit includes: a transceiver capable of transmitting and receiving signals complying with the standard Universal Serial Bus (USB) specification. The transceiver is further capable of transmitting and receiving signals at a frequency higher than the signals complying with standard USB specification. The transceiver is further capable of configuring itself between transmitting and receiving the higher frequency signals and the standard USB signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portions of this specification. The invention, however, both as to organization, and method of operation, together with objects, features and advantages thereof, may best be understood by reference to the following detailed description, when read with the accompanying drawings in which:
[0008] [0008]FIG. 1 is a schematic diagram illustrating portions of embodiments of, for example, two integrated circuits in accordance with the present invention, the integrated circuits being coupled by a cable; and
[0009] [0009]FIG. 2 is a circuit diagram illustrating an embodiment of drivers that may be employed, for example, in one of the integrated circuits of FIG. 1.
DETAILED DESCRIPTION
[0010] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components and circuits have not been described in detail so as not to obscure the present invention.
[0011] [0011]FIG. 1 is a schematic diagram that shows an embodiment 100 illustrating portions of embodiments of two integrated circuits in accordance with the present invention. Embodiment 100 includes integrated circuits 200 and 205 , although the invention is not limited in scope in this respect. These integrated circuits may be included or incorporated into a variety of systems. For example, without limitation, a host computer and a peripheral in communication with the host computer. As illustrated in FIG. 1, these integrated circuits are coupled via a cable 110 , which operates effectively as a transmission line in this context. In this particular embodiment, cable 110 comprises a twisted pair copper wire, although the invention is not limited in scope in this respect. In this particular embodiment, integrated circuit 205 includes an upstream transceiver and integrated circuit 200 includes a downstream transceiver. In this context, the upstream transceiver transmits communication signals to the downstream, such as from a host to a peripheral, as mentioned above, although the invention is not limited in scope in this respect. It is also noted that this definition of upstream and downstream is the reverse of the approach employed in the previously referenced standard USB specification.
[0012] The transceivers illustrated are capable of communicating at low speed, that is 1.5 megabits per second, and at full speed, that is 12 megabits per second, for a standard USB transceiver, as well as at a higher speed. In this particular embodiment, the speed of the high speed signals is 125 megabits per second, although the invention is not limited in scope in this respect. Therefore, at low and full speed, the operation, in terms of signals, of this embodiment is substantially identical to standard USB compliant devices or transceivers. However, as shall be explained in more detail hereinafter, the transceiver is self-configurable in that it is capable of operating in a high speed mode, as well as at a low or a full speed mode. To accomplish this, in this particular embodiment, the transceiver configures itself between two architectures, a standard architecture and a high speed architecture. The added circuitry for the high speed architecture is transparent to the circuitry that operates in a manner that complies with the standard USB specification.
[0013] As is well-known, in standard USB, voltage mode drivers are employed with near end series termination. One reason that this approach is undesirable for high speed operation is due to the electromagnetic interference that would be generated by a voltage mode driver operating rail-to-rail at a relatively high speed, such as on the order of 125 megabits per second. A relatively large signal swing in a short period of time, due to the high frequency, may produce an undesirable amount of interference. Therefore, in this particular embodiment, for high speed operation, current driven circuitry with far end parallel termination is employed instead, as shall be described in more detail hereinafter. Signal transmission using current driven signals, as opposed to voltage driven signals, allows for a smaller, better controlled signal swing, as well as for differential signals. Another advantage of the transceiver embodiment illustrated in FIG. 1 is that the transceiver power consumption is lower in high speed mode at 125 megabits per second, for this particular embodiment, than the power consumption for the transceiver in full speed mode at 12 megabits per second. One reason this occurs is because a smaller voltage signal swing consumes less power.
[0014] In addition to being current driven, in this particular embodiment, the high speed circuitry employs single side termination. Furthermore, in this particular embodiment, the termination is asymmetrical. More specifically, far end termination is employed when communicating downstream, whereas near end termination is employed when communicating upstream.
[0015] Communication occurs upstream because the cable or bus is bi-directional. Therefore, one advantage of this approach is that it employs fewer additional pins to accomplish termination then alternative approaches.
[0016] Referring to FIG. 1, as illustrated, receiver 120 operates as a low speed and full speed receiver, whereas drivers 130 and 140 respectively operate as full speed and low speed drivers. Of course, 120 could be two receivers as well. The downstream configuration is similar in that receiver 220 operates as a full speed receiver and low speed receiver, whereas 230 and 240 operate as full speed and low speed drivers. Again, 220 could be two receivers also. As illustrated, the circuitry includes the capability to comply with the standard USB specification and it includes the appropriate terminations for satisfactory operation to take place. Therefore, if this transceiver embodiment is communicating either upstream or downstream with a transceiver that does not include high speed capability, low speed or full speed operation may be employed. Likewise, this transceiver embodiment in accordance with the present invention, illustrated in FIG. 1, includes high speed circuitry so that high speed communication may be employed when communicating with a transceiver that likewise includes a similar high speed capability. Therefore, referring to the upstream high speed transceiver, high speed receiver 150 and high speed drivers 160 and 170 may be employed, whereas on the downstream high speed transceiver, high speed receiver 250 and high speed drivers 260 and 265 may be employed. Likewise, the high speed portion of the circuitry includes a voltage source, in this particular embodiment voltage source 180 on the upstream transceiver and voltage source 270 on the downstream transceiver, as illustrated in FIG. 1 in this embodiment. These voltage sources may typically comprise bandgap circuits, although the invention is not limited in scope in this respect. In this embodiment, the downstream transceiver also includes a voltage regulator 275 , described in more detail hereinafter.
[0017] When communication occurs from the upstream transceiver to the downstream transceiver, far end termination is employed. This occurs in this embodiment because regulator 275 is operational in high speed mode downstream and, therefore, for the downstream transceiver, regulator 275 appears as a relatively low impedance in series with externally supplied resistances 310 and 320 . As illustrated, assuming cable 110 in this embodiment has a 90 ohm impedance, such as for a twisted pair of copper wires, resistances 310 and 320 provide a desired far end termination. Of course, the invention is not limited in scope to these resistances. Furthermore, these resistances could alternatively be provided on-chip rather than off-chip.
[0018] In contrast, when communication takes place from the downstream transceiver to the upstream transceiver, near end termination is employed. Therefore, the previously described termination also provides the desired termination for downstream to upstream communications. This occurs in this particular embodiment because the upstream high speed drivers, such as 160 and 170 , are tri-stated and have a relatively high impedance, while the upstream high, full, and low speed receivers are active (and therefore high impedance). Therefore, the signal transmitted from the downstream transceiver to the upstream transceiver is effectively reflected back due to the high impedance of the upstream transceiver. However, the externally provided 45 ohm resistance of 310 and 320 forms a voltage divider with 90 ohm cable 110 so that approximately half of the energy of the signal is transmitted from the downstream transceiver to the upstream transceiver. Therefore, when the signal is reflected back due to the upstream high impedance just described, the original and reflected signal sum constructively at the upstream transceiver to provide the full signal at the upstream receiver. As previously indicated, another aspect of this particular embodiment of a transceiver is that the transceiver is self-configurable. This particular embodiment has several different self-configurable aspects, although the invention is not limited in scope to having all these aspects in one embodiment. For example, the transceiver includes the capability to turn the appropriate drivers and receivers on and off depending upon the particular speed of operation that is desired. This capability is not specifically illustrated in FIG. 1, however, in order not to obscure the present invention. However, various signaling protocols may be employed for the transceiver to determine the speed of operation desired and, therefore, configure the drivers and receivers appropriately. For example, although the invention is not limited in scope in this respect, a given transceiver might initially assume operation in a full speed mode and wait for an indication from another transceiver with which it is communicating as to whether that another transceiver is high speed capable. Then if that another transceiver indicates that it is high speed capable, the transceiver in full speed mode may upgrade its communication speed as appropriate. Of course, the invention is not limited in scope to this technique for establishing high speed communication. Regardless of how this is accomplished, if we assume that a transceiver has the capability through signaling protocols to determine the appropriate mode of operation, then this particular transceiver embodiment is self-configurable in that it may couple the appropriate circuit configurations in order to accomplish the desired speed of operation.
[0019] In this particular embodiment, the self-configuration is accomplished at the downstream transceiver, although the invention is not limited in scope in this respect. For example, this might be accomplished instead by an upstream transceiver. One advantage of this approach is that providing the self-configurable capability employs, in this embodiment, three additional external connections. Therefore, placing these extra connections or pins with the downstream transceiver may ultimately reduce the number of additional pins in a system because, for example, a multi-port device, such as a hub, will typically employ one downstream transceiver yet multiple upstream transceivers. Therefore, this technique reduces the number of extra pins employed in order to have this self-configuration capability since multiple upstream transceivers would result in multiple extra pins if that approach were employed.
[0020] For the embodiment illustrated in FIG. 1, one aspect of this self-configuration capability is exhibited by switch 340 and resistor 330 . As is known, one aspect of complying with the standard USB specification is providing a 1.5 kilo-ohm pull-up resistor, such as resistor 330 , for full speed mode operation. Therefore, switch 340 may be provided on integrated circuit 200 in this particular embodiment and will remain open for high speed operation and closed for full speed operation. Of course, the invention is not limited in scope in this respect and an additional pin and resistor 330 may be avoided by instead providing a current source that simulates the rise time specified in the standard USB specification when connection to a cable is accomplished for full speed operation. This is shown in FIG. 1 by a dotted line. In this context, the term “current source” refers to a transistor coupled so that in operation it resembles the circuit characteristics of a current source. In embodiments in which this latter approach is employed, the downstream transceiver may therefore be self-configurable and employ two external connections instead of three external connections.
[0021] As illustrated in FIG. 1, these two external connections are employed to couple two resistors 310 and 320 providing the parallel terminations previously described, although, of course, the invention is not limited in scope in this respect. However, as shall be explained in more detail hereafter, these pins couple these parallel terminations to voltage regulator 275 . Providing parallel far end termination for the upstream transceiver is only one aspect of employing voltage regulator 275 in this particular embodiment. As previously described, when voltage regulator 275 is operational, it provides as a relatively low impedance in series with parallel termination resistors 310 and 320 . However, in an alternative mode, voltage regulator 275 may no longer operate as a voltage regulator and in this mode of operation may provide a relatively high impedance. This mode of operation for voltage regulator 275 is desirable when full speed or low speed operation is desired for the transceiver, hence, furthering the self-configurability of the transceiver.
[0022] The effect of employing the voltage regulator in this fashion provides for the two different signaling techniques or modes previously described. When the voltage regulator is operational providing a relatively low impedance, this allows the transceiver to perform current mode signaling, as previously described, so that high speed communication may occur. Alternatively, when the voltage regulator is off, and, therefore providing a relatively high impedance, this allows for voltage mode signaling, as is traditionally employed in standard USB, to take place. Thus, voltage regulator 275 is another aspect of the self-configurability in this transceiver embodiment.
[0023] In addition to providing the capability to disconnect or decouple the parallel termination, as previously described, voltage regulator 275 also sinks and sources current when high speed communication is occurring, while maintaining a substantially constant voltage level. Maintaining a substantially constant voltage level, particularly above ground, is desirable because it maintains the voltage level of the downstream transceiver at a voltage level so that a high speed receiver may operate satisfactorily. Although the invention is not limited in scope in this respect, one embodiment of such a voltage regulator is described in the aforementioned concurrently filed patent application titled “Voltage Regulator,” (attorney docket 041390.P6877) by M. Beck, assigned to the assignee of the present invention and herein incorporated by reference.
[0024] [0024]FIG. 2 is a circuit diagram illustrating an idealized embodiment of high speed drivers for embodiment 205 of an integrated circuit in accordance with the present invention shown in FIG. 1. These drivers correspond to drivers 160 and 170 in FIG. 1, although, the invention is not limited in scope to this particular embodiment. Many other embodiments of high speed drivers may be employed in an integrated circuit in accordance with the present invention. Likewise, as previously described, this particular embodiment assumes far end termination is employed. As illustrated FIG. 2, each high speed driver in this particular embodiment comprises two switched current sources coupled in parallel. In this context, the term “current source” refers to a transistor 2 coupled so that in operation it resembles the circuit characteristics of a current source. To signal a logical one, the current source in the first driver formed by transistors 510 and 520 turns on,. supplying current to the 90 ohm twisted pair cable, and to the terminating resistors 310 and 320 , in this particular embodiment. The current source in driver 170 formed by transistors 440 and 450 are also turned on, sinking current from the terminating resistors and the cable. To signal a logical zero, driver 170 sources current and driver 160 sinks current. Assuming about a 500 millivolt signal swing, although the invention is not limited in scope in this respect, that is, the predetermined voltage level of voltage regulator 275 plus or minus about 250 millivolts, a current of about 5.5 milliamps is employed. To reduce electromagnetic interference, it is desirable that the signals produced by the driver be symmetrical, which makes employing substantially identical drivers desirable. It is likewise desirable to match the rise and fall times for the signals produced.
[0025] It is therefore desirable to size the transistors forming the current mirrors of the drivers appropriately because the size of the transistors affects gate capacitance, which may impact the signal rise and fall times. In this particular embodiment, as illustrated in both FIG. 1 and FIG. 2, two pins are employed for voltage regulator 275 . This provides the capability to disconnect or decouple the parallel termination provided by resistors 320 and 310 when desired without allowing these two resistors to form a circuit loop through the voltage regulator. Thus, placing the voltage supply in a high impedance state in order to accomplish full speed operation effectively switches out the parallel terminations from the transceiver, as is desired for this embodiment.
[0026] While certain features of the invention have been illustrated as described herein, many modifications, substitutions, changes and equivalents will now occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | Briefly, in accordance with one embodiment of the invention, an integrated circuit includes: a transceiver capable of transmitting and receiving signals complying with the standard Universal Serial Bus (USB) specification. The transceiver is further capable of transmitting and receiving signals at a frequency higher than the signals complying with standard USB specification. The transceiver is further capable of configuring itself between transmitting and receiving the higher frequency signals and the standard USB signals. | 7 |
SUMMARY OF THE INVENTION
The present invention relates to a method of joining together two pipe ends to form a pipe, preferably of metal. The invention relates particularly to pipes of such large diameter as those used for transporting of oil and gas. Other pipes for which the invention is suitable are pipes for district heating plants. These pipes are generally so heavy that it is impractical to move two ends together into contact with each other to enable joining. Pipes of the type mentioned are generally known as pipe-lines.
The object of the present invention is to achieve a joint between two pipes where the opposing pipe ends are spaced from each other and where movement of the pipes is to be avoided. The joint is provided by preparing a splicing tube, having a length substantially corresponding to the distance between the two pipe ends to be joined. The splicing tube has the same dimension as the two pipes to be joined. Two joint areas are formed and joining is performed at these points by means of explosive welding with the aid of an outer peripheral body at each joining point and an inner peripheral body also arranged at each of the two joint points, the latter peripheral bodies being caused, each by its own explosive charge, to form an explosive weld at each joint area. The outer peripheral bodies may of course be replaced by a tool used only while explosive welding is being performed. The peripheral bodies may also be such that after explosive welding they are destroyed.
The explosive welding at each of the joint areas is initiated simultaneously.
One requirement is that the splicing tube is such that two explosive welds can be performed, one at each end of the tube. If the distance between the two pipe ends to be joined is too short to allow the use of a splicing tube for explosive welding, one or both ends of the two pipes to be joined should be cut to give sufficient space between the two pipe ends.
The invention is also particularly suitable for repairing pipes having a defect somewhere between the ends. A section of the pipe containing the defect is cut away, the removal of said defect section resulting in two pipe ends with a gap between them where a splicing tube as described above can be applied with outer and inner peripheral bodies and explosive charges.
Outer and inner peripheral bodies may either be placed on each pipe end or on a splicing tube which is to constitute a connection element between the pipe ends. All peripheral bodies must be arranged inside the end edges of the pipe ends or splicing tube, respectively. This is to enable the splicing tube to be inserted between the two pipe ends to be joined.
According to the invention displacement means are also arranged to displace at least the inner peripheral bodies to a position covering the two joints formed. For this purpose one or more pull-strips, cords or wires may be used. Pre-stressed springs are also feasible, spring-force being exerted upon displacement. A pressure medium such as gas or liquid may also be used for the displacement.
At least the inner peripheral bodies are provided with blocking means cooperating with a gap arising at the two joint areas.
According to the invention a prefabricated unit is preferably used consisting of a splicing tube provided at the ends with both inner and outer peripheral bodies, the inner peripheral bodies being provided with explosive charges and displacement means which can be released are arranged between the inner peripheral bodies.
The explosive charges are preferably initiated electrically, voltage being transmitted inductively through a pipe wall from a voltage source to an initiator at the explosive charge inside the splicing tube.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be described in more detail with reference to the accompanying eight drawings in which
FIG. 1 shows a pipe with a defect,
FIG. 2 shows the defective part cut away, thus producing two pipe ends,
FIG. 3 shows the pipe ends each provided with an inner and an outer peripheral body and with an explosive charge for each inner peripheral body and a splicing tube for insertion between the two pipe ends,
FIG. 4 shows the splicing tube placed between the two pipe ends and the inner and outer peripheral bodies placed over the joint areas formed,
FIG. 5 shows the two pipe ends after joining by means of explosive welding,
FIG. 6 shows a detailed view of a pipe end and a splicing tube before the inner and the outer peripheral bodies have been moved over a joint area,
FIG. 7 shows the inner peripheral body in FIG. 6 in position at a joint area, and
FIG. 8 shows a unit consisting of splicing tube with inner and outer peripheral bodies and displacement means.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a large-diameter pipe 1 with a hole or defect 2. The pipe consists of metal and is intended for use in pipe-lines for transporting oil and gas. It may of course equally well be used for district heating. Characteristic of the pipe is that it is part of a pipe-line and cannot therefore be moved. Even on its own it is too heavy to be moved manually. The pipe requires mending and this is done by cutting away a section including the hole 2, thereby forming two pipe ends 3 and 4 located opposite each other, as can be seen in FIG. 2. The situation may also be such that instead of repairing the pipe 1 in FIG. 1, the object is to join two pipe ends 3 and 4 in a pipe which cannot be moved. The two pipe ends 3 and 4 are jointed with the aid of a splicing tube 5 having a length corresponding to the distance between the pipe ends 3 and 4. The gaps which may occur at the joints may be up to 20 mm. Before the splicing tube 5 is positioned an inner peripheral body 11 of metal must be inserted in each pipe end. The peripheral body 11 is provided around its circumference with a number of holes 14 containing a spring 15 and a cylindrical body or plug 16.
Inside the peripheral body 11 is a cylindrical body 10 constituting an explosive charge which may consist of dynamite, dynamex, trinitro toluene or other suitable explosive. At the centre of the explosive charge 10 is a disc 12 constituting an initiator which may consist of pentyl or some other equivalent explosive. At the centre of the disc 12 is an electric detonator 13. An outer peripheral body 7 of metal is applied on the outer surface of the pipe end 3 in order to provide support. The pipe end 4 is also provided with an outer peripheral body 6 and an inner peripheral body corresponding to the peripheral body 11, also provided with explosive charge, initiator and detonator. When both pipe ends 3 and 4 have been equipped as described above, the splicing tube 5 is positioned between the two pipe ends 3 and 4. After this, the two inner peripheral bodies are moved, to where one of the bodies 11 is visible against the splicing tube 5 so that the cylindrical bodies or plugs snap into the gaps formed between the pipe ends 3 and 4 and the splicing tube 5. Thereafter, the outer peripheral bodies 6 and 7 are also moved to cover the gap between the pipe ends 3 and 4 and the splicing tube 5. If the detonators are initiated in this position, a double explosion will occur, the two inner peripheral bodies producing explosion welds while the outer peripheral bodies 6 and 7 are deformed and produce mechanical joints. FIG. 4 shows the outer peripheral bodies located over the gaps before explosive welding, and FIG. 5 shows the outer peripheral bodies 6 and 7 after explosive welding.
FIGS. 6 and 7 show in greater detail how the inner peripheral body 11 is moved to the joint area after the splicing tube 5 has been positioned. A number of pull-strips or cords 17 attached to the inner peripheral body 11 and passing out through the gap 18 between the pipe end 3 and splicing tube 5 are used for the displacement. If the strip 17 is pulled the peripheral body 11 will be displaced to the joint and the cylindrical body 16 will then snap into the gap 18. The peripheral body 11 is thus located symmetrically in relation to the pipe end 3 and the end of the splicing tube 5. This symmetrical position can be seen clearly in FIG. 7.
The displacement of the inner peripheral body can also be performed in other ways, such as by releasing a spring located inside the pipe end 3. Another possibility is to use a pressure medium, also located inside the pipe end 3. The pressure medium may be created by releasing a weak detonation. The peripheral body at the left side of the splicing tube is brought into a position corresponding to that for the righthand inner peripheral body in the same manner as the latter. The two explosive charges, one of which is designated 10, are released by electric triggering of the detonator, one of which is designated 13. For this purpose a voltage unit or pulse generator 19 is used, which supplies voltage or pulses via conductors 20 to a coil 22 with an iron core 21. Voltage generated in the coil 22 is transmitted inductively through the wall of the splicing tube 5 to a coil 23 with iron core 24, located inside the splicing tube. The coil 23 is connected to the electric detonator 13 via conductors 25. The coil 23 is also connected to the second detonator. The two explosive charges are initiated simultaneously.
A description has been given above of how the inner and outer peripheral bodies are arranged around the pipe ends 3 and 4. However, it must be evident that a unit can be prepared consisting of splicing tube 5 containing two units 8 and 9 each consisting of an inner peripheral body with explosive. Between the units 8 and 9 is a means 26 for displacing the units 8 and 9 when triggered. The prefabricated unit is also provided with the necessary outer peripheral bodies 6 and 7. A prefabricated unit facilitates pipe-joining since the unit need only be positioned and displacement of the units 8 and 9 triggered, followed by displacement of the peripheral bodies 6 and 7, whereupon an explosive weld is effected. The latter method is probably the quickest way of achieving a joint between two pipe ends. These ends may either being the ends of two pipes to be joined which cannot be moved, or they may have been formed after removal of a defective part of a pipe.
A condition of the present invention is that the splicing tube 5 must be long enough to permit double explosive welding. Should the distance between the two pipe ends 3 and 4 be shorter that the length required for the splicing tube, one or both the pipe ends must be cut to provide a distance corresponding to the length necessary for the splicing tube 5. | When joining together pipes the pipe ends are usually placed opposite each other and then welded together. This cannot be done with heavy pipes. A gap exists between the ends (3 and 4) to be joined. The invention provides a joint by producing a splicing tube (5) the length of the gap and joining this by means of explosive welding. The invention is also applicable for mending a defect (2) in a pipe (1) by the removal of a sufficiently large section of the pipe (1) to allow the splicing tube (5) to fit into the space obtained, the part removed containing the defect (2). | 5 |
FIELD OF THE INVENTION
This invention relates to aligning and holding apparatus and more particularly to aligning and holding apparatus especially suitable for plumbing applications, particularly for facilitating the installation of faucets having two spaced apart handle valves.
BACKGROUND OF THE INVENTION
In installing faucets with two wide spread handles a problem is encountered during installation of valve assemblies in holding the two valve assemblies in a properly aligned position while tightening them from under the sink. If the valve assemblies, particularly the handle stops, are misaligned during installation the handles, which are normally mounted on the valves after the valve have been installed in the sink or countertop, will not be properly aligned with each other. There thus exists a need for a device which holds the two valve assemblies, particularly the handle stops of the assemblies, in predetermined positions while the valve assemblies are being secured to the sink in order to insure and maintain proper relative positioning and alignment of the handle stops with a minimum of time and effort. The instant invention provides such a device which is relatively simple and easy to use.
SUMMARY OF THE INVENTION
The instant invention is directed to an aligning and holding apparatus for holding against rotational movement and consequent misalignment handle stops of valve assemblies of faucets which have two spaced apart handle valves during the installation of such faucets. The apparatus of the present invention is an elongate, relatively flat, relatively thin integral member having a plurality of longitudinally spaced apart openings extending therethrough. The openings are located at predetermined positions and are adapted to fit over valve stems and handle stops of valve assemblies to keep the handle stops from rotating and becoming misaligned during installation. By using the apparatus of the instant invention the valves are held against movement during assembly to the sink so that the handles, once installed, will be properly oriented relative to each other and the spout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the aligning and holding apparatus of the instant invention;
FIG. 2 is a side view in elevation of the apparatus of FIG. 1;
FIG. 3 is an exploded perspective view of the apparatus of the invention and two faucet handle valves; and
FIG. 4 is a top plan view of a faucet handle valve of FIG. 3 illustrating the valve stem and handle stop.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The aligning and holding apparatus 10 of the instant invention comprises an elongated, relatively flat, thin and relatively rigid integral planar plate having a front leading edge 12, a rear edge 14, and two side edges 15 and 16. A plurality of longitudinally spaced apart openings 20, 30 are provided at predetermined and preselected intervals. For example, in the embodiment illustrated openings 20 are provided at one inch intervals, and openings 30 are also provided at one inch intervals. The openings are of two types. The first type 20 is comprised of a generally circular central portion 22 and a radially extending fan shaped side portion 24. The second type 30 is comprised of a generally circular center portion 32 and two radially extending fan shaped side portions 34 and 35. Fan shaped side portions 34 and 35 are spaced apart 180°. The central circular portion 22 of opening 20 and central portion 32 of opening 30 are adapted to fit over and receive a valve stem 110. The fan shaped side portion 24 of opening 20 and side portions 34 and 35 of opening 30 are adapted to fit over and receive handle stop 112. A third type of opening, 40, generally circular in shape is located midway between front edge 12 and rear edge 14. The purpose of openings 20 and 30, more specifically side sections 24, 34 and 35, is to hold and secure handle stops 112 against rotation. The purpose of opening 40 is for spout location in the case holes, e.g., valve assembly holes, spout holes, or both valve assembly holes and spout holes, must be drilled in the sink or countertop.
In the embodiment illustrated openings 20 are disposed between opening 40 and leading edge 12, while openings 30 are disposed between opening 40 and rear edge 14.
Indicia, particularly measurement indicia such as distance in inches, 50 and 60 are disposed on apparatus 10. Indicia 50 are disposed adjacent side edge 16 while indicia 60 are disposed adjacent side edge 16.
In the preferred embodiment illustrated the apparatus is made from metal, preferably aluminum or a light weight alloy of aluminum but may also be made from a plastic or resin material having good dimensional stability and rigidity.
In operation, as illustrated in FIG. 3, the aligning and holding apparatus 10 is placed over the valve stems 110 and handle stops 112 of valves 100. More specifically, as illustrated in FIG. 3, the central circular section 24 of opening 20 is placed over valve stem 110 and the fan shaped section 24 is placed over handle stop 112 of the right valve assembly 100 of a pair of handle valves while circular central section 32 of opening 30 is placed over valve stem 110 and fan shaped section 35 is placed over handle stop 112 of the left valve assembly 100.
In FIG. 3 the two valve assemblies 100 are about 16 inches apart and openings 20a and 30a are utilized. If the valve assemblies are spaced a lesser distance apart openings 30 and 20 which lie closer to central opening 40 can be utilized.
With the valve stems 110 and handle stops 112 of the two valve assemblies disposed in the appropriate openings in the apparatus, e.g., 30a and 20a, the two valve assemblies can be secured to the sink and/or to the pipes underneath the sink. Once the valve assemblies are securely mounted the apparatus is lifted off the valve stems and handle stops. Appropriate handles are then mounted on the valve stems.
In view of the foregoing, it is readily apparent that the apparatus of the present invention provides a device for dependably holding the handle stops of valve assemblies against rotation while the valve assemblies are attached to the sink and corresponding pipes. The apparatus enables such attachment operation to be accomplished by a single person readily and easily with the apparatus being thereafter easily removable from the valve stems. Furthermore, since the apparatus 10 has a plurality of longitudinally spaced apart openings 20 and 30 it can be used with valve assemblies whose distance from each other varies. | A handle stop aligning and holding apparatus for facilitating the installation of valve assemblies in a faucet having wide spread valves. The apparatus is an integral one-piece, flat, elongate plate having a plurality of openings longitudinally spaced from each other at preselected intervals. The openings are adapted to receive and hold against rotation handle stops of valve assemblies. | 4 |
BACKGROUND AND STATEMENT OF THE INVENTION
The invention relates to a method and apparatus which is particularly useful for regulating the individual shares of gaseous constituents of oxygen, nitrogen, carbon dioxide and water in reaction processes in the metallurgical field. Such methods generally aim at savings in energy, and especially savings with respect to the use of expensive means for transporting energy supplies. The reasons for this may be availability, dependence on importation, environmental factors, potential risks during conveyance, and last but not least prices and costs of certain fuels. Accordingly, such methods also aim at the utilization of gaseous and liquid fuels which question the economy of metal extraction, particularly crude iron and/or steel production in metallurgical processes where high temperatures are involved.
In the reduction of ore approximately 3000 normal or standard cubic meters of air are required for the combustion of one ton of coke. The air quantity actually to be delivered is still higher by about 25% due to atmospheric moisture, and due to leaks in pipes and air heaters (e.g. in blast heaters in blast furnaces). In order to save fuel, such as coke, the air is heated to a maximum of 1,300° C. in air heaters. In order to heat the air, the blast furnace gas escaping from the metallurgical furnace is used with a coke gas additive which is burned in the air heater, thereby heating latticed refractory stones in the interior of the air heater to a maximum of 1,550° C. After the heating period, the gas burner is switched off, and the cold air, which is produced in blower engines at higher pressures, is blown through the hot latticed masonry of the air heater. The hot stones heat the air, which is then injected, into the blast furnace, via the hot blast annular conduit and the blast pipes. Two such blast heaters alternate in heat and blast periods. About 66% of the total energy of a metallurgical plant are used in the extraction of crude iron in blast furnaces. The coke consumption in the Federal Republic of Germany alone in the year of 1975 amounted to about 500 kilograms per ton of crude iron. In addition, about 60 kg of heavy diesel oil per ton of crude iron were injected.
The blast furnace gas at the blast furnace, however, is a gas low in calorific value (3,140 to 3,560 kJ/m 3 ). This disadvantage may be compensated for in order to obtain higher flame temperatures, usually by adding heavy gases, such as coke furnace gas. Other auxiliary means to obtain higher flame temperatures exist in the preheating of gas and/or combustion air. It has also been suggested to decrease the inert gas quantities in the combustion air (particularly nitrogen) by adding oxygen in order to save fuel and at the same time increase the output of the blast furnace.
The oxygen added previously in the blast furnace originates mainly with the low temperature distillation of atmospheric air, for which special oxygen extraction plants are required in metallurgical plants. On the other hand, metallurgical plants may also be connected to extensive oxygen conduit systems, which join the individual oxygen consumption points in the metallurgical plant with far removed oxygen extraction plants.
The mere addition of oxygen to the combustion air and/or to gases low in calorific value, in particular blast furnace gases, is therefore not only relatively involved, but, in addition, it does not solve the problem of the other attendant gaseous constituents present, such as for example the inert gases, and particularly nitrogen which has to be carried as ballast in the metallurgical process. The supply of pure oxygen is, furthermore, unable to solve the problem of the carbon dioxide and the water vapor in the combustion air.
The present invention is a new method and apparatus for regulating the individual quantities of combustion air constituents, including the content of oxygen, nitrogen, carbon dioxide, and water in reaction processes in metallurgy, making it possible to individually determine a desired composition of the combustion gas according to calorific value, temperature and combustion gas volumes required for any type of process. This is achieved by supplying the reduction processes and/or oxidation processes with a controllable quantity of air, where the oxygen share has previously been increased in relation to the existing oxygen share of the inlet air, by continuously absorbing by molecular screening and/or straining in a flow of nitrogen, carbon dioxide and water molecules in substances forming crystal lattices. This method has the advantage of, simultaneously with an enrichment of the combustion air in oxygen, reducing the share of gases not participating in the combustion, and even inhibiting the latter. Thus, the share of ballast and unnecessary gases which is often found to be disadvantageous in reduction processes and oxidation processes, is lowered considerably.
Another advantage is that this share is controllable depending upon the temperature level to be set. For use as the molecular screen, such substances are suitable which are able to bind larger quantities of water in the crystal lattice, and which may be removed continuously by simple heating without collapse of the crystal lattice. In an atmosphere containing water vapor, such drained crystals may again absorb water or, in its place, sulfur hydrogen, sulfur carbon, nitrogen, carbon dioxide, and other molecules. Such crystal lattices are known under the name of Zeolite. Since the natural Zeolites are not adequate for this purpose, synthetic Zeolites have been manufactured for about 50 years which fulfill the practical demands.
The special advantage of the method described lies, in short, in the use of substances forming crystal lattices, which are of corresponding pore sizes and crystal lattice structures where foreign molecules with smaller diameter than the hollow spaces of the lattice may be absorbed. The other advantage lies in the typically metallurgical application. For the latter, the method of the invention presents opportunities to introduce gases lower in ballast into reduction or oxidation processes, to introduce gases which are more intensly reactive, to completely utilize generally unused waste heat of reduction or oxidation processes, and to regenerate substances forming crystal lattices and pores. Furthermore, the invention produces far drier combustion gases, and finally provides for the carrying out of more intensive reduction and oxidation processes by producing oxygen-enriched air. The last advantage serves to intensify the processes, thereby increasing the output of metallurgical furnaces and combustion processes. One of these advantages, therefore, consists in obtaining higher temperatures--as far as required--in reduction and oxidation processes.
According to the invention, it is advantageous for the controlled air in quantity to be fed through a Zeolite molecular screen consisting of crystalline metal alumino-silicates. Such zeolite molecular screens are in themselves known. Their suitability for absorbing certain constituents attendant with the supply air which are undesirable in certain quantities in reduction processes and/or oxidation processes, has so far been overlooked. The method of the invention is furthermore improved in that the zeolite molecular screen is regenerated with air heated to temperature between 200° C. and 300° C., for purging nitrogen, carbon dioxide and water contents by molecular displacement in an air flow in opposite direction to the previously set up operational flow. It is, further, advantageous to carry out regeneration of the molecular screen in an alternating temperature method by periodic heating of the molecular screen. Also, regeneration of the molecular screen can be done by alternating pressure application by periodic lowering of the pressure of the air flow at a constant temperature.
As a further feature of the invention, provision is now made that the air enriched with oxygen is supplied to reduction processes in shaft furnaces (e.g. in a blast furnace) for the ore reduction or oxidation processes and/or reduction processes and/or smelting processes in steel mill converters, cupola furnaces and/or electro-furnaces for the refining of crude iron and/or smelting of metal scrap, iron sponge and/or for the extraction of nonferrous metals, as well as hot and glow furnaces for heating and heat treatment of metals. Another use of the method of the invention is that the air enriched with oxygen may be burned together with blast furnace gas in the combustion chamber of a blast heater, so that there is a saving of coke gas. Also, another use of the invention is that the oxygen-enriched air may be heated together with fresh air in a blast furnace blast heater.
The apparatus of the invention is formed so that a metallurgical furnace is preceded by several containers with molecular screen substances, which alternately may be connected to an air supply, and which are, furthermore, alternately connectable to a source of heat coupled with a cold air supply. The alternating connection is of advantage inasmuch as the molecular screens must be relieved from time to time from accumulated materials. With at least two containers with molecular screen substances there is always one ready for operation. During the operation period of one of the molecular screen containers, the other container or containers may be regenerated. To this end, the respective molecular screen containers are mounted to allow air flow in opposite directions depending upon whether they are receiving hot air or fresh air. In principle, the undesirable constituents attending the air, which are not to participate in the respective reaction, may be purged from the molecular screen container. To this end, it is useful that each molecular screen container be provided with an escape valve for nitrogen, carbon dioxide and water.
In a metallurgical operation where the metallurgical furnace operates as consumer and heat accumulates at the same time, the apparatus as per invention is suitably formed so that at least three molecular screen containers are provided with alternate connections between each other while being coordinated with a metallurgical furnace and/or combustion shaft. Suitably, the heat source for the regeneration circuit of the molecular screen containers consists of a tube recuperator. For an extensive run of the processes in the molecular screen crystals, it is, furthermore, important that the molecular screen containers contain a heat-insulated steel jacket.
An example of the apparatus of the invention is shown in the drawing, wherein an example of the apparatus and the method of the invention is illustrated.
DESCRIPTION OF THE DRAWING
The single FIGURE illustrates an example of the invention by showing a schematic overall view of the form of a blast furnace plant which is not, or only partially, operated with pure oxygen from low temperature distillation.
DETAILED DESCRIPTION OF THE INVENTION
The example shows as the metallurgical furnace a blast furnace 1, which might for other applications consist of a cupola furnace, a shaft furnace for nonferrous metal extraction, an electro-furnace, a steel mill, a nonferrous metal converter, or a hot and/or glow furnace for metals. For the reduction process, i.e. for the crude iron extraction, besides the iron ores and additives charged from above through the charge lock 2, coke is required as the carbon carrier whose share must be kept down due to the high cost involved. The saving in coke is realized according to the invention by means of the air-oxygen supply 3. The blast-furnace gas 4 originating in the blast furnace 1 travels through the coarse dust removal plant 5, the fine dust removal plant 6, and then reaches the combustion shaft 7a of the blast heater 7 in a purified state. This oxidation process is also, in accordance with the invention supplied with oxygen-enriched air via the air-oxygen supply 3a, as the blast-furnace gas 4 loses heat on the way down to and through the dust removal plants 5 and 6 and also contains, besides, still combustible carbon monoxide and carbon dioxide gas, thus having a relatively low calorific value. The hot combustion gases originating in the combustion shaft 7a heat the latticed masonry 7b of the blast heater 7 and subsequently flow through the tube recuperator 8a representing a source of heat yet to be described. The combustion gases leaving the tube recuperator 8a are at a low temperature level, and are discharged to the open air via the gas conduit 9 and the stack 10.
For reasons of technological functioning, the containers 11, 12, and 13, made of heat-insulated steel sheets, are arranged before the blast furnace 1. Each of the containers holds molecular screen substances 14. In the example shown, these consist of zeolite substances forming crystal lattices of the calcium type with 5 angstrom pore size (1 angstrom=1×10 -7 mm). Each of the containers 11, 12, and 13 is connected to the blast furnace 1 via an air-oxygen conduit 11a, 12a, 13a, whereby valves 11b, 12b, and 13b open and close. Each of the containers 11, 12, 13 is further connected to an air supply 15, whereby the blower 16 feeds the air via the conduit 13c, with shutoff valve 13d to the container 13, via the conduit 11c with shutoff valve 11d to the container 11, and via the conduit 12c with shutoff valve 12d to the container 12.
Another fresh air supply 17 is provided before the source of heat 8, whereby the blower 18 feeds the air through the tube recuperator 8a, so that the air flows through conduit 19 preheated, and is fed by means of the valve 11e and the conduit 11f to the container 11, by means of the valve 12e and the conduit 12f to the container 12, and by means of the valve 13e and the conduit 13f to the container 13. In the direction of flow, there is an outlet valve 11g, 12g, 13g, at the outlet of the containers 11, 12, 13.
A flow direction shown by arrows 21 opposite to the operational flow direction shown by arrows 20 is produced by the blower 22 which delivers cold air, whereby the air flows via the valve 11h, the conduit 11i into the container 11, via the valve 12h, the conduit 12i into the container 12, and via the valve 13h and the conduit 13i into the container 13.
Furthermore, the blower 23 is cut into the air-oxygen supply 3 and also another mixed air supply 24. A similar blower 29 with a similar mixed air supply 25 is located in the air-oxygen supply 3a. Between the blower 23 and the blast furnace 1 a second blast heater 26 is inserted which operates alternately with the blast heater 7 heating the oxygen-enriched air before it is injected into the blast furnace 1.
Having described the individual components of the invention, the following describes the mode of operation of the apparatus for carrying out the method of the invention. With reference to the container 13, we proceed on the basis that it contains absorbing molecular screen substances 14. This means that the container 13 is able to absorb nitrogen, carbon dioxide and water vapor. In this phase, the valves 13e, 13g, and 13h are closed. Fresh air now flows via the blower 16 through the conduit 13c, via the opened valves 13d and 13b in operational flow direction 20 and the air in container 13 is relieved of carbon dioxide, atmospheric moisture and a large share of nitrogen. The air is thus enriched to 70 to 90% oxygen and regulated in the desired quantity before adding it to the intake air of the blower 23. The oxygen-enriched blast is heated in the blast heater 26 and fed to the blast furnace 1 via the air-oxygen supply 3. This mode of operation is carried out, depending on the capacity for adsorption of the molecular screen substances 14 individually and successively with the containers 11, 12 and 13.
The regeneration of a container no longer capable of adsorbing, such as the container 12, for example, is then carried out as follows: in the first stage of regeneration, air flows through the tubes of the source of heat 8, here being the tube recuperator 8a, in countercurrent to the hot waste gases from the combustion shaft 7a and/or the latticed masonry 7b. The air is delivered by the blower 18, which is heated in the tube recuperator 8a to a temperature of 200° to 300° C., and enters through the conduit 19 with opened valve 12e into the container 12 and escapes through the opened valve 12g to the outside. This prepares the molecular screen substances 14 for the subsequent adsorption of nitrogen. This first step in the method to prepare the crystals for the adsorption of nitrogen is also carried out for the containers 11 and 13, only at different times.
In the second stage of the regeneration, a container such as 11, heated in this manner, is now cooled to ambient temperature by means of blowing fresh air with the blower 22 with open valve 11h through the conduit 11i and the container 11. In this phase, valves 11b, 11d, and 11e are closed. The fresh air supplied leaves the container through the open valve 11g. After cooling the container 11 is again at disposal for oxygen-enrichment of the supplied air.
In a selected time period, the molecular screens may be thus heated in the container 12 to 200° to 300° C., while in the container 11 the molecular screen is cooled to ambient temperature, and in the container 13 oxygen-enriched air is provided by adsorption of the nitrogen as well as the carbon dioxide and the water vapor.
The valve 27 is open when the blast furnace 1 is operated with oxygen-enriched air. Otherwise the valve 27 is closed. The valve 28 is open when the blast heater 7 is operated during the heating period with oxygen-enriched air. Otherwise the valve 28 is closed. | Methods and apparatus are provided for regulating the percentage quantities of individual gases present in the combustion air supplied for reaction processes in metallurgy. This is achieved by utilizing molecular sieve absorption processes upon the intake air in a sequential manner to remove undesirable gases attendant with the intake air and to enhance and regulate the quantity of oxygen present. The arrangement may be operated in a continuous manner through the utilization of several molecular sieve devices wherein one of such devices may be purged for regeneration and later use by countercurrent flow of heated intake air which air has been heated by the heat derived from the metallurgical reaction process in the first place. | 2 |
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