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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional utility patent application claims the benefit of provisional patent application No. 61/403,782 and filing date Sep. 20, 2010. The application is a complete version of the provisional application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
FIELD OF THE INVENTION
[0003] The present invention relates to locating devices and cell phone devices. Specifically, it is a way to make a Child Emergency Locating Device (CELD) that is small, silent and easy to conceal on the clothing of a child/wearer. This device is not a cell phone, but it uses the operating and locating means which enable cell phones to be found on cell phone service. The device is used to find lost or abducted children.
BACKGROUND OF THE INVENTION
[0004] When I started on the present invention, I did not know that there were child locating devices on the market. After some research, I found that there were several. However, the devices as well as the service were expensive and complicated to purchase. Moreover, the companies were ones that neither I nor my acquaintances had heard of, which indicated that their marketing was not effective. For the above reasons, I concluded that these companies were not meeting their goal to help lost or abducted children, which is a tragedy.
[0005] There is a serious need for a solution to this problem. In the US, the increase in missing children since 1982 is 468%, so it's no surprise that the FBI receives over 2,000 missing child reports every day. Another child goes missing every 40 seconds, 24 hours a day, 365 days a year. The US Department of Justice and the World Almanac place the chances of any child being abducted at 1 in 42. However, about half of all children abducted are between 4 and 11 years old.
[0006] The cell phone industry is already involved in providing services to locate family members through their phones, In fact, in 2005, the FCC ruled that all cell phones transmit their phone numbers and location when dialing 911, which is why cell phone manufacturers have built GPS into phones. Unfortunately, if a family member were to be abducted, the first thing an abductor would take would be their cell phone. As previously mentioned, 50% of children abducted are between 4-11 years old and most in this age bracket don't carry cell phones; there are 25 million children in this age range in the US and ten times this amount worldwide, and there remains no way to protect them in an abduction situation.
[0007] An effective solution to the child abduction crisis is the present invention, which is a process (method) of making a CELD from cell phone parts, as well as using cell phone operating and locating technology and cell phone service. The demonstration phone mentioned in the step-by-step instructions in the Detailed Description of the Drawings below, and which I used for this invention is the Motorola V3m. Let it be clear that this phone was used for demonstration purposes only in the making of the demonstration CELD described below, and the present invention is in no way connected with Motorola, nor does the present invention require Motorola parts or a certain type or make of any brand of cell phone to be effective. Indeed, with the cell phone industry advancing at such an incredible pace, today's top selling cell phones will be outdated or obsolete tomorrow. The present invention utilizes these cell phones, recycling them to produce an effective and affordable child emergency location device.
[0008] Although there are other inventions for child emergency locating devices, the present invention is distinctly unique. During the patentability search for this invention, the following patent documents for child emergency location devices were discovered. U.S. Pat. Nos. 5,365,570; 7,308,246; 6,785,387; 7,251,471; Des. 491,157; 6,243,039; 6,636,732; 5,515,419; 7,251,458; 5,021,794. However, unlike the present invention, a) not one of these follows the present invention process (method) set forth in this application, and b) none operate on existing cell phone service.
[0009] Reference information and statistics used in this application came from the following documents:
“AT&T Family Map” at familymap.wireless.att.com “Child Abduction Statistics” by kidsafe.com “How Cellphones Work” by howstuffworks.com “How Location Tracking, Smartphones, GPS Phones and GPS Receivers Work” by howstuffworks.com “The Ultimate GPS Child Tracking Buyers Guide” by GPSmagazine.com “US Census on Children in the USA” at usgov.com/census
BRIEF SUMMARY OF THE INVENTION
[0016] The purpose of making the present invention is to provide mankind with a viable means of finding lost or abducted children in a quick and inexpensive manner so that all parents and guardians can afford to protect their children.
[0017] The present invention is the process of creating a locating device that is made from cell phone parts and technology and operates on cell phone service. Unlike a cell phone, which is always visible during use and produces sound, the present invention is small and easily concealed in the child/wearer's clothing in order to hide the fact that children/wearers have the device on them. Furthermore, the device emits no sounds so as to not give away its concealment on the child/wearer in an abduction situation.
[0018] In one embodiment, the present invention is a new process to make locating devices by recycling cell phones that are outdated, obsolete or deemed unmarketable by the cell phone industry. The parts and components are used to build the CELDs. This would result in fewer phones in landfills and offer a “green” solution to dealing with much of society's cell phone waste.
[0019] In another embodiment, the CELD components can be manufactured rather than gathered from recycled cell phones while still using the present invention's new process (method) to manufacture said locating devices.
[0020] Another embodiment describes the process of how a cell phone operates and is located through cell phone service, which is a new process (method) of locating lost/abducted children with the child emergency locating device such as those described in the previous embodiments (in 0011 and 0012).
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIGS. 1 , 1 a , 1 b , 1 c , and 1 d illustrate the several views of the present invention's case.
[0022] FIG. 2 illustrates a Motorola V3m cell phone that was used for the demonstration purposes only and Motorola is in no way connected to the present invention.
[0023] FIG. 3 illustrates the top flip cover of the cell phone.
[0024] FIG. 4 illustrates the electronic screen panel of the top flip of the cell phone.
[0025] FIG. 5 illustrates the battery compartment of the cell phone.
[0026] FIG. 6 illustrates the printed circuit board, or mainboard with the connecting ports.
[0027] FIG. 7 through 7 e illustrate the keypad/battery frame in different stages of modification.
[0028] FIG. 8 illustrates the ground for the mainboard.
[0029] FIG. 9 illustrates the keypad/circuit.
[0030] FIG. 10 illustrates the Gatwick Hinge flex connector that connected the top flip electronic screen panel to the mainboard.
[0031] FIG. 11 illustrates the Gatwick hinge flex connector needed for the present invention.
[0032] FIG. 12 illustrates the battery used.
[0033] FIG. 13 illustrates the keypad activation buttons that get removed from the keypad/circuit in the present invention.
[0034] FIG. 14 illustrates the battery/mainboard adapter for the present invention.
[0035] FIG. 15 illustrates the components of the locating device in the order they will be configured in.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The present invention is detailed in one or more of the embodiments in the following description with reference to the figures, in which like numerals represent the same or similar elements. While the invention is described in terms of the best mode for achieving the invention objectives, it will be appreciated by those skilled in the art that it is intended to cover alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims and their equivalents as supported by the following disclosure and drawings.
[0037] FIG. 1 is the top view of the present invention and is intended to be the front page of the patent application publication and patent as the illustration of the invention.
[0038] FIG. 2 is a Motorola V3m Cell phone that was used for demonstration purposes only. The present invention is not connected to and is in no way implied that it has any ties to Motorola. With the variety of cell phones on the market, the modifications will vary, but will stay within the spirit and scope of the present invention.
[0039] In the demonstration cell phone used, all of the electronic components of the cell phone were used except the camera, the speakers, and microphone, which don't not change the circuitry. With no modifications to the circuitry, the costs are kept to a minimum.
[0040] Step 1: Before the cell phone is taken apart, with the battery in and charged, turn the phone on and make sure the locating capabilities are also on. When on, there will be a locator icon that appears on the top of the screen.
[0041] Step 2: Remove the speakers and microphone. However, they could be left in if the master volume can be turned off or permanently disengaged. This step is vital because it is imperative that the device make no sound so as to not give away its concealment in an abduction or emergency situation.
[0042] Step 3: Set the number 2 button on the speed dial to 911. With the one touch option, the child/wearer will be able to press and hold the button for one second and not have to press the send button. This button is used in an emergency situation but only if the wearer can activate it without giving away the concealment of the device.
[0043] Step 4: Remove the cover that is shown in FIG. 3 to gain access to the electronic screen panel FIG. 4 . Do not discard the cover in FIG. 3 as it will be used as a ground plate later in the application. As an alternative, a thin metal ground plate could be manufactured for this purpose as well as for FIGS. 7 d and 7 e.
[0044] Step 5: Turn the cell phone over, back side up, and remove and discard the battery cover in FIG. 12 . Keep the battery. Remove the two screws from the battery compartment in FIG. 5 .
[0045] Step 6: Turn the cell phone back over, top side up, and remove the keypad function cover and peel back the glued in the keypad/circuit in FIG. 9 removing it from the keyboard circuit frame, FIG. 7 (so that the frame in FIG. 7 can be cut later) but leaving it connected to the mainboard port, FIG. 6 .
[0046] Step 7: Disconnect the Gatwick Hinge flex connector FIG. 10 from the electronic screen panel FIG. 4 and remove screen panel FIG. 4 . Save the connector in FIG. 10 so you can use the part number on the connector FIG. 10 and contact a Gatwick representative to make the new connector FIG. 11 to fit the application, in Step 10 in (0042).
[0047] Step 8: Cut the keypad frame FIG. 7 on the cut lines shown in the illustration. Remove the flip and hinge and discard. The unit will look like FIG. 7 b from the bottom.
[0048] Step 9: Turn the unit back over and remove the top cover FIG. 7 c , which will still be connected to FIG. 7 d by two screws. Remove the screws and cut FIG. 7 on the cut lines in the illustration so it looks like FIG. 7 d and FIG. 7 e for the purpose of making the mainboard frame, FIG. 7 d and the battery keypad plate, FIG. 7 e.
[0049] Step 10: Access and remove the Gatwick Hinge flex connector in FIG. 10 and the keypad/circuit connector FIG. 9 from the mainboard ports FIG. 6 . Then, put the Gatwick Hinge flex connector FIG. 11 into the mainboard port FIG. 6 and the flexible keypad/circuit FIG. 9 .
[0050] Step 11: To modify the keypad/circuit, peel open the protective cover and remove all the keypad activation buttons FIG. 13 except the power button, which has a red circle on the white protective cover, and the number 2 button, which is used for the one touch speed dial function. The reason the keypad activation buttons FIG. 13 are removed is so they don't accidentally get pushed and cause a function which might interfere with the necessary functions. As an alternative, FIG. 9 , a flexible keypad/circuit, could be manufactured so the connector is in the center of the side and since only two functions are used for the present invention—on/off and Emergency 911 on the number 2 on speed dial—the keypad/circuit can be made much smaller for the present invention.
[0051] Step 12: Next, seal the protective cover back in place and reconnect to the mainboard port FIG. 6 .
[0052] Step 13: Make a small cut in the plastic above the battery connector on the bottom of the mainboard as shown in FIG. 5 . and reassemble in the reverse order, making sure not to forget the ground for the mainboard FIG. 8 and the ground straps depicted in FIG. 15 .
[0053] Step 14: Put foam with adhesive spacers as depicted in FIG. 15 on all four corners of the new bottom case FIG. 1 c , which has a clear window on the bottom so as to be able to see the charge function indicator and light to know if the device is on or off on the screen panel FIG. 4 .
[0054] Step 15: Place the screen panel, FIG. 4 , inside the bottom case FIG. 1 c big screen down and set the mainboard FIG. 6 in front, upside down. Hook Gatwick Hinge flex connector FIG. 11 to the screen panel port in FIG. 4 .
[0055] Step 16: Cut the top flip cover, FIG. 3 , on the cut lines shown in the illustration and glue it in place on the screen panel FIG. 4 in its original position. Now adhere the foam with adhesive spacers on the four corners of the cover FIG. 3 and flip the mainboard FIG. 6 on top of the cover FIG. 3 .
[0056] Step 17: FIG. 14 is a battery/mainboard adapter that is a plastic connector. Snap it on over the back edge of the battery FIG. 12 and the battery connector depicted in FIG. 6 . The adapter has two copper strips molded in the plastic and rolled on each end to make the connection with battery FIG. 12 and the mainboard FIG. 6 . The length of the adapter FIG. 14 is ⅛″ longer than the width of the battery FIG. 12 and the copper strips are 3/16″ so when snapped in place, the strips with the rolled ends apply a constant pressure to make a solid connection. On the back of the adapter, there is a rubber pad glued on so that when the top cover FIG. 1 b makes contact with the adapter, the connector cannot come loose, which adds a safety feature.
[0057] Step 18: Put the battery FIG. 12 on the battery/keypad frame FIG. 7 d , and make sure the contact points are aligned. Then, put the adapter FIG. 14 on as described in Step 17. Adhere four spacers with foam adhesive on the corners of the battery FIG. 12 and put the battery/keypad plate FIG. 7 e on top with the battery side down. Glue the keypad/circuit FIG. 9 to the top of the battery/keypad plate FIG. 7 e as depicted in FIG. 15 . Be sure to fold as depicted in FIG. 15 OR as the alternate method explained in Step 11.
[0058] Step 19: Now put the top case FIG. 1 b onto the bottom case FIG. 1 c , which will now look like FIGS. 1 and 1 a and put the screws in the corners. The top case FIG. 1 has two holes, ⅜″ over the Power and the Emergency 911 buttons, which are inset. The holes for the buttons have a rubber film glued on to seal them. The charging port is on the side of the bottom case FIG. 1 d.
[0059] This should complete the steps necessary for making the CELD following the process (method) of the present invention. This process began with a cell phone and has resulted in a CELD made from cell phone components.
[0060] The present invention, can be made of cell phone components or equivalent. Or it can be manufactured using the necessary components and technology and by making a small case to house said components. By doing so it stays within the spirit and scope of the present invention. The components are a small printed circuit board that contains analog to digital and digital to analog conversion chips or their equivalent, a digital signal processor for the transmission mode technology for the service provider, the microprocessor, and the ROM or flash memory or an equivalent. The microprocessor handles the functions for the keypad and display along with the command and control signals with the base station. The ROM and flash memory chips store the operating system features. A radio frequency and power section handles the power management and charging and the radio frequency amplifiers for the antenna to get a signal, along with these subcomponents or their equivalents. The cell phone codes (ESN), (MIN), and (SID), are all used and on some units a SIM card is used or an equivalent. There is also a backup battery for the internal clock. As well there are subcomponents capable of receiving GPS signals in order to calculate the coordinate address and/or transmit the address to a receiving device. A GPS antenna and a lithium-ion battery or an equivalent will be used as will such mechanisms as an LED or similar type of light indicator to indicate that the device is on and functioning properly if the screen panel is not used.
[0061] The following embodiment is a detailed description of the process (method) of the present invention and how the present invention uses cell phone provider service and locating technology. In order to understand how the present invention works, and the detailed description of the process, one needs to understand the working means of cell phones and cell phone service. This is because cell phone service is used in the present invention, but for a different purpose. For this reason, the operating and locating means and technology will be thoroughly explained in a detailed description below.
[0062] Transmission mode technology is the way a cell phone service provider sends the signal so more cell phones can operate in a cell. TDMA stands for Time Division Multiple Access. Time is the access method. Division means splitting the call according to the access method. Multiple Access means more than one user can utilize each cell. TDMA assigns each call a certain portion of time on a designated frequency.
[0063] The cell phone codes are the identification numbers each cell phone has. The Electronic Serial Number (ESN) is the Federal identification. The Mobile Identification Number (MIN) is the 10 digit number of the cell phone used to identify and locate the cell phone. In tandem with the MIN, The System ID Code (SID) is the number that identifies the service provider. It is also used in the identification and locating of the cell phone.
[0064] Each cell phone service provider has a Mobile Telephone Switching Office (MTSO), which handles all the calls through an incredible computer system that connects calls and keeps track of phones' locations in a database. Therefore, the MTSO knows the cell your phone is in when you get a call.
[0065] When a call is made, the phone sends the MIN along with the SID on the service provider's radio frequency bands using the service provider's transmission mode technology. The MIN and SID are sent to the MTSO of the service provider along with a registration request to locate the phone in the MTSO's database. Therefore, the MTSO knows which cell the phone is in to contact. The MTSO picks a frequency pair in the service provider's designated frequencies that the phone will use in that cell to take the call. The MTSO communicates with the phone over the control channel which tells it which frequencies to use and once the phone and the tower switch on those frequencies, the call is connected.
[0066] The Global Positioning System (GPS) is a system of 27 earth-orbiting satellites in which 24 are in operation at all times. The satellites circle the globe 2 times a day. The GPS receiver's job is to locate 4 or more of these satellites and figure out the distance to each and deduce their location. This operation is called trilateration. To make this calculation, the GPS receivers need to know the location of at least 3 satellites and the distance between the receiver and each of the satellites. The GPS receiver figures this out by analyzing high frequency-low power radio signals from the GPS satellite. The satellite and receiver both send a pseudo-random code (PRC). When the PRC reaches the receiver, the transmission pattern will lag behind the receiver's pattern. The length of the delay is equal to the signal's travel time. The receiver multiplies this time by the speed of light to determine how far the signal traveled. The receiver and the satellite both use clocks that can be synchronized down to the nanosecond. The GPS receiver stores and almanac that tells it where every satellite should be at any given time. The most essential function of the GPS receiver is to pick up the transmissions of at least 4 satellites and combine the information in those transmissions with the information in the almanac to figure the receivers position on earth.
[0067] In 2005, the Federal Communications Commission (FCC) required all cell phone manufacturers and service providers to have Phase II of the Emergency 911 (E911) system be in place. Phase II requires carriers to place GPS receivers in cell phones in order to deliver specific longitude and latitude information
[0068] Because of this requirement, when a phone calls E911, the call is automatically forwarded to a Public Safety Answering Point (PSAP), which is an E911 call center. When answered, the Emergency 911 operator is provided with Automatic Location Information (ALI) pinpointing the exact location of the call.
[0069] In the present invention, this is used if the CELD Emergency 911 button is activated by the child/wearer. Or if the parent/concerned party knows the child/wearer is missing or abducted, and gives the E911 operator the contact number of the CELD and information that child/wearer is wearing the CELD.
[0070] When E911 calls the CELD's contact number, the Phase II system is used in reverse, so when contact is made to the GELD by E911, the operator knows the location of the child/wearer immediately and it is shown by the E911 operator's computer, which is linked to the ALI database, which stores address data and other information.
[0071] Another way to track a cell phone is to download the software for GPS tracking into the cell phone from sites such as Mologogo.com. This will enable parents/concerned parties to access the site which can be an APP on a smartphone to check the location of the cell phone, or in the present invention, the CELD.
[0072] In the present invention, this technology is used in the CELD to have several ways of checking on the child/wearer, which could save the child/wearer in an emergency/abduction situation. First, the parent can check to see where the child/wearer is, and if he/she is not in an appropriate location can go to the exact location the child/wearer is and determine if an abduction/loss has occurred and decide what to do about it.
[0073] Second, the parent/concerned party can contact E911 if the child/wearer appears to have been abducted/lost and law enforcement can be dispatched for a rescue with accurate information about the child/wearer's location.
[0074] Although the primary use of the present invention's CELD device is to locate lost or abducted children, it has other uses as well. The device could be placed on wearers other than children whose whereabouts need to be monitored. It could also be placed on pets. Or it could be placed on or inside valuable objects or possessions that are considered likely to be stolen in order to recover them from theft.
[0075] While one or more embodiment of the present invention has been illustrated in detail, the skilled artisan will appreciate that modifications and adaptations to those embodiments may be made without departing from the scope and spirit of the present invention as set forth in the following claims. | The present invention is a new process (method) of making, manufacturing, operating, locating, and providing service for a Child Emergency Locating Device (CELD). The invention uses the resources of technology the cell phone industry uses to operate and locate cell phones. This technology is used to provide the operational and locating capabilities in the invention. It's used in a new method that is different from cell phones. The invention is made small and is used in a strategically concealed and silent manner so when in use, no one knows the child is using the device. The purpose of the invention is to provide mankind the best means of locating lost/abducted children quickly and inexpensively. Since the cell phone industry has such vast resources to locate their phones, they can make the CELDs inexpensively. The savings means parents can afford to protect their children should they become lost or abducted. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to the fields of drilling and producing hydrocarbon wells, and to the measuring of downhole formation characteristics, and to drill string telemetry for bidirectional communication of measurement and control information between dowhhole and surface equipment, and to a surface communication system for bidirectional communication between drill string telemetry and a surface processor.
BACKGROUND OF THE INVENTION
[0002] The advent of measurement while drilling (MWD) and logging while drilling (LWD), as well as development of surface control of special drilling processes, such as directional drilling, have been important advances in the art of drilling and producing hydrocarbon wells. These processes require communication, in both directions, between the surface and the downhole measuring and drilling equipment. At present, mud pulse telemetry is the only technique in widespread commercial use for communication while drilling, between downhole equipment and the surface. [Unless otherwise indicated, references, throughout, to “while drilling,” or the like, are intended to mean that the drill string is in the borehole or partially in the borehole as part of an overall drilling operation including drilling, pausing, and or tripping, and not necessarily that a drill bit is rotating.] In mud pulse telemetry, data is transmitted as pressure pulses in the drilling fluid. However, mud pulse telemetry has well known limitations, including relatively slow communication, low data rates, and marginal reliability. Current mud pulse technology is capable of sending MWD/LWD data at only about 12 bits per second. In many cases, this rate is insufficient to send all the data that is gathered by an LWD tool string, or is limiting on the configuration of a desired tool string. Also, mud pulse technology does not work well in extended reach boreholes. Signaling from uphole to downhole, by regulating mud pump flow, in order to control processes such as directional drilling and tool functions, is also slow, and has a very low information rate. Also, under certain circumstances, for example underbalanced drilling employing gases or foamed drilling fluid, current mud pulse telemetry cannot function.
[0003] There have been various attempts over the years to develop alternatives to mud pulse telemetry that are faster, have higher data rates, and do not require the presence of a particular type of drilling fluid. For example, acoustic telemetry has been proposed, which transmits acoustic waves through the drill string. Data rates are estimated to be about an order of magnitude higher than mud pulse telemetry, but still limiting, and noise is a problem. Acoustic telemetry has not yet become commercially available. Another example is electromagnetic telemetry through the earth. This technique is considered to have limited range, depends on characteristics, especially resistivity, of the formations surrounding the borehole, and also has limited data rates.
[0004] The placement of wires in drill pipes for carrying signals has long been proposed. Some early approaches to a wired drill string are disclosed in: U.S. Pat. Nos. 4,126,848, 3,957,118 and 3,807,502, and the publication “Four Different Systems Used for MWD,” W. J. McDonald, The Oil and Gas Journal, pages 115-124, Apr. 3,1978.
[0005] The idea of using inductive couplers, such as at the pipe joints, has also been proposed. The following disclose use of inductive couplers in a drill string: U.S. Pat. No. 4,605,268, Russian Federation published patent application 2140527, filed Dec. 18, 1997, Russian Federation published patent application 2040691, filed Feb. 14, 1992, and WO Publication 90/14497A2, Also see: U.S. Pat. Nos. 5,052,941, 4,806,928, 4,901,069, 5,531,592, 5,278,550, and 5,971,072.
[0006] The U.S. Pat. No. 6,641,434 describes a wired drill pipe joint that was a significant advance in the wired drill pipe art for reliably transmitting measurement data in high-data rates, bidirectionally, between a surface station and locations in the borehole. The '434 Patent discloses a low-loss wired pipe joint in which conductive layers reduce signal energy losses over the length of the drill string by reducing resistive losses and flux losses at each inductive coupler. The wired pipe joint is robust in that it remains operational in the presence of gaps in the conductive layer. The performance attendant these and other advances in the drill string telemetry art provides opportunity for innovation where prior shortcomings of range, speed, and data rate have previously been limiting on system performance.
[0007] When a wired drill pipe system is used, it is necessary to have a communication link between the topmost wired drill pipe and a surface processor (which, inter alia, typically performs one or more of the following functions: receiving and/or sending data, logging information, and/or control information to and/or from downhole and surface equipment, performing computations and analyses, and communicating with operators and with remote locations). Various approaches have been suggested, some of which are summarized in U.S. Pat. No. 7,040,415, including use of a slip ring device, and use of rotary electric couplings based on induction or so-called transformer action. A slip ring (also known as brush contact surfaces) is a well known electrical connector designed to carry current or signals from a stationary wire into a rotating device. Typically, it is comprised of a stationary graphite or metal contact (a brush) carried in a non-rotating component which rubs on the outside diameter of a rotating metal ring (e.g., carried on the upper portion of a kelly joint). As the metal ring turns, the electrical current or signal is conducted through the stationary brush to the metal ring making the connection.
[0008] Rotary electrical couplings based on induction (transformer action), known, as rotary transformers, provide an alternative to slip rings and contact brushes based upon conduction between rotating and stationary circuitry, so no direct contact is necessary. The transformer windings comprise a stationary coil and a rotating coil, both concentric with the axis of rotation. Either coil can serve as the primary winding with the other serving as the secondary winding.
[0009] These types of approaches for surface communication have certain limitations and drawbacks attendant the use of complex electromechanical structures, and it is among the objects of the present invention to provide a system for bidirectional communication of signals between the topmost wired drill pipe and a surface processor, with improved efficiency and reliability.
[0010] A further aspect of the drilling and measurement art that is addressed herein relates to safety at the wellsite, and the problem of powering a rotating assembly, at a location that may be classified as a hazardous area, without the use of power carrying wires. Existing techniques have certain limitations. For example, mud turbines, which are powered by the moving drilling fluid, are relatively complex and expensive to build and to maintain. The use of ordinary batteries can be problematic when the drilling operation must be interrupted for battery replacement. It is accordingly among the further objects hereof to provide a safe, efficient, and reliable source of electric power in conjunction with the rotating drill string.
SUMMARY OF THE INVENTION
[0011] It has been recognized that wireless surface communication could be used for communication between a drill string telemetry system and a surface processor (see, for example, U.S. Pat. No. 7,040,415). However, the manner in which this can be advantageously achieved has not heretofore been realized.
[0012] A form of the invention is directed for use in an operation of drilling an earth borehole using: a drilling rig, a drill string having its generally upper end mechanically coupleable with and suspendable from the drilling rig, and downhole equipment on the drill string. A system is provided for bidirectional communication between the downhole equipment and a processor subsystem at the earth's surface, comprising: a section of wired drill pipes comprising at least the upper portion of the string of drill pipes, and forming at least a portion of a bidirectional communication link between the downhole equipment and the top of the string of drill pipes; a drive string portion of the drill string, mechanically coupleable with the topmost wired drill pipe; a drive mechanism mechanically coupleable with said drive string portion, for rotating the drill string; a first wireless transceiver subsystem mounted on the drive string portion of the drill string, for rotation in conjunction with the drill string; a cable, electrically coupled between the top joint of the topmost wired drill pipe and the first transceiver subsystem; and a second wireless transceiver subsystem coupled with the uphole processor subsystem, the second wireless transceiver subsystem communicating bidirectionally with the first wireless transceiver subsystem. [As used herein, the “drive string” portion of the drill string comprises all subs, kelly, top drive, or the like that are connected above the topmost drill pipe of the drill string. In illustrated embodiments hereof, the topmost drill pipe is also the topmost wired drill pipe of the drill string.]
[0013] Although, in some circumstances, a single wire could be used, in a preferred embodiment of the invention, the cable comprises a plurality of wires, such as a wire pair. In a form of this embodiment, the section of wired drill pipe has inductive couplers at the joints of each pipe, and the cable is electrically coupled to the top joint of said topmost wired drill pipe by an inductive coupling. Also, in a preferred embodiment of the invention, the first transceiver subsystem includes a first antenna subsystem, and the second transceiver subsystem includes a second antenna subsystem. Each of the antenna subsystems can comprise a plurality of antennas. The antennas can be at different azimuthal positions with respect to the drive string.
[0014] In one embodiment of the invention, the drive string portion of the drill string comprises a kelly, and in a form of this embodiment, the drive string portion of the drill string further comprises a saver sub between the kelly and the topmost wired drill pipe. In another embodiment of the invention, the drive string portion of the drill string comprises a top drive sub, and the drive mechanism comprises a top drive that engages the top drive sub. In a form of this embodiment, the drive string portion of the drill string further comprises a saver sub between the top drive sub and said topmost wired drill pipe.
[0015] In an embodiment of the invention, an antenna of the first antenna subsystem and the first wireless transceiver subsystem are mounted at substantially the same position on the drive string portion of the drill string, and in another embodiment, an antenna of the first antenna subsystem and at least part of said first wireless transceiver subsystem are mounted at respectively different positions on the drive string portion of the drill string.
[0016] In accordance with a further form of the invention, an electric generator is provided for generating electric power for use by the first transceiver subsystem, the electric generator including a rotating generator component that is mounted on the drive string portion of the drill string and a stationary generator component that is mounted on a stationary portion of the drilling rig. In an embodiment of this form of the invention, the stationary generator component comprises a ring of magnets, and the rotating generator component comprises at least one stator coil. The rotating generator component and stationary generator component are disposed in close proximity such that magnetic flux from the ring of magnets crosses the at least one stator coil.
[0017] Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a diagram, partially in schematic form and partially in block form, of a system in which embodiments of the invention can be employed.
[0019] FIG. 2 is a diagram, partially in block form, of an existing scheme for bidirectional wireless communication between a surface communication sub and a surface computer.
[0020] FIG. 3 is a cross-sectional schematic diagram, partially in block form, of a bidirectional surface communication subsystem in accordance with an embodiment of the invention.
[0021] FIG. 4 is a cross-sectional schematic diagram, partially in block form, of a bidirectional surface communication subsystem in accordance with another embodiment of the invention.
[0022] FIG. 5 is a cross-sectional schematic diagram, partially in block form, of a bidirectional surface communication subsystem in accordance with a further embodiment of the invention.
[0023] FIG. 6 is a cross-sectional schematic diagram, partially in block form, of a bidirectional surface communication subsystem in accordance with another embodiment of the invention.
[0024] FIG. 7 is a diagram of an electric power generating subsystem in accordance with an embodiment of the invention.
[0025] FIG. 8 is an exploded diagram of the FIG. 8 electric power generating subsystem in accordance with an embodiment of the invention.
[0026] FIG. 9 is a schematic diagram, partially in block form, of the electric power generating subsystem of FIGS. 7 and 8 , in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0027] FIG. 1 illustrates a wellsite system in which the present invention can be employed. The wellsite can be onshore or offshore. In this exemplary system, a borehole 11 is formed in subsurface formations by rotary drilling in a manner that is well known. The drilling could alternatively be mud-motor based directional drilling, as is also well known.
[0028] A drill string 12 is suspended within the borehole 11 and has a bottom hole assembly 100 which includes a drill bit 105 at its lower end. The surface system includes platform and derrick assembly 10 positioned over the borehole 11 , the assembly 10 including a rotary table 16 , kelly 17 , hook 18 and rotary swivel 19 . The drill string 12 is rotated by the rotary table 16 , energized by means not shown, which engages the kelly 17 at the upper end of the drill string. The drill string 12 is suspended from a hook 18 , attached to a traveling block (also not shown), through the kelly 17 and a rotary swivel 19 which permits rotation of the drill string relative to the hook. As is well known, a top drive system could alternatively be used.
[0029] In the example of this embodiment, the surface system further includes drilling fluid or mud 26 stored in a pit 27 formed at the well site. A pump 29 delivers the drilling fluid 26 to the interior of the drill string 12 via a port in the swivel 19 , causing the drilling fluid to flow downwardly through the drill string 12 as indicated by the directional arrow 8 . The drilling fluid exits the drill string 12 via ports in the drill bit 105 , and then circulates upwardly through the annulus region between the outside of the drill string and the wall of the borehole, as indicated by the directional arrows 9 . In this well known manner, the drilling fluid lubricates the drill bit 15 and carries formation cuttings up to the surface as it is returned to the pit 27 for recirculation.
[0030] As is known in the art, sensors may be provided about the wellsite to collect data, preferably in real time, concerning the operation of the wellsite, as well as conditions at the wellsite. For example, such surface sensors may be provided to measure parameters such as standpipe pressure, hookload, depth, surface torque, rotary rpm, among others.
[0031] The bottom hole assembly 100 of the illustrated embodiment includes an interface sub 110 , a logging-while-drilling (LWD) module 120 , a measuring-while-drilling (MWD) module 130 , a roto-steerable system and motor 150 for directional drilling, and drill bit 105 .
[0032] The LWD module 120 is housed in a special type of drill collar, as is known in the art, and can contain one or a plurality of known types of logging tools. (See also the above-referenced copending U.S. Pat. Application Ser. No. ______[file 19.DST], filed of even date herewith and assigned to the same assignee as the present application.) The LWD module includes capabilities for measuring, processing, and storing information, as well as for communicating with the surface equipment. The LWD module can include, for example, one or more of the following types of logging devices that measure formation characteristics: a resistivity measuring device, a directional resistivity measuring device, a sonic measuring device, a nuclear measuring device, a nuclear magnetic resonance measuring device, a pressure measuring device, a seismic measuring device, an imaging device, and a formation sampling device.
[0033] The MWD module 130 is also housed in a special type of drill collar, as is known in the art, and can contain one or more devices for measuring characteristics of the drill string and drill bit. The MWD tool can further include an apparatus (not shown) for generating electrical power to the downhole system. This may typically include a mud turbine generator powered by the flow of the drilling fluid, although other power and/or battery systems may be employed. The MWD module can include, for example, one or more of the following types of measuring devices: a weight-on-bit measuring device, a torque measuring device, a vibration measuring device, a shock measuring device, a stick slip measuring device, a direction measuring device, and an inclination measuring device.
[0034] In the system of FIG. 1 , a drill string telemetry system is employed which, in the illustrated embodiment, comprises a system of inductively coupled wired drill pipes 180 that extend from a surface sub 185 to an interface sub 110 in the bottom hole assembly. Depending on factors including the length of the drill string, relay subs or repeaters can be provided at intervals in the string of wired drill pipes, an example being represented at 182 . The relay subs, which can also be provided with sensors, are further described in the above-referenced copending U.S. patent application Ser. No.______ (file 19.0410/11), filed of even date herewith, and assigned to the same assignee as the present Application.
[0035] The interface sub 1 10 provides an interface between the communications circuitry of the LWD and MWD modules and the drill string telemetry system which, in this embodiment, comprises wired drill pipes with inductive couplers. The interface sub 110 , which can also be provided with sensors, is described further in the above-referenced copending U.S. patent application Ser. No. ______ (file 19.0410/11).
[0036] At the top of the wired drill string, a further interface sub 185 , can be provided, and serves, in this case, as a surface sub. As described, for example, in the U.S. Pat. No. 7,040,415, the wired drill pipes can be coupled with electronics subsystem that rotates with kelly 17 and include a transceiver and antenna that communicate bidirectionally with antenna and transceiver of logging and control unit 4 which, in the present embodiment, embodies the uphole processor subsystem. In an embodiment hereof, the interface sub 185 can comprise a wired saver sub (to be described), and the electronics of a transceiver 30 is mounted on the kelly, or other part of the drive string, as will be described. In FIG. 1 , a communication link 175 is schematically depicted between the electronics subsystem 30 and antenna of the logging and control unit 4 . Accordingly, the configuration of FIG. 1 provides a communication link from the logging and control unit 4 through communication link 175 , to surface sub 185 , through the wired drill pipe telemetry system, to downhole interface 110 and the components of the bottom hole assembly and, also, the reverse thereof, for bidirectional operation.
[0037] As described in the referenced copending U.S. Application Ser. No. ______(file 19.0410/11), while only one logging and control unit 4 at one wellsite is shown, one or more surface units across one or more wellsites may be provided. The surface units may be linked to one or more surface interfaces using a wired or wireless connection via one or more communication lines. The communication topology between the surface interface and the surface system can be point-to-point, point-to-multipoint or multipoint-to-point. The wired connection includes the use of any type of cables (wires using any type of protocols (serial, Ethernet, etc.) and optical fibers. The wireless technology can be any kind of standard wireless communication technology, such as IEEE 802.11 specification, Bluetooth, zigbee or any non-standard RF or optical communication technology using any kind of modulation scheme, such as FM, AM, PM, FSK, QAM, DMT, OFDM, etc. in combination with any kind of data multiplexing technologies such as TDMA, FDMA, CDMA, etc.
[0038] FIG. 2 shows a block diagram of a type of wireless transceiver subsystem electronics that can be used for the electronics 30 of FIG. 1 . Reference can also be made to U.S. Patent No. 7,040,415. A signal from/to the inductive coupler of the top joint of topmost wired drill pipe is coupled with a WDP modem. The WDP modem 221 is, in turn, coupled with wireless modem 231 . A battery 250 and power supply 255 are also provided to power the modems. Other power generating means, which may be more preferred, are described hereinbelow. The logging and control unit also has, for example, a transceiver with a wireless modem.
[0039] The WDP surface modem is adapted to communicate with one or more modems, repeaters, or other interfaces in the downhole tool via the wired drill pipe telemetry system. Preferably, the modems provide two way communications. The modem communicates with another modem or repeater or other sub located in the downhole tool. Any kind of digital and analog modulation scheme may be used, such as biphase, frequency shift keying (FSK), quadrature phase shift-keying (QPSK), Quadrature Amplitude Modulation (QAM), discrete multi tone (DMT), etc. These schemes may be used in combination with any kind of data multiplexing technologies such as Time Division Multiplexing (TDM), Frequency Division Multiplexing (FDM), etc. The modem may include functionality for drill pipe diagnostics and downhole tool diagnostics.
[0040] Although a single surface processor is depicted, it will be understood that plural surface processors, in the form of logging/control units or other forms, can be provided at diverse locations, with wired and/or wireless transceiver connection, it being further understood that any of the modes of communication mentioned herein can be utilized, and that compression and/or encryption of data can also be utilized. Each unit can have its own antenna(s) and/or shared antennas. The antennas can be provided at optimum locations and with optimum orientations to maximize signal strength and quality. Communication to/from remote locations, including communication via satellite, can also be implemented.
[0041] FIG. 3 shows an embodiment of the invention in which a special saver sub 340 is provided between the kelly 350 and the topmost wired drill pipe 181 . The saver sub 340 has an inductive coupler 341 at its lower end that electrically couples with the inductive coupler 189 of the topmost wired drill pipe. A cable 315 , which is connected to inductive coupler 341 , exits saver sub 340 through a sealed port, and runs externally of kelly 350 to the transceiver subsystem 330 , which includes antenna(s) 335 . At the exit position of the cable on the saver sub 340 , a connector 346 can be provided. The cable running along the outside of kelly 350 can be sealed in a groove in the kelly and, for example, be protected by an epoxy or peek materials. A further connector can be provided at the transceiver subsystem electronics. The cable 315 is provided with at least a wire pair.
[0042] In the embodiment of FIG. 4 , the saver sub 440 and kelly 450 have internal electrical cabling, and the drive string includes a special top sub 470 , above kelly 450 , on which the wireless transceiver subsystem 430 is mounted. In a form of this embodiment, the saver sub 440 and the kelly 450 each have inductive couplers at both ends, with a cable (again, and throughout, preferably including at least a wire pair), designated 441 and 451 , respectively, running between the ends of each. It will be understood that other types of coupling at the joints could alternatively be used, here, and in other embodiments. The special top sub 470 , which is mounted above kelly 450 , rotates with the drill string. In this example, the top sub 470 has an inductive coupler at its lower end, and an internal cable 471 that couples with the wireless transceiver subsystem 430 .
[0043] In the examples of the embodiments of FIGS. 3 and 4 , the wireless transceiver subsystem electronics, as well as the associated antenna(s), are in one general location on the drive string portion of the drill string, but, it will be understood that parts or all of the electronics, with contiguous or separated antenna(s), can be at a plurality of locations. For example, in the embodiment of FIG. 5 , a special surface sub 590 is employed between saver sub 440 and kelly 550 . In this example, the saver sub 440 has inductive couplers at both ends and internal wiring (as in FIG. 4 ), and the special surface sub 590 has an inductive coupler at its lower end, with internal wiring, represented at 591 , running to the electronics 530 . In this example, the wireless transceiver subsystem electronics 530 , or at least a portion thereof, are mounted internally in the special surface sub 590 . An example of internal packaging of electronics in a sub is shown in the above referenced U.S. patent application Ser. No. ______(file 19.0410/11), filed of even date herewith, and assigned to the same assignee as the present application. In the present embodiment, the antenna(s) 535 (and, if desired, a portion of the associated electronics) are mounted on the kelly 550 and coupled with the rest of the electronics 530 via cable 531 which, in this embodiment, exits the special sub 590 at a sealed port or connector, and can be carried in a groove in the kelly in the same manner as was described above. If desired, the bidirectional link between electronics 530 and antenna(s)/electronics 535 can carry a digitized signal. In this embodiment, it will be understood that the sub 590 and a portion of kelly 550 may be under the level of the mud at least some of the time, but the antenna(s)/electronics 535 will be above the mud level. FIG. 5 shows plural antennas that rotate with the kelly, as it will be understood that azimuthally redundant antennas on the rotating drive string will minimize dead spots or weak spots of the wireless link. The same is applicable to the other embodiments. Also, plural antennas of the wireless transceiver subsystem can be advantageous.
[0044] FIG. 6 shows an embodiment of the invention for use in conjunction with a top drive 605 . In the FIG. 6 example, a saver sub 440 , coupled with the topmost wired drill pipe 181 , has inductive couplers at both ends, connected by cable 441 , as in the embodiments of FIGS. 4 and 5 . A top drive sub 690 is provided between the top drive 605 and saver sub 440 , and the wireless transceiver subsystem 630 of this embodiment is mounted on the top drive sub 690 . Also in this embodiment, the top drive sub has an inductive coupler at its lower end, and internal cable 691 that runs from the inductive coupler to the subsystem 630 . However, it will be understood that an external cable could be used, as in the FIG. 3 embodiment, or that the electronics and/or antenna(s) could be split, as in the FIG. 5 embodiment.
[0045] FIGS. 7-9 show an embodiment of a form of the invention wherein a safe and reliable source of power is provided on rotational components at the well site, which can be used, for example, to power the wireless transceiver subsystem 30 and/or for other applications. In this embodiment, a magnet ring 710 operates as a stationary generator component and is mounted on a stationary portion of the drilling rig represented at 705 , for example a mounting adjacent a kelly or a top drive. A surface sub 720 (which may, for example, be one of the surface subs of FIGS. 3-6 ) includes a stator 725 ( FIGS. 8 and 9 ), rectifier 726 , charging circuit 727 , and rechargeable batteries 728 ( FIG. 9 ), which are used, inter alia, for powering the first transceiver subsystem 30 . The stator 725 has one or more stator coils, is annularly aligned with the magnet ring, and is in close proximity therewith so that flux from the magnet ring crosses the one or more stator coils of the stator 725 as the stator 725 rotates with the drive string portion of the drill string. The magnet ring, in this embodiment, comprises magnets arranged with alternating polarities. The alternating current from the stator is rectified by rectifier 726 , the output of which is direct current that is input to charging circuit 727 , the output of which, in turn, charges rechargeable batteries 728 . In an embodiment hereof, the batteries power the first wireless transceiver subsystem 30 , and can also power other circuits, such as for measurement and/or communication. Also, it will be understood that the output of the generator and/or rectifier could, if desired, be used for directly powering circuits or subsystems of the equipment.
[0046] The invention has been described with regard to a number of particular preferred embodiments, but variation within the spirit and scope of the invention will occur to those skilled in the art. For example, although FIGS. 3-6 show various combinations of couplers, internal and external cabling, internal and/or external mounting of portions of the electronics, use of a saver sub(s) and/or special surface sub(s), etc., it will be understood that other combinations are possible and are contemplated within the scope defined by the claims. Also, while a wired drill pipe subsystem is one preferred embodiment of a drill string telemetry subsystem, it will be recognized that other forms of drill string telemetry, an example being acoustic drill string telemetry, can be used, in which case a transducer subsystem can be provided at the top of drill string telemetry subsystem to convert to/from electrical signals. Also, it will be understood that other techniques which make use of motion of the drill string, including rotational or vibrational motion, can be used to generate power in the region of the drill string. | A system for bidirectional communication between the downhole equipment and a processor subsystem at the earth's surface, including: a section of wired drill pipes comprising at least the upper portion of a string of drill pipes, and forming at least a portion of a bidirectional communication link between downhole equipment and the top of the string of drill pipes; a drive string portion of the drill string, mechanically coupleable with the topmost wired drill pipe; a drive mechanism mechanically coupleable with said drive string portion, for rotating the drill string; a first wireless transceiver subsystem mounted on the drive string portion of the drill string, for rotation in conjunction with the drill string; a cable, electrically coupled between the top joint of the topmost wired drill pipe and the first transceiver subsystem; and a second wireless transceiver subsystem coupled with the uphole processor subsystem, the second wireless transceiver subsystem communicating bidirectionally with the first wireless transceiver subsystem. | 4 |
TECHNICAL FIELD
[0001] The invention relates to a method for providing information to a subscriber of a mobile communication network. Further the invention relates to a node adapted to perform a method for providing information to a subscriber of a mobile communication network.
BACKGROUND
[0002] In communication networks in countries, where the legislation forbids charging of unanswered calls, these calls are used to pass information to a called subscriber without generating a chargeable connection between a caller and a called subscriber. Both communication parties predefined which information is linked to a specific number of ringing tones or consecutive call attempts. It is e.g. possible that one ringing tone or call attempt means “call me back” or two ringing tones or call attempts means “come home”. Therefore the caller has e.g. to count the ringing tones after he set up a call to the called subscriber or he has to count the number of call attempts. When the number of ringing tones or call attempts reaches a predefined or specific number of rings which is linked to specific information, the caller releases the call. The called subscriber did not pick up the phone to prevent the establishment of a chargeable connection.
[0003] Every unanswered call generates traffic load on the control plane and the user plane of the net of a provider of a telecommunication network.
[0004] One solution of a cost effective transport of information is the use of a Short Message Service (SMS). This service is defined in the 3 rd Generation Partnership Project 2 standard 3GPP2 C.S0015-0 and allows the transmission of 160 characters in one SMS message. Sending a SMS message generates costs for the originator even if these costs are sometimes included in a flatrate. Sending of SMS messages is not possible if the caller uses a phone or mobile phone without any display. Coin boxes and most wireline phones do not contain means for showing or generating the content of a SMS message.
SUMMARY
[0005] It is an object of the present invention to improve the sending of information messages to a subscriber of a mobile communication network. This object is achieved by the independent claims. Advantageous embodiments are described in the dependent claims.
[0006] In an embodiment of the invention, a method for providing information to a subscriber of a mobile communication network is proposed, comprising the step of receiving a call setup message which is used to set up a call between the originator associated to the call setup message and the subscriber. The method further comprises the step of detecting an indicator in the call setup message which indicates the sending of a message to the subscriber. The method further comprises the step of releasing the call towards the originator and sending a message to the subscriber. The call setup message is initiated by an originator of the call in the originating network. This call setup message might be of different format in accordance with the current network type. This network could be a wireline (PSTN=public switched telephone network) or any other kind of mobile network. In this embodiment, the call between both parties is not established because after an indicator is detected, the call is released. Releasing the call means that resources which are allocated to this call will be deleted or released and can be used for other purposes or calls. In the switching node which detected the indicator, the resources for this call must be reserved until the message to the subscriber is sent. This message can be sent to a message system, such as a Short message Service (SMS) system, which can create and forward a SMS message to the subscriber. It is also possible to have another message system instead of the SMS system to create and forward a message to the subscriber. The message can be any kind of information element, such as a SMS or MMS (Multimedia message system) message.
[0007] In a further embodiment said method comprises the further step of determining an identifier in the call setup message which is indicative of one message out of a plurality of messages and sending the message to the subscriber in dependence on the identifier. It is therefore possible to differentiate between pluralities of contents in a message. It is possible that the identifier and the indicator are of the same value. The message which is sent to the subscriber may comprise the identifier of the call setup message. It is also possible that the message comprises a corresponding text which is linked with the identifier. That means that every identifier (e.g. 1, 2, etc . . . ) is linked with a corresponding text like:
[0008] 1 “Please come home”
[0009] 2 “Call me back”
[0010] The identifier and the corresponding specific text may be stored in a database. The database could be located in a node of the mobile communication network. The text message could further comprise the number of the originator to allow the subscriber to identify the originator of the message.
[0011] In a further embodiment the call setup message is an Initial Address Message, IAM. It is also possible that the indicator is a routing number prefix.
[0012] In another embodiment of the invention the identifier is a suffix value of the call setup message.
[0013] In a further embodiment of the invention the originator of the call setup message receives a release-indication when the call is released. The release-indication can be a tone indication.
[0014] In a further embodiment of the invention, a roaming number query is conducted to determine the address of the subscriber after the call is released.
[0015] The invention further comprises a switching node of a circuit-switched network, comprising a receiving unit, adapted to receive a call setup message which is used to set up a call between the originator associated to the call setup message and the subscriber, a first processing unit, adapted to detect an indicator in the call setup message which indicates the sending of a message to the subscriber, a communication unit, adapted to release the call towards the originator and a sending unit, adapted to send a message to the subscriber.
[0016] In a further embodiment of the invention the switching node comprises a second processing unit, adapted to determine an identifier in the call setup message which is indicative of one message out of a plurality of messages, and wherein the sending unit is adapted to send the message to the subscriber in dependence on the identifier.
[0017] The inventive switching node may be adapted to perform all the steps of the prescribed method of at least one of the other embodiments.
[0018] The present invention also concerns computer programs comprising portions of software codes in order to implement the method as described above when operated by a respective processing unit of a user device and a recipient device. The computer program can be stored on a computer-readable medium. The computer-readable medium can be a permanent or rewritable memory within the user device or the recipient device or located externally. The respective computer program can also be transferred to the user device or recipient device for example via a cable or a wireless link as a sequence of signals.
[0019] In the following, detailed embodiments of the present invention shall be described in order to give the skilled person a full and complete understanding. However, these embodiments are illustrative and not intended to be limiting.
BRIEF DESCRIPTION OF THE FIGURES
[0020] FIG. 1 shows an exemplary sequence diagram of a first embodiment of the invention,
[0021] FIG. 2 shows an alternative exemplary sequence diagram of a second embodiment of the invention,
[0022] FIG. 3 shows a further alternative exemplary sequence diagram of a third embodiment of the invention,
[0023] FIG. 4 shows a schematic block diagram of a switching node, illustrating functional units of the switching node being connected to other network nodes according to an embodiment of the invention.
DETAILED DESCRIPTION
[0024] FIG. 1 shows a first embodiment of the invention and depicts a sequence diagram which comprises a wireline or mobile network 11 and a mobile network. The mobile network comprises a gateway mobile switching center (GMSC) 12 , a short message service (SMS) system 13 and a mobile subscriber (MS) 14 . The wireline or mobile network 11 can be any type of network, such as a public switched telephone network or any kind of circuit switched mobile or packet switched mobile network. A GMSC can be any type of gateway node of a mobile network such as GSGSN in a packet switched environment. A SMS system 13 can be any type of message system in a mobile network which is adapted to create and send messages to a subscriber.
[0025] A subscriber of this wireline or mobile network 11 , who is not depicted in FIG. 1 , wants to send a message to the MS 14 . The subscriber of the wireline or mobile network 11 might use a telephone system which is not able to send or receive SMS-messages. An example of such a telephone system is a coin-operated telephone or a coin-box telephone.
[0026] In a first step 110 , a node in the wireline or mobile network 11 of the originator sends a call setup message to the GMSC of the network in which the receiver of the call (MS) 14 is located. This call setup can be an initial address message (IAM) using the bearer independent call control protocol (BICC) or the ISDN user part protocol (ISUP). The call setup message comprises, among others, the called party number and several routing data. According to the invention and the first embodiment, the call setup message comprises an additional prefix or suffix which was added to the called party number by the originator. An example for a suffix is #3 which is added to a called party number. An example is 12345#3 wherein 12345 is the called party number and #3 is the suffix. In a further embodiment, the suffix or prefix is divided into an indicator and an identifier. The indicator indicates the special handling of this call in accordance with the invention which is described further below. The identifier can be used to identify the content of information sent to the called MS. Therefore, the suffix or prefix can consist of two different information elements e.g. numbers. An example is the called number “12345#13” wherein “12345” is the called party number and “#13” is the suffix, consisting of an indicator “1” and an identifier “3”. The symbol “#” is used to separate between the called party number and the suffix. It is possible to use other symbols, such as “*”. It is also possible to combine the called party number with a prefix to indicate the sending of a message to the MS 14 . Reason to change the separator could be that if the called subscriber uses the received calling party number for a return call “as is”, the call would be ineffective because some of the separators are used in a different way. An example for a prefix number is “0888” which can be a routing number prefix. The using of this routing number prefix is to avoid impacts in other operator network infrastructure, especially in countries where number portability according to the standard 3GPP 23.066 or according to other national standards is used. The purpose of this prefix number is to bypass all number portability impacts and related costs.
[0027] In a second step 111 of the first embodiment of this invention, the control node 12 detects an indicator in the call setup message. If an indicator is detected, the control node 12 deals this call in a specified manner.
[0028] In a third step 112 , the control node 12 releases the call leg to the originator of the call if an indicator was detected in the second step 111 . No resources for the user plane will be seized.
[0029] After the identifier in the call setup message is determined 113 , the control node 12 generates a SMS 115 to the called party 14 and sends it to the SMS system 13 . The content of the text message is a text or symbol corresponding to the value of the identifier. The SMS system delivers 115 the SMS to the MS 14 . The SMS system 13 is an example and can be any kind of message transportation system which is implemented in a communication network. To find the logical interconnection between the identifier and the content of the text message, the control node 12 can retrieve data from a database in the network. This database can be located in the control node 12 or in any other network node of the communication system. It is possible that the SMS system 13 comprises this database.
[0030] In another embodiment of the invention, the control node 12 might send a message including the number of the called subscriber 14 and the identifier to the SMS system 13 . The SMS system 13 generates a text message based on the received identifier and sends it to the MS 14 by using the number of the called subscriber 14 . In another embodiment of the invention, the called subscriber will receive additionally the number of the originator of this call.
[0031] In another embodiment of the invention, the originator receives an indicator that the information is transferred to the MS 14 . This indicator can be a tone-indication to make sure that the originator is informed even if the originator does not have a display or other indication means available.
[0032] FIGS. 2 and 3 show a second embodiment of the invention. The first step 210 is comparable to the first step 110 of the first embodiment, wherein the originator sends a call setup message to the GMSC 22 of the network in which the MS 14 is located. In a second step 211 the GMSC 22 starts a normal data base enquiry to the number portability database and a roaming number enquiry to the HLR 23 in accordance with standardized procedures. The number portability database is not shown in FIGS. 2 and 3 to reduce the complexity of the figures. The GMSC only uses the mobile subscriber integrated services digital network number (MSISDN number) without any suffix or prefix number to avoid an impact to the number portability database, the HLR 23 or the VLR of the MSC 24 .
[0033] After the roaming procedure, the GMSC 22 knows the MSC 24 at which the MS 25 is linked at this moment. The GMSC 22 then starts the normal call setup procedure 212 including the mobile station routing number (MSRN), plus the extra suffix or prefix. No resource for the user plane is seized (e.g. in the media gateways). The normal call setup procedure 212 can also include the number of the originator if this number should be displayed at the device of the MS 25 .
[0034] In a next step 213 , the MSC/VLR 24 detects the indicator in the call setup message 212 which could be an IAM message. After the indicator is detected 213 , the MSC/VLR releases the call leg 215 with the GMSC 22 . The GMSC 22 then releases the call leg 214 to the wireline or mobile network 21 . The resources needed for this call can now be used to establish other calls.
[0035] In a next step 216 , the MSC 24 determines the identifier in the call setup message follows by a call offering message 217 to MS 25 including this identifier. The identifier could be modified by the MSC 24 to prevent failures due to different interpretation of prefixes or suffixes. By passing this information in the call offering, e.g. inside the calling party number, guaranties that all different type of phone devices are able to display this information during the phone is ringing. After the call is offered to the MS 25 , the call is released by the MSC in the next step 218 . If the real calling party number is not available or prohibited to be shown because e.g. the call was initiated via a coin telephone box, just the additional prefixes or suffixes will be shown on the display of the MS 25 .
[0036] It is possible that the MS 25 comprises means for a further processing of the received prefix or suffix. It might be possible that the MS 25 comprises a database which translates the prefix or suffix into a clear text message.
[0037] The difference between the second embodiment, depicted in FIG. 2 and the third embodiment, depicted in FIG. 3 , is the call release 313 of the call leg between the GMSC 32 and the wireline or mobile network 31 of the originator of the call. The call release 313 is performed after the GMSC detects 311 the indicator in the call setup message 310 . The advantage of an early release of the call leg between the GMSC 32 and the wireline or mobile network 31 of the originator of the call is that the resources have been de-allocated for other call establishments.
[0038] FIG. 4 depicts a switching node 401 of a circuit-switched network. The switching node can be a mobile switching center (MSC) or Gateway MSC (GMSC) in a circuit switched network, a Serving or Gateway GPRS Support Node in a packet switched network or any other node which is adapted to process call control messages like call setup messages. The switching node comprises a receiving unit 402 , adapted to receive a call setup message which is used to set up a call between the originator associated to the call setup message and the subscriber, a first processing unit 403 , adapted to detect an indicator in the call setup message which indicates the sending of a message to the subscriber, a communication unit 404 , adapted to release the call towards the originator and a sending unit 406 , adapted to send a message to the subscriber. Further the switching node 401 comprises a second processing unit 405 , adapted to determine an identifier in the call setup message which is indicative of one message out of a plurality of messages, and wherein the sending unit 406 is adapted to send the message to the subscriber in dependence on the identifier. | The invention relates to a method for providing information to a subscriber ( 14; 25; 35 ) of a mobile communication network, said method comprising the steps of receiving a call setup message ( 110; 210; 314 ) which is used to set up a call between the originator associated to the call setup message ( 110; 210; 314 ) and the subscriber ( 14; 25; 35 ), detecting ( 111; 213; 315 ) an indicator in the call setup message which indicates the sending of a message to the subscriber ( 14; 25; 35 ), releasing the call ( 112; 215; 316 ) towards the originator and sending ( 114; 217; 318 ) a message to the subscriber. | 7 |
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX
[0002] Not applicable.
COPYRIGHT NOTICE
[0003] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0004] One or more embodiments of the invention generally relate to clothing care. More particularly, the invention relates to means for drying clothing.
BACKGROUND OF THE INVENTION
[0005] In today's economic circumstances, consumers are being much more cautious and careful with their clothing purchases. However these consumers are buying clothing maintenance products in a much higher volume. Instead of purchasing new clothes, today's consumers are protecting the clothes they already own. Buttons, needles and thread used to mend clothes, stain removers, replacement belt buckles, at-home treatment products for dry-clean-only clothing, and other relevant product fields have enjoyed notable spikes in sales while the general clothing industry itself sits by the wayside. In other words, rather than spending money on clothing, consumers are buying products to protect the clothing they already have and to make their maintenance cheaper and easier.
[0006] Many consumers love the look and feel of fashionable fabrics, yet do not care for the trouble involved in their care. Many fashionable fabrics such as, but not limited to, wool, cashmere, and silk require special care when drying. This special care often requires the garment to be dried flat rather than being tumble or line dried. Tumble drying these fabrics can lead to shrinkage or damage. Line drying can cause stretching, creases and wrinkles, and hang drying using clothes hangers can cause shoulder bumps where the hanger contacts the garment. These clothes typically do not hold the same fashionable appearance after improper drying. Too often, special care instructions can make a consumer regret buying new, fashionable clothing because of the inconvenience. If the clothing cannot be tossed into the dryer, many consumers find their appreciation for such clothing to fade.
[0007] Proper care of clothing is important. A person's appearance in their clothes is what sets a first impression, and one mere blemish or one sign of improper maintenance of their clothing can negatively affect that first impression. That is why it is important to care for clothing in an appropriate manner. However it can be difficult to do so at times, especially with particular clothing items that require specific care. Items that require flat drying, for example, without limitation, most sweaters, can be tedious to tend to and can also be quite inconvenient to care for in limited space. Flat drying clothing can require a large amount of space, which is often not available in a typical laundry room, and most people do not want to have their clothing spread throughout their house to dry. It is therefore an objective of the present invention to provide means for flat drying clothing.
[0008] There are products currently available that are meant to make it easier to care for clothing that requires flat drying, for example, drying racks. However, no matter how easy these products make flat drying, they are not easy to work with. In fact, some of these products can make the whole process more inconvenient. These products are typically large and heavy and must be carried to a place of use. Many of these products must be unfolded and set-up, and then their location of use must be avoided until the clothes are dry. Then, they must be broken down, folded up and carried back to an area large enough to store them.
[0009] In view of the foregoing, there is a need for improved techniques for providing means for easily flat drying clothing that is easy to set up and put away and does not require a large amount of space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0011] FIGS. 1A through 1F illustrate an exemplary flat drying device, in accordance with an embodiment of the present invention. FIG. 1A is a front perspective view. FIG. 1B is a side perspective view. FIG. 1C is a rear perspective view. FIG. 1D is a front perspective view with netting in an extended position. FIG. 1E is a front perspective, partially transparent view, and FIG. 1F is a side perspective view of a netting hem bar attached to a wall;
[0012] FIG. 2 is a front perspective view of an exemplary flat drying device in use in a laundry room, in accordance with an embodiment of the present invention; and
[0013] FIGS. 3A and 3B illustrate an exemplary box for a flat drying device, according to an embodiment of the present invention. FIG. 3A is a rear perspective view of the box in a closed position, and FIG. 3B is a front perspective view of the box in an open position.
[0014] Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.
SUMMARY OF THE INVENTION
[0015] To achieve the forgoing and other objects and in accordance with the purpose of the invention, an apparatus for flat drying garments is presented.
[0016] In one embodiment an apparatus includes a canister comprising a rear wall, a bottom and a curved front panel. The curved front panel has a horizontal slit extending across a width of the front panel. The canister is operable for being supported from a first vertical surface. A spring-loaded axle is operable for being rotated in a first direction from a first position to a second position to generate a tension sufficient to rotate the spring-loaded axel in a second direction from the second position to the first position. End caps are joined to the canister for substantially enclosing the spring-loaded axel within the canister. One of the two end caps has an opening for enabling an end of the spring-loaded axel to protrude outside of the canister. A netting supports wet garments to lay flat for drying. The netting comprises a netting width, a length, a first end, a second end. The first end is joined to the spring-loaded axel and the netting is rolled about the spring-loaded axel with the second end protruding from the horizontal slit. A hem bar is joined to the second end of the netting. Means removably secures the hem bar to a second vertical surface opposing the first vertical surface where the netting is operable for supporting wet garments to lay flat for drying. A tension knob is joined to the end of the spring-loaded axel protruding outside of the canister. The tension knob is operable for adjusting a level of the tension with the wet garments laying flat on the netting.
[0017] In another embodiment an apparatus includes means for housing a portion of the apparatus. The housing means is operable for mitigating pooling of moisture and for being supported on a first vertical surface. Means rotates in a first direction from a first position to a second position to generate a tension sufficient to rotate the rotating means in a second direction from the second position to the first position. Means encloses the rotating means in the housing means. Means supports wet garments to lay flat for drying. The supporting means is joined to the rotating means and protrudes from the housing means. Means mitigates a full retraction of the supporting means into the housing means. The mitigating means is joined to the supporting means. Means secures the mitigating means to a second vertical surface opposing the first vertical surface. Means adjusts a level of the tension with the mitigating means being secured proximate the second vertical surface, the rotating means being at the second position and the wet garments laying flat on the supporting means. The adjusting means is joined to the rotating means.
[0018] In another embodiment an apparatus includes a canister comprising a flat rear wall, a flat bottom and a curved front panel. The curved front panel has a shape operable for mitigating pooling of moisture and having a horizontal slit extending across a width of the front panel. The flat rear wall has hosting apertures operable for supporting the canister upon screws that project from a first vertical surface. A spring-loaded axle comprises a length larger than the width of the front panel. The spring-loaded axel is operable for being rotated in a first direction from a first position to a second position to generate a tension sufficient to rotate the spring-loaded axel in a second direction from the second position to the first position. Two end caps are each joined to an end of the flat rear wall, flat bottom and curved front panel to substantially enclose the spring-loaded axel within the canister. One of the two end caps has an opening for enabling an end of the spring-loaded axel to protrude outside of the canister. A netting supports wet garments to lay flat for drying. The netting comprises a netting width, a length, a first end, a second end, reinforced edges, and a waterproof coating. The netting width is less than the width of the front panel. The first end is joined to the spring-loaded axel and the netting is rolled about the spring-loaded axel with the second end protruding from the horizontal slit. A hem bar is joined to the second end of the netting. The hem bar comprises dimensions sufficient to mitigate a full retraction of the netting into the canister. The hem bar further comprises two apertures extending through the hem bar with each aperture being proximate a lateral end of the hem bar. Two hook structures are configured for securing to a second vertical surface opposing the first vertical surface at a distance less than the length of the netting. The two hook structures are further configured for removably passing through the two apertures of the hem bar to secure the hem bar proximate the second vertical surface where the netting is operable for supporting wet garments to lay flat for drying. A tension knob is joined to the end of the spring-loaded axel protruding outside of the canister. The tension knob comprises an ergonomic grip system comprising bumps and valleys for user gripping. The tension knob is operable for adjusting a level of the tension with the hem bar being secured proximate the second vertical surface, the spring-loaded axel being at the second position and the wet garments laying flat on the netting.
[0019] Other features, advantages, and objects of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention is best understood by reference to the detailed figures and description set forth herein.
[0021] Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.
[0022] It is to be further understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications, described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.
[0023] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices, and materials are described, although any methods, techniques, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the present invention. Structures described herein are to be understood also to refer to functional equivalents of such structures. The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings.
[0024] From reading the present disclosure, other variations and modifications will be apparent to persons skilled in the art. Such variations and modifications may involve equivalent and other features which are already known in the art, and which may be used instead of or in addition to features already described herein.
[0025] Although Claims have been formulated in this Application to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalization thereof, whether or not it relates to the same invention as presently claimed in any Claim and whether or not it mitigates any or all of the same technical problems as does the present invention.
[0026] Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination. The Applicants hereby give notice that new Claims may be formulated to such features and/or combinations of such features during the prosecution of the present Application or of any further Application derived therefrom.
[0027] References to “one embodiment,” “an embodiment,” “example embodiment,” “various embodiments,” etc., may indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an exemplary embodiment,” do not necessarily refer to the same embodiment, although they may.
[0028] As is well known to those skilled in the art many careful considerations and compromises typically must be made when designing for the optimal manufacture of a commercial implementation any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application.
[0029] It is to be understood that any exact measurements/dimensions or particular construction materials indicated herein are solely provided as examples of suitable configurations and are not intended to be limiting in any way. Depending on the needs of the particular application, those skilled in the art will readily recognize, in light of the following teachings, a multiplicity of suitable alternative implementation details.
[0030] A preferred embodiment of the present invention and at least one variation thereof provide convenient and space-saving means for drying clothes that cannot be or are preferably not tumble or hang dried. Many preferred embodiments comprise a retractable sheet of netting that can be withdrawn from a canister upon which clothing can be laid flat for drying. Many preferred embodiments may be mounted upon a wall or other plane so that, when not in use, the drying means does not occupy a large amount of space. Many preferred embodiments can accommodate the growing number of consumers who refrain from clothes dryer use due to potential damage upon clothing, utility costs and environmental reasons. Many preferred embodiments of the present invention can encourage consumers to properly care for their clothing and can help consumers generally prevent common damages to their clothing.
[0031] FIGS. 1A through 1F illustrate an exemplary flat drying device, in accordance with an embodiment of the present invention. FIG. 1A is a front perspective view. FIG. 1B is a side perspective view. FIG. 1C is a rear perspective view. FIG. 1D is a front perspective view with netting 101 in an extended position. FIG. 1E is a front perspective, partially transparent view, and FIG. 1F is a side perspective view of a netting hem bar 105 attached to a wall. In the present embodiment the drying device comprises netting 101 , a spring-loaded axle 110 for the hosting of netting 101 , and a canister 115 which hosts spring-loaded axle 110 . Canister 115 is preferably produced of lightweight aluminum, and measures approximately twenty-seven inches in length by three inches in depth (27″×3″). Canister 115 comprises a flat rear wall 120 , a flat bottom 125 , and a curved front panel 130 that are enclosed by end caps 135 . End caps 135 are preferably produced of high-density polyethylene (HDPE). The shape of canister 115 generally ensures that moisture slides off the device and does not pool on the device, which can increase the life and attractiveness of the device. In alternate embodiments, the canister can be made in various lengths and widths. For example, without limitation, some embodiments may comprise larger canisters for use in professional applications such as, but not limited to, for a dry cleaner or a Laundromat. Furthermore, it is contemplated that the canisters in some alternate embodiments may have various different shapes such as, but not limited to, square or rectangular tubes or cylinders. Yet other alternate embodiments may be implemented without a canister in order to provide an even more space-saving design. In the present embodiment canister 115 is completely enclosed. This seals spring-loaded axle 110 within canister 115 and generally prevents a person's fingers or clothing from getting caught in spring-loaded axle 115 . Also, keeping interior components completely encased within canister 115 protects these components which can result in longer life.
[0032] Referring to FIGS. 1C and 1E , rear wall 120 of canister 115 has a flat plane, and upon each lateral side of rear wall 120 are hosting apertures 140 for support of the device upon screws 145 that slightly project from a wall or other vertical surface. Referring to FIG. 1E , within canister 115 , spring-loaded axle 110 of an approximate one and one-half inch (1½″) diameter extends from one end cap 135 of canister 115 for approximately one inch (1″). The extending portion of spring-loaded axle 115 is encased within an ergonomically styled tension knob 150 preferably produced of high-density polyethylene (HDPE). Tension knob 150 enables a user to adjust the tension of netting 101 when the device is in use. Tension knob 150 has a specially designed, ergonomic grip system comprising bumps and valleys to generally ensure that users can easily grip tension knob 150 and turn it, even when their hands are moist. The bumps enable a user to insert their fingertips into the valleys between the bumps so it is difficult for the fingers to slip or fall out of place even if the fingers are moist due to water, detergent, fabric softener, etc. Those skilled in the art, in light of the teachings of the present invention, will readily recognize that a multiplicity of suitable ergonomic designs may be used for the tension knobs in alternate embodiments such as, but not limited to, textured, grooved or ribbed surfaces; however, these designs may not be optimal as these textured surfaces may become filled with moisture, fabric softener or other residue and become slick. In some alternate embodiments, the tension knob may include a rubberized coating for added grip.
[0033] Referring to FIGS. 1E and 1F , mounted upon spring-loaded axle 110 is netting 101 that is preferably made of a nylon-polyester blend material with a waterproof coating that measures approximately six feet in length by twenty-six inches in width (72″×26″). The waterproof coating protects netting 101 as wet clothes dry on it; however, in alternate embodiments the netting may not include a waterproof coating and may come in different sizes depending on many factors including, but not limited to, the size of the canister or the intended application of the device. In the present embodiment, the outer edges of netting 101 are thicker, making them reinforced. This helps to maintain the condition of netting 101 for an extended length of time. Netting 101 will be rolled up and extended numerous times over its lifetime so the reinforced edges provide longevity and generally prevent fraying of netting 101 . The reinforced outer edges also help to support the weight of wet garments that are flat drying on netting 101 . Apertures in netting 101 enable moisture to drip from the clothing. Netting 101 can be pulled and kept taught when in use by tension knob 150 . Referring to FIG. 1D , netting 101 can be withdrawn and retracted through a horizontal slit 155 featured upon, and running the length of, front panel 130 of canister 115 . Slit 155 has a height of approximately one-half of one inch (½″) to enable netting 101 to easily pass through slit 155 . Additionally, there are no impediments near slit 155 to generally prevent friction on netting 101 which in turn generally prevents fraying and increases longevity of netting 101 .
[0034] Enlarged netting hem bar 105 is featured upon the exterior end of netting 101 for prevention of the full retraction of netting 101 into canister 115 . Hem bar 105 is preferably made of high-density polyethylene (HDPE) and has an approximate depth of three-quarters of one inch (¾″) and a height of one-half inch (½″). In alternate embodiments, the hem bar can be of various sizes to prevent it from retracting within the canister of the drying device. Hem bar 105 can be textured to provide grip to moist hands as the drying device is typically used in a laundry area so most likely a user's hands will be wet from water, detergent, fabric softener, etc. In an alternate embodiment, the hem bar may include a handle to make pulling the netting from the canister easier. In the present embodiment, referring to FIG. 1F , extending through each lateral end of hem bar 105 are two apertures 160 for the hosting of wall-mounted hooks 165 . Hooks 165 pass completely through apertures 160 of hem bar 105 to generally ensure that hem bar 105 is adequately supported and to generally eliminate the risk of hem bar 105 coming off of hooks 165 . This design also thoroughly supports netting 101 when it is pulled out from canister 115 . Hooks 165 can be screwed into a wall via a threaded shaft projecting from a rear wall 170 . In some implementations, rear wall 170 of hooks 165 may feature a slightly protruded rubber liner. This liner is pliable and helps to protect the wall in which hooks 165 are applied. In some embodiments, the hooks can feature small rubber caps that can be slipped on to the tips of the hooks. These caps cover the tips of the hooks to generally prevent items from accidently getting snagged on the hooks and to help hold the netting on the hooks when being loaded with clothing. In alternate embodiments, the hem bar itself may comprise hooks to be attached to various different objects such as, but not limited to, eyelets, other hooks, a bar, knobs, wire shelving, etc. rather than or in addition to apertures for placement on hooks.
[0035] Those skilled in the art, in light of the teachings of the present invention, will readily recognize that flat drying devices in alternate embodiments may be produced from a multiplicity of suitable combinations of adequate materials. For example, without limitation, the canister and end caps may be made of various materials such as, but not limited to, high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), various metal materials, etc. The hem bar in alternate embodiments can be made of various materials such as, but not limited to, aluminum, high-density polyethylene (HDPE) and acrylonitrile butadiene styrene (ABS). Furthermore, the netting of the drying device in alternate embodiments can be made of various applicable materials such as, but not limited to, cotton, various plastics, nylon and polyester. In some alternate embodiments the netting may be replaced by a solid sheet of an absorbent material such as, but not limited to, cotton, terry, chamois material, etc.
[0036] In the present embodiment, the drying device provides means for flat drying sweaters and other garments to provide a consumer needed accommodation for the care of particular clothing items. It is not just sweaters that need flat drying. Garments that require flat drying may be anything made out of wool, cashmere, silk and several blend combinations. Flat drying may also be recommended for manmade fabrics such as, but not limited to, polyester, rayon and even acetate. This means that the drying device may be used with almost any type of clothing including, but not limited to, sweaters, skirts, hosiery, blouses, delicate undergarments, swimsuits, jeans, etc. The drying device can also accommodate clothing that requires hanging such as, but not limited to, stockings Clothing that requires hanging can be accommodated in at least two ways, as follows, without limitation. The first way is to simply lay the clothing flat upon the netting and allow it to flat dry. All though clothing may state it can be hanged to dry; it can also be laid flat to dry so this product would work perfectly. The second way it to hang the hanger that supports the wet clothing on the reinforced outer edging of the net. The net may be secured in a taut position and the reinforced edging can support the hanger.
[0037] FIG. 2 is a front perspective view of an exemplary flat drying device 200 in use in a laundry room, in accordance with an embodiment of the present invention. In typical use of the present embodiment, a user mounts drying device 200 to a hosting wall 205 using a mounting template on the packaging, as described by way of example in FIGS. 3A and 3B . Using the same template, the user mounts hooks on an opposite wall 210 at the same height as a canister 215 . The user then withdraws a netting 220 from canister 215 and mounts a hem bar 225 upon the hooks of opposite wall 210 . The user can then lay clothing 230 flat upon netting 220 to dry. If needed, the user may rotate a tension knob 235 attached to a spring-loaded cylinder attached to netting 220 to generally ensure that netting 235 remains taut. By drying clothing 230 flat, drying device 200 does not create noticeable shoulder indentations, like those created by clothing hangers, and does not leave noticeable marks near the hems of clothing, like those created by clothespins. Drying device 200 also enables clothing 230 to dry evenly, unlike hanging methods in which moisture simply declines throughout the structure of the garment. Furthermore, drying device 200 supports clothing 230 throughout the drying process, unlike hanging methods that include a high risk of garments falling upon the floor. When clothing 230 is removed from netting 220 , the user may remove hem bar 225 from the hooks to enable netting 220 to retract back within canister 215 .
[0038] Drying device 200 enables flat drying to be done in a reserved space within the home or other environments. Drying device 200 takes advantage of unused space (i.e., vertical wall space) and satisfies a particular need of persons in small spaces such as, but not limited to, small homes, apartments, dormitories, barracks, and other living quarters. However, drying device 200 can be used in almost any location including, but not limited to, in homes and in businesses. Alternate embodiments can be implemented in formats and sizes for commercial use in businesses such as, but not limited to, hotels, motels, Laundromats, camping grounds, dormitories, and other facilities that offer clothes washing and clothes washing facilities. Some embodiments of the present invention may also be used by drycleaners and laundry service companies. In the present embodiment, drying device 200 is easy to set-up. Unlike other products that require set-up each time use is desired, drying device 200 only requires set-up during its initial installation. By requiring only initial installation, drying device 200 saves time, energy and space that other products require for their set-up, tear down and subsequent storage. In the present embodiment, the screws that mount canister 215 to wall 205 are inserted into wall 205 and the actual canister 215 can be put on the screw heads and removed from the screw heads very easily and quickly. This enables the user to keep canister 215 installed on wall 205 all the time, or the user can remove canister 215 from wall 205 to store drying device 200 somewhere and re-apply it to the screws only when needed. This also enables drying device 200 to be portable so that it can be brought to other locations for use. In alternate embodiments the canister may be permanently mounted to a wall.
[0039] FIGS. 3A and 3B illustrate an exemplary box for a flat drying device, according to an embodiment of the present invention. FIG. 3A is a rear perspective view of the box in a closed position, and FIG. 3B is a front perspective view of the box in an open position. In the present embodiment, the box of the flat drying device comprises a template 301 to generally ensure that the installation of support screws for the drying device is easy and accurate. Template 301 can be used for the simple and accurate installation of the support hooks on the opposite wall as well. The box comprises perforations around template 301 so a user can easily remove template 301 from the box without the use of scissors or any other cutting device. This feature enables the user to use template 301 without having to hold the entire box during product set-up and without needing a cutting utensil. The perforations also generally ensure that template 301 stays in good working condition as it is removed from the box. Positioned on the face of template 301 are three other perforated areas, two screw/hook indicators 305 and a horizontal slit 310 . Screw/hook indicators 305 generally ensure that the distance between the screws and hooks is accurate. Horizontal slit 310 is near the bottom center of template 301 and can hold the securing end of a tape measure. The height of the canister of the drying device and the height of the hooks on the opposite wall need to closely match each other. Horizontal slit 310 enables a user to hook a tape measure to slit 310 , pull it down to the floor and generally ensure accurate height between the canister and the hooks on the opposite wall. In alternate embodiments the template may not be perforated. In other alternate embodiments, the template may be separate from the box, for example, without limitation, a piece of cardboard or paper included in the box with the drying device. In the present embodiment, the interior face of template 301 features two adhesive areas 315 that are protected by a removable covering that may be made of a thin, removable material such as, but not limited to, wax paper or plastic. Adhesive areas 315 hold template 301 on the wall so the user can have both hands free to complete installation. The adhesive for adhesive areas 305 is hypoallergenic and residue free; therefore, it does not negatively affect users or damage the wall on which it is placed. Some alternate embodiments may not include adhesive areas on the templates.
[0040] In typical use of the present embodiment, the user removes template 301 from the box and removes screw/hook indicators 305 and horizontal slit 310 . Then, the user removes the coverings from adhesive areas 315 and places template 301 on the installation wall in the approximate area they want the canister and hooks. The user then uses a tape measure to find the desired height, and can adjust the template a few times to achieve the desired placement. Adhesive areas 315 allow for several adjustments before losing their stickiness. The user then marks the location for the screws using screw/hook indicators 305 . Once the user has the screws in place for the canister installation, they can remove template 301 and attach it to the opposite wall. The user uses the tape measure to check that the height of template 301 is the same as for the other wall and can then mark and install the hooks. This process typically ensures accurate installation the first time, which can generally prevent errant holes in the wall from the placing of screws in the wrong area. Some alternate embodiments of the present invention may not include an installation template.
[0041] In an alternate embodiment of the present invention, the rear wall of the canister is covered with a textured, rubber coating. This rubber coating can help to protect the wall on which the drying device is mounted. When a user extracts or retracts the netting, the canister moves slightly, which may cause the canister to scratch the wall. The rubber coating acts as a buffer to protect the wall. The rubber coating also provides additional grip to help maintain the product in a secure position on the wall.
[0042] It is contemplated that alternate embodiments may be implemented with a multiplicity of additional features. For example, without limitation, one alternate embodiment may be implemented with a fan for improving the speed of drying. Some alternate embodiments may include lights, hooks for hanging items, or containers for holding items such as, but not limited to, pocket change, detergent, clothespins, etc. Additionally, alternate embodiments can be produced in various colors, and may or may not bear various images, designs and/or logos, which may or may not be of registered trademark and/or copyright status.
[0043] Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of providing means for flat drying clothing according to the present invention will be apparent to those skilled in the art. The invention has been described above by way of illustration, and the specific embodiments disclosed are not intended to limit the invention to the particular forms disclosed. For example, the particular implementation of the drying means may vary depending upon the particular type of mounting method used. The drying means described in the foregoing were directed to wall mounted implementations; however, similar techniques are to provide means for flat drying clothing that are not wall mounted; for example, without limitation, the flat drying device may be placed on a stand or may use suction cups to be removably mounted to a surface such as, but not limited to, tile or a washing machine. Non-wall mounted implementations of the present invention are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.
[0044] Claim elements and steps herein may have been numbered and/or lettered solely as an aid in readability and understanding. Any such numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims. | An apparatus includes a canister having a front panel. The front panel has a slit extending across a width of the panel. The canister is operable for being supported from a first vertical surface. A spring-loaded axle is operable for rotating in a first direction to generate a tension sufficient to rotate the axel in a second direction. Caps are joined to the canister for substantially enclosing the axel within the canister. A netting supports wet garments to lay flat. The netting comprises a first end and a second end. The first end is joined to the axel with the second end protruding from the slit. A hem bar is joined to the second end of the netting. Means secures the hem bar to a second vertical surface. A tension knob is joined to the end of the axel and is operable for adjusting a level of the tension. | 3 |
This application relies for priority upon Korean Patent Application No. 2003-0079476 filed on Nov. 11, 2003, the contents of which are herein incorporated by reference in their entirety.
BACKGROUND
1. Field of the Invention
The present invention relates to an encoding circuit and a redundancy control circuit using the same, and specifically, to an encoding circuit for generating a global signal from encoding a local repair signal provided by a redundancy block.
2. Discussion of Related Art
In general, a semiconductor device includes a multiplicity of redundancy blocks in order to improve a yield thereof. A specific redundancy block becomes active in accordance with an address and input/output (I/O) signal to be repaired. During this, it needs a global repair signal to represent an activation of a repair mode in a chip operation. Such a global repair signal is generated by encoding local repair signals, supplied by each repair block.
FIG. 1 illustrates an encoding circuit within a conventional redundancy circuit.
Referring to FIG. 1 , the encoding circuit includes first through sixteenth NOR gates NO 1 to NO 16 for outputting first through sixteenth logic signals respectively in response to two local repair signals among first through thirty-second local repair signals REP< 0 : 31 >, first through eighth NAND gates NA 1 to NA 8 receiving the first through sixteenth logic signals outputted from the NOR gates NO 1 to NO 16 , wherein each NAND gate receives two logic signals among the first through sixteenth logic signals, seventeenth through twentieth NOR gates NO 17 to NO 20 receiving output signals of the first to eighth NAND gates NA 1 to NA 8 , wherein each NOR gate receives two logic signals among the output signals of the NAND gates NA 1 to NA 8 , ninth and tenth NAND gates NA 9 and NA 10 receiving output signals of the NOR gates NO 17 to NO 20 , wherein each NAND gate receives two logic signals among the output signals of the NOR gates NO 17 to NO 20 , and a twenty-first NOR gate NO 21 and an inverter I 1 that generates a global repair signal REDGEN by receiving an output signals of the NAND gates NA 9 and NA 10 .
In the encoding circuit shown in FIG. 1 , when one of the first through thirty-second local repair signals REP< 0 : 31 > is logically high at least, the global repair signal is set to high to inform that a redundancy operation is being carried out in a chip.
However, as a size of the encoding circuit block conventionally used is very large, the encoding circuit block occupies a large portion in a chip. Especially, when the number of local repair signals is increased as the number of redundancy blocks is increased, an area for the encoding circuit may be non-linearly and sharply expanded. Moreover, since it is required that the local repair signals have to be passed to logic gates for five time of logic combination in order to generate the global repair signal, a time delay about 3 ns is consumed until the generation of the global repair signal from the supply of the local repair signals in the conventional encoding circuit, which is disadvantageous to enhancing the processing speed of the redundancy operation. As a result, there is a problem of inducing glitch signals in generating I/O signals.
SUMMARY OF THE INVENTION
The present invention is directed to an encoding circuit of a semiconductor apparatus and a redundancy control circuit using the same, solve the aforementioned problems, capable of reducing an area occupied by a redundancy circuit by employing an encoder with a common encoding scheme and eliminating unnecessary glitch signals and time delays by contemporizing the generation of global signals and I/O signals.
One aspect the present invention is to provide an encoding circuit of a semiconductor apparatus, including: a precharge node; a first PMOS transistor for supplying a power supply voltage to the precharge node; a multiplicity of NMOS transistors connected between the precharge node and a ground voltage in parallel, being driven by a multiplicity of external signals; and an output circuit for generating an encoding signal in accordance with a logical state of the precharge node.
Another aspect of the present invention is to provide an encoding circuit of a semiconductor apparatus, comprising: a precharge node; a 100'th NMOS transistor for supplying a ground voltage to the precharge node; a multiplicity of PMOS transistors connected between the precharge node and a power supply voltage in parallel, being driven by a multiplicity of external signals; and an output circuit for generating an encoding signal in accordance with a logical state of the precharge node.
The present invention also provides a redundancy control circuit of a semiconductor apparatus, including: a multiplicity of repair address selector for generating local redundancy signals in accordance with an address signal and a redundancy enable signal; a multiplicity of repair I/O selectors for outputting I/O information signals to be repaired in accordance with the local redundancy signals, corresponding each to the repair address sectors; an I/O decoder for generating I/O signals from the I/O information signals; and an encoder for generating reset signals to initiate the I/O information signals and for generating a global redundancy signal to inform an activation of a redundancy operation in a chip and to control the I/O decoder, in accordance with the local redundancy signals.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may be had by reference to the following description when taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an encoding circuit within a conventional redundancy circuit;
FIG. 2 is a block diagram of a redundancy control circuit according to the present invention;
FIG. 3 is a circuit diagram of an encoder according to an embodiment of the present invention; and
FIG. 4 is a circuit diagram of an encoder according to another embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. The present invention may, however, be embodied in different forms and should not be constructed 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 numerals refer to like elements throughout the specification.
FIG. 2 is a block diagram of a redundancy control circuit according to the present invention.
Referring to FIG. 2 , the redundancy control circuit includes: a plurality of repair address selectors 100 _ 1 to 100 _M for generating local redundancy signals REP< 1 :M> in accordance with an address signal Address and a redundancy enable signal REDEN; a plurality of repair I/O selectors 200 _ 1 to 200 _M for outputting I/O information signals IOBUS< 0 : 3 > for the repair in accordance with the local redundancy signals REP< 1 :M> of the repair address selectors 100 _ 1 to 100 _M, each corresponding to each of the repair address selectors 100 _ 1 to 100 _M; an I/O decoder 300 for generating I/O signals IO< 0 : 15 > by decoding the I/O information signals IOBUS< 0 : 3 > to be repaired; and an encoder 400 for generating reset signals RESET< 0 : 3 > to initiate the I/O information signals IOBUS< 0 : 3 >, and generating a global redundancy signal REDGEN to inform an activation of a redundancy operation in a chip and to control the I/O decoder 300 , in accordance with the local redundancy signals REP< 1 :M>.
Now will be described about an operation of the redundancy control circuit constituted as aforementioned.
When the redundancy enable signal REDEN is logically high and a specific address Address is input thereto, a local redundancy signal (e.g., one of REP< 1 :M>) corresponding to the specific address is generated with a logical high level from its corresponding repair address selector among the repair address selectors 100 _ 1 to 100 _M. Other repair address selectors disaccording to the specific address generate logical-low local redundancy signals of logically low (e.g., the rest of REP< 1 :M>). The local redundancy signals REP< 1 :M>, as outputs of the repair address selectors 100 _ 1 to 100 _M repectively, are used each to operate a plurality of redundancy blocks.
As the repair I/O selectors 200 _ 1 to 200 _M are connected to the repair address selectors 100 _ 1 to 100 _M, corresponding to each other, a repair I/O selector (one of 200 _ 1 to 200 _M) corresponding to the logical-high local redundancy signal (one of REP< 1 :M>) of logically low only outputs an I/O information stored therein. In other words, the repair I/O selectors 200 _ 1 to 200 _M have their own I/O information for the repair and output the I/O information, which needs to be repaired, through the I/O buses (i.e., IOBUS< 0 : 3 >) in accordance with the local redundancy signals REP< 1 :M> transferred thereto. For instance, if there is a need to repair I/O=3, the I/O information signal is set to 0011 (I/O bus< 3 : 0 >=0011).
The I/O decoder 300 is driven by the global redundancy signal REDGEN, decodes the I/O information signals IOBUS< 0 : 3 > and outputs the decoded I/O information signals by way of IO< 15 : 0 > as the I/O signals IO< 0 : 15 > to be repaired.
By the way, the encoder 400 outputs the global redundancy signal REDGEN of logically low to inform there is no redundancy operation and controls the I/O decoder 300 not to be active, when any one of the local redundancy signals REP< 1 :M> does not set to logically high to condition a non-operation state. The encoder 400 outputs the reset signals RESET< 0 : 3 > to initiate the I/O information signals IOBUS< 0 : 3 >, outputs of the repair I/O selectors 200 _ 1 to 200 _M, all to logically low. In other words, the reset signals RESET< 0 : 3 > of logically low are applied to the IO buses to initiate the I/O information signals IOBUS< 3 : 0 > all to logically low levels.
On the other hand, if a redundancy operation is enabled according when at least one of the local redundancy signals REP< 1 :M> goes to a logic high level, the global redundancy signal REDGEN is outputted in a logic high level to inform that the redundancy operation is being active at present, and controls the I/O decoder 300 to be operable. And, the reset signals RESET< 0 : 3 > are floated (i.e., inactive) to permit the I/O information signals IOBUS< 0 : 3 >, the outputs of the repair I/O selectors 200 _ 1 to 200 _M, to be transferred into the I/O decoder 300 .
FIG. 3 is a circuit diagram of an encoder 400 according to the preferred embodiment of the present invention.
Referring to FIG. 3 , the encoder 400 includes a precharge node Q 100 , a first PMOS transistor P 10 for supplying a power supply voltage to the precharge node Q 100 , a plurality of NMOS transistors 410 connected between the precharge node Q 100 and a ground voltage in parallel and being driven by a plurality of external signals, and an output circuit 420 for outputting an encoding signal REDGEN (i.e., the global redundancy signal) in accordance with a logical state of the precharge node Q 100 .
Now, it will be described in more detail about the structure and operation of the encoder relative to the redundancy control circuit as cited above.
The encoder 400 also includes a reset circuit 430 for generating the reset signals RESET< 0 : 3 > to initiate the I/O buses IOBUS< 0 : 3 > in accordance with a voltage state of the precharge node Q 100 . The reset circuit 430 is constructed of a plurality of NMOS transistors that are connected between the I/O buses IOBUS< 0 : 3 > (output terminals of the reset signals) and the ground voltage Vss and driven by a voltage state of the precharge node Q 100 .
The local redundancy signals REP< 1 :M> (REP 1 to REPM) are used as the external signals to the encoder 400 . The plural NMOS transistors 410 are connected between the precharge node Q 100 and the ground voltage Vss in parallel, in which first through M th NMOS transistors NT 1 to NTM (i.e., the plural NMOS transistors 410 ) are constructed to be driven each by the local redundancy signals REP< 1 :M>.
The output circuit 420 generates the global redundancy signal REDGEN as its encoding signal depending on a logic state of the precharge node Q 100 . The output circuit includes an inverter I 10 converting a logic state of the precharge node Q 100 into the global redundancy signal REDGEN, and a second PMOS transistor P 20 supplying the power supply voltage Vcc to the precharge node Q 100 in accordance with the global redundancy signal REDGEN.
An exemplary operation of the encoder constructed as aforementioned will be explained in conjunction with the operation the redundancy control circuit.
When there is no occurrence of a redundancy operation according to the address Address, the local redundancy signals REP< 1 :M> applied to the encoder 400 are all set to logical low. Therefore, the NMOS transistors NT 1 to NTM controlled by the local redundancy signals REP< 1 :M> is not turned on. During this, a logical-high signal is applied to the precharge node Q 100 by way of the first PMOS transistor P 10 .
The logical-high signal at the precharge node Q 100 turns on the NMOS transistors NT 10 to NT 40 of the reset circuit 430 on to output the reset signals RESET< 0 : 3 > of logical low. The reset signals RESET< 0 : 3 > reset all the I/O buses, to which the I/O information signals IOBUS< 0 : 3 > become logically low. And, the logical-high signal of the precharge node, which is the power supply voltage level, is output as the global redundancy signal REDGEN of logical low through an inverter of the output circuit 420 . According to the global redundancy signal REDGEN of logical low, the second PMOS transistor P 20 is turned on to continuously supply the logical-high power supply voltage to the precharge node Q 100 .
Otherwise, when a redundancy operation is enabled in accordance with the address Address applied thereto, at least one of the local redundancy signals REP< 1 :M> (i.e., REP 1 to REPM) becomes a logical-high signal. Therefore, at least one of the NMOS transistors NT 1 to NTM is turned on. And, the power supply voltage Vcc is supplied to the precharge node Q 100 by way of the first PMOS transistor P 10 .
Here, if the NMOS transistors NT 1 to NTM are designed to have their current drivability larger than those of the tenth PMOS transistor P 10 , the power supply voltage Vcc charging the precharge node Q 100 through the first PMOS transistor P 10 is connected to the ground voltage Vss by way of at least one of the NMOS transistors NT 1 to NTM and thereby the precharge node Q 100 is discharged to the ground voltage that is logically low.
The logical-low signal of the precharge node Q 100 does not turn on the NMOS transistors NT 10 to NT 40 to thereby make the reset signals RESET< 0 : 3 > to be floated. The logical-low signal of the precharge node Q 100 , i.e., the ground voltage level, is output as the global redundancy signal REDGEN of logical high by way of the inverter of the output circuit 420 . According to the global redundancy signal REDGEN of logical high, the second PMOS transistor P 20 is turned off to keep the precharge node Q 100 on the ground voltage Vss as logical low.
By a simulation result, provided that the first PMOS transistor P 10 was designed with 3 μm in channel width and with 1,5 μm in channel length while the NMOS transistors NT 1 to NTM with 3 μm in channel width and with 0.35 μm in channel length, a current less than 50 μA was flown and the global redundancy signal is generated in a switching time less than 1 ns.
FIG. 4 is a circuit diagram of an encoder 400 according to another embodiment of the present invention.
Referring to FIG. 4 , the encoder 400 according to another embodiment of the present invention includes a precharge node Q 200 , a first NMOS transistor NT 100 for supplying a ground voltage to the precharge node Q 200 , a plurality of PMOS transistors 415 connected between the precharge node Q 200 and a power supply voltage in parallel and being driven by a plurality of external signals, and an output circuit 425 for outputting an encoding signal REDGEN (i.e., the global redundancy signal) in accordance with a logical state of the precharge node Q 200 .
Now, it will be described in more detail about the structure and operation of the encoder relative to the redundancy control circuit as cited above.
The encoder shown in FIG. 4 also includes a reset circuit 435 for generating the reset signals RESET< 0 : 3 > to initiate the I/O buses IOBUS< 0 : 3 > in accordance with a predetermined control signal of the output circuit 425 . The reset circuit 435 is constructed of a plurality of resetting NMOS transistors NT 200 to NT 230 that are connected between the I/O buses IOBUS< 0 : 3 > (output terminals of the reset signals) and the ground voltage Vss and driven by the predetermined control signal of the output circuit 425 .
Reversed local redundancy signals REPb< 1 :M> (REPb 1 to REPbM) are used as the external signals to the encoder 400 . The plural PMOS transistors 415 are connected between the precharge node Q 200 and the power supply voltage Vcc in parallel, in which first through Mth PMOS transistors P 1 to PM (i.e., the plural PMOS transistors 415 ) are constructed to be driven each by the reversed local redundancy signals REPb< 1 :M>.
The output circuit 425 generates the global redundancy signal REDGEN as its encoding signal depending on a logical state of the precharge node Q 200 . The output circuit 425 includes a first inverter I 100 converting a logic state of the precharge node Q 200 into the predetermined control signal, a PMOS transistor P 100 supplying the power supply voltage Vcc to the precharge node Q 200 in accordance with the predetermined control signal (i.e., an output of the first inverter I 100 ), and a second inverter I 200 converting a reversed logic state of the precharge node Q 200 into the global redundancy signal REDGEN.
An exemplary operation of the encoder constructed as aforementioned will be explained in conjunction with the operation the redundancy control circuit.
When there is no occurrence of a redundancy operation according to the address Address, the reversed local redundancy signals REPb< 1 :M> applied to the encoder 400 are all set to logical high. Therefore, the PMOS transistors P 1 to PM controlled by the reversed local redundancy signals REPb< 1 :M> do not conductive. During this, a logical-low signal is applied to the precharge node Q 200 by way of the first NMOS transistor NT 100 .
The logical-low signal at the precharge node Q 200 is generated as a logical-high control signal through the first inverter I 100 . The logical-high control signal is output as the global redundancy signal REDGEN of logical low by way of the second inverter I 200 . During this, the logical-high control signal turns the resetting NMOS transistors NT 200 to NT 230 of the reset circuit 435 on to output the reset signals RESET< 0 : 3 > of logical low. As a result, the reset signals RESET< 0 : 3 > reset all the I/O buses, to which the I/O information signals IOBUS< 0 : 3 > becomes logical low.
Otherwise, when a redundancy operation is enabled in accordance with the address Address applied thereto, at least one of the reversed local redundancy signals REPb< 1 :M> (i.e., REP 1 to REPM) becomes a logical-low signal. Therefore, at least one of the PMOS transistors P 1 to PM is turned on.
Here, it is desirable to differentiate resistance values between the PMOS transistors P 1 to PM and the NMOS transistor NT 100 so as to apply a logical-high signal to the precharge node Q 200 by the condition of voltage division effect thereof.
The logical-high signal of the precharge node Q 200 is converted into a predetermined control signal of logical low by the first inverter I 100 . The logical-low control signal is outputted as the global redundancy signal REDGEN of logical high by way of the second inverter I 200 . During this, the logical-low control signal turns on the PMOS transistor P 100 to supply the power supply voltage Vcc to the precharge node Q 200 , and turns the resetting NMOS transistors NT 200 to NT 230 off to make the reset signals RESET< 0 : 3 > be floated.
As aforementioned, the present invention can reduce the size of the encoder (or encoding circuit) that just includes a plurality of NMOS transistors, a PMOS transistor, and an inverter. And, it is convenient to expand a circuit volume by a single unit of NMOS or PMOS transistor even when the number of the external signals increases. Moreover, while the conventional scheme has the problem of being late a time delay in a redundancy operation because there is a time delay about 3 at least from an apply of the external signal to an output of the encoding signal due to passing multiple logic states, the present invention overcomes such a limit. Further there are undesirable glitches at a subsequent I/O decoder due to the time delay of signal propagation in the conventional art, the encoder according to the present invention can eliminate the glitches of the I/O decoder because it is possible to the encoding signal, i.e., the global redundancy signal, without such a time delay.
In summary, the present invention can reduce a size of an encoding circuit (or encoder) by connecting a multiplicity of external signals to a single common precharge node to output a predetermined encoding signal.
Furthermore, the present invention prevents a time delay from the apply of the external signal to the generation of the encoding signal.
As a result, the present invention rnhances the performance of a chip because it is possible to prevent the time delay in generating the global redundancy signal of the redundancy circuit and the inducement of the glitch signals thereby.
Although the present invention has been described in connection with the embodiment of the present invention illustrated in the accompanying drawings, it is not limited thereto. It will be apparent to those skilled in the art that various substitutions, modifications and changes may be made thereto without departing from the scope and spirit of the invention. | An encoding circuit for a semiconductor apparatus and a redundancy control circuit using the same, in which a multiplicity of external signals are coupled to a precharge node in common to output a predetermined encoding signal. According to the encoding circuit, it is possible to reduce an area occupied by the encoding circuit and advantageously to prevent a time delay effect from the supply of the external signals to the generation of the encoding signal. Further, it is possible to lessen the generation of glitch signals due to delays in generating global redundancy signals of a redundancy circuit, so that the performance of the semiconductor apparatus can be improved. | 6 |
CROSS REFERENCES
The present application is a continuation-in-part of our application Ser. No. 557,282 filed Mar. 11, 1975, now U.S. Pat. No. 4,015,964, which, in turn, is a continuation-in-part of our application Ser. No. 353,984 filed Apr. 24, 1973 and issued May 27, 1975 as U.S. Pat. No. 3,885,940. The subject matter of said patent is also disclosed in the related Levecque and Battigelli U.S. Pat. No. 3,874,886.
BACKGROUND
The invention relates to the production of fine fibers from attenuable materials, particularly attenuable materials which soften upon entering a molten state as a result of the application of heat and which harden or become relatively solid upon cooling.
The method and equipment of the invention are especially suited to the formation of fibers from glass and the disclosure herein accordingly emphasizes production of glass fibers from molten glass.
Many techniques are already known for production of fibers from molten glass, some of the techniques most widely used heretofore being identified and briefly described just below.
1. Longitudinal Blowing: Other terms sometimes used include "blown fiber", "steam blown wool", "steam blown bonded mat", "low pressure air blowing", or "lengthwise jets".
2. Strand: Other terms sometimes used are "continuous filament", or "textile fibers".
3. Aerocor: Another term sometimes used is "flame attenuation".
4. Centrifuging: Other terms sometimes used include "rotary process", "centrifugal process", "tel process", or "supertel process".
There are numerous variants of each of the above four processes, and some efforts in the art to combine certain of the processes. Further, there are other techniques discussed in the prior art by which prior workers have attempted to make glass fibers. However, the variants, attempted combinations, and attempted other techniques, for the most part have not met with sufficient success to achieve a separate and recognizable status in the art.
The four techniques above referred to may briefly be described as follows.
1. Longitudinal Blowing
Longitudinal blowing (examples of which are referred to as items 1, 2, 3 and 4 in the bibliography herebelow) is a glass fiber manufacturing process according to which melted glass flows from the forehearth of a furnace through orifices in one or two rows of tips protruding downwardly from a bushing, the glass being thereby formed into multiple glass streams which flow down into an attenuating zone where the streams pass between downwardly converging gaseous blasts. The blast emitting means are located in close proximity to the streams so that the converging blasts travel in a downward direction substantially parallel to the direction of travel of the glass streams. Generally the glass streams bisect the angle between the converging blasts. The blasts are typically high pressure steam.
There are two longitudinal blowing techniques. In the first technique the attenuating blasts engage already drawn fibers and the product resulting is typically a mat, commonly known as "steam blown bonded mat", suitable for reinforcement. In the second longitudinal blowing technique the attenuating blasts strike directly on larger streams of molten glass and the product resulting is typically an insulation wool commonly known as "steam blown wool".
In a variation (see item 5) of the first longitudinal blowing technique, the entire bushing structure and associated furnace are enclosed within a pressure chamber so that, as the streams of glass emerge from the bushing, the streams are attenuated by pressurized air emerging from the pressure chamber through a slot positioned directly beneath the glass emitting tips of the bushing, this variation being commonly referred to as "low pressure air blowing", and products being commonly known as "low pressure air blown bonded mat and staple yarn".
2. Strand
The strand glass fiber manufacturing process (see items 6 and 7) begins in the manner described above in connection with longitudinal blowing, that is, multiple glass streams are formed by flow through orifices in tips protruding downwardly from a bushing. However, the strand process does not make use of any blast for attenuation purposes but, on the contrary, uses mechanical pulling which is accomplished at high speed by means of a rotating drum onto which the fiber is wound or by means of rotating rollers between which the fiber passes. The prior art in the field of the strand process is extensive but is of no real significance to the present invention. Strand techniques therefore need not be further considered herein.
3. Aerocor
In the aerocor process (see items 8 and 9) for making glass fibers, the glass is fed into a high temperature and high velocity blast while in the form of a solid rod, rather than flowing in a liquid stream as in the longitudinal blowing and strand processes discussed above. The rod, or sometimes a coarse filament, of glass is fed from a side, usually substantially perpendicularly, into a hot gaseous blast. The end of the rod is heated and softened by the blast so that fiber can be attenuated therefrom by the force of the blast, the fiber being carried away entrained in the blast.
4. Centrifuging
In the centrifuging glass fiber manufacturing process (see items 10 and 11) molten glass is fed into the interior of a rapidly rotating centrifuge which has a plurality of orifices in the periphery. The glass flows through the orifices in the form of streams under the action of centrifugal force and the glass streams then come under the influence of a concentric and generally downwardly directed hot blast of flames or hot gas, and may also, at a location concentric with the first blast and farther outboard from the centrifuge, come under the action of another high speed downward blast, which latter is generally high pressure air or steam. The glass streams are thereby attenuated into fine fibers which are cooled and discharged downwardly in the form of glass wool.
In addition to the four categories of fiber forming techniques which have been very generally referred to and distinguished above, various refinements and variations of those techniques have also been known and repeated efforts have been made to optimize the manufacture of glass fibers by one or more of the processes which start with molten streams of glass. Various of these prior art techniques have been concerned with trying to optimize the attenuation process by extending or lengthening the attenuation zone, either by providing special means to accomplish the addition of heat to the streams of glass and to the embryonic fibers (see item 12), or through the use of confining jets (see items 13 and 14), or both (see item 15).
The approach taken in the just mentioned prior art technique suggests that the realization of optimum fiberization lies in extending the length of a single attenuating zone.
In contrast, in the practice of the present invention, attenuation is accomplished by subjecting a glass stream to two sequential stages of attenuation, performed under different conditions, as will further appear.
Various other approaches have been suggested for introducing glass in the molten state into an attenuating blast (see items 16, 17, 18 and 19). In such attempts to introduce a stream of molten glass into an attenuating blast it has been noted that there often is a tendency for the glass stream to veer to a path of travel on the periphery of the blast, that is, to "ride" the blast, rather than penetrating into the core region of the blast where attenuating conditions are more effective. Suggestions have been made to deal with this "riding" problem, including the use of physical baffles as in Fletcher (item 16), and the transfer of substantial kinetic energy to the glass stream as, for example, by the modifications of the centrifuging process taught in Levecque (item 11), Paymal (item 18), and Battigelli (item 19).
An alternate approach to the problem, more closely akin to the aerocor process, has been the introduction of the glass in the form of a solid (item 9) or pre-softened (item 20) glass rod or in the form of powdered glass (item 14).
______________________________________BIBLIOGRAPHY OF PRIOR PATENTS______________________________________(1) Slayter et al 2,133,236(2) Slayter et al 2,206,058(3) Slayter et al 2,257,767(4) Slayter et al 2,810,157(5) Dockerty 2,286,903(6) Slayter et al 2,729,027(7) Day et al 3,269,820(8) Stalego 2,489,243(9) Stalego 2,754,541(10) Levecque et al 2,991,507(11) Levecque et al 3,215,514(12) Stalego 2,687,551(13) Stalego 2,699,631(14) Karlovitz et al 2,925,620(15) Karlovitz 2,982,991(16) Fletcher 2,717,416(17) Eberle 3,357,808(18) Paymal 3,634,055(19) Battigelli 3,649,232(20) Stalego 2,607,075______________________________________
General Statement of the Invention and Objects
In contrast with all of the foregoing prior art techniques, it is a major objective of the present invention to provide certain improvements in the production of fibers from streams of molten glass or similar attenuable materials. The technique of the present invention in part utilizes the fiber toration techniques or principles disclosed in our prior applications above identified Ser. No. 557,282, now U.S. Pat. No. 4,015,964, and Ser. No. 353,984, which latter is now U.S. Pat. No. 3,885,940. Thus, the technique of the present invention makes use of the attenuating capability of a zone of interaction developed by the direction of a secondary jet of relatively small cross section transversely into a principle blast or jet of relatively large cross section. However, according to the present invention, instead of directly admitting or delivering a stream of molten glass to the zone of interaction, the glass stream is delivered from an appropriate orifice spaced an appreciable distance above the zone of interaction.
Moreover, in a typical technique according to the present inventon, the blast is discharged in a generally horizontal direction, the glass admission orifices are arranged in spaced relation above the blast, and at an intermediate elevation, secondary jets are discharged downwardly toward the blast from jet orifices positioned adjacent to the decending glass streams, and preferably inclined somewhat with respect to the vertical, so that the glass streams enter the influence of the jets at a point above the upper boundary of the blast, but well below the glass orifices. Preferably also each secondary jet orifice and the associated glass stream are spaced from each other in a direction upstream and downstream of the direction of flow of the blast, with the jet orifice located, with respect to the direction of flow of the blast, on the upstream side of the glass stream.
The system of the invention, as just briefly described, functions in the following manner:
Each secondary jet, being spaced appreciably above the upper boundary of the blast, causes induction of the ambient air so that the jet develops a sheath or envelope of induced air which progressively increases in diameter as the upper boundary of the blast is approached. The jet thus is comprised of two portions, i.e. the core itself which is initially delivered from the jet orifice and the main body of the jet which is frequently referred to as the mixing zone, i.e. the zone represented by the mixture of the gas of the core with induced air.
In a typical embodiment, the jet core extends for a distance beyond the jet orifice equal to from 3 to 10 times the diameter of the jet orifice, depending primarily upon the velocity of the jet through the orifice. Since in installations of the kind here involved, the jet orifices are of only very small diameter, the extent to which the jet core is projected beyond the orifice is relatively short. The jet core is conical and the mixing zone surrounds the jet core from the region of delivery from the jet orifice and is of progressively increasing diameter downstream of the jet, including a length of travel extended well beyond the tip of the jet core cone. In such a typical installation, the spacing between the jet orifice and the boundary of the blast is such that the point of intersection of the blast lies beyond the tip of the core, although with certain proportions the jet core may come close to or somewhat penetrate the blast. In any event, it is contemplated that at the point of intersection of the jet and blast, the body of the jet or jet stream retains sufficient kinetic energy or velocity to penetrate the blast and thereby develop a zone of interaction between the jet and the blast. This zone of interaction has the same general characteristics as the zone of interaction referred to and fully described in our prior applications Ser. No. 557,282 and Ser. No. 353,984, above identified.
With the foregoing in mind, attention is now directed to the glass stream and its behavior in relation to the jet and blast. As already noted, the glass stream is delivered from an orifice spaced above the blast and also spaced appreciably above the point of delivery or discharge of the secondary jet. Preferably the glass discharge orifice is so located as to deliver a stream of glass which by free-fall under the action of gravity will follow a path which would intersect the axis of the jet at a point appreciably above the upper boundary of the blast and thus also above the zone of interaction. As the glass stream approaches the jet, it is influenced by the currents of induced air and is thereby caused to deflect toward the jet above the point where the glass stream would otherwise have intersected the axis of the jet. The induction effect causes the stream of glass to approach the jet and, depending upon the position of the glass orifice, the induction effect will either cause the glass stream to enter the envelope of induced air surrounding the core, or will cause the glass stream to enter the main body of the jet at a point downstream of the jet core. In either case, the glass stream will follow a path leading into the mixing zone and the glass stream will travel within the body of the jet downwardly to the zone of interaction with the blast.
Thus, the glass stream is carried by the induced air currents into the mixing zone of the jet, but does not penetrate the jet core. The glass stream may be carried by the induced air to the surface of the jet core, but will not penetrate the core, which is desirable in order to avoid fragmentation of the glass stream. Since the glass stream is at this time in the influence of the mixing zone of the jet, the stream of glass will be subjected to a preliminary attenuating action and its velocity will increase as the upper boundary of the blast is approached.
In addition to this attenuating action, which is aerodynamic in character, the attenuating stream is subjected to certain other dynamic forces tending to augment the attenuation. This latter attenuation action is caused by the tendency for the attenuated stream to move toward the center of the jet and then be reflected toward the boundary of the jet into the influence of the air being induced. The attenuating stream is then again caused to enter into the interior of the jet. This repeated impulsion supplements the aerodynamic attenuating action.
In the region of interaction with the blast, the partially attenuated stream of glass will be caused to enter the zone of interaction, in part because of the acceleration of the glass resulting from the action of gravity and from the preliminary attenuation described just above, and in part under the influence of the currents established in the zone of interaction itself, in the manner fully explained in our prior applications Ser. No. 557,282 and Ser. No. 353,984, above identified.
Thus it will be seen, that according to the invention, the glass stream is subjected to two successive stages of attenuation. It is also to be observed that since the glass stream is caused to come under the influence of the jet by virtue of the induced currents surrounding the jet, the preliminary attenuation is accomplished without fragmenting the glass stream. Moreover the succeeding or second stage of attenuation which is effected in the zone of interaction between the jet and the blast is also accomplished without fragmenting the fiber being formed. By this two stage attenuating technique it is thus possible to produce long fibers.
The technique of the present invention has important advantages as compared with various prior techniques. Thus, it provides a technique for the production of long fibers while at the same time making possible greater separation between certain components of the equipment, notably the blast generator or burner, with its nozzle or lips, the jet nozzle and the gas or air supply means associated therewith and the glass supply means including the bushing or similar equipment having glass orifices. This separation of components is not only of advantage from the standpoint of facilitating the structural installation, but is further of advantage because the separation makes possible more convenient and accurate regulation of operating conditions, notably temperature of the blast, jets and glass supply means. Still another advantage of the arrangement according to the present invention, is that the spacing of the glass supply means with its orifices for discharging streams of glass makes possible the utilization of larger glass orifices (which is sometimes desirable for special purposes or materials) because, in the distance of free-fall provided for the glass streams, such streams decrease in diameter under the influence of the gravitational acceleration. The streams should of course be of relatively small diameter at the time of initiation of attenuation, and the desired small diameter can readily be achieved, because of the distance of free-fall, notwithstanding the employment of delivery orifices of relatively large size.
The foregoing has still another advantageous feature, namely the fact that a higher temperature may be utilized in the glass bushing or other supply means, thereby enabling use of attenuable materials at higher temperatures, because during the distance of free-fall of the glass stream, the stream is somewhat cooled because of contact with the surrounding air, thereby bringing the stream down to an appropriate temperature for the initiation of attenuation.
Because of various of the foregoing factors, the system of the present invention facilitates the use of certain types of molten materials in the making of fibers, for instance slag or certain special glass formulations which do not readily maintain uniformity of flow through discharge orifices of small size. However, since both larger diameter discharge orifices and higher temperatures may be used in the supply of the molten material, it becomes feasible to establish uniformity of feed and attenuation even with certain classes of attenuable materials which could not otherwise be employed in a technique based upon production of fibers by attenuation of a stream of molten material.
It is also noted that various of the four principle prior art techniques referred to above are subject to a number of limitations and disadvantages. For example, various of the prior techniques are limited from the standpoint of production capacity or "orifice pull rate", i.e. the amount of production accomplished within a given time by a single fiber producing center. In other cases, the fiber product contains undesirable quantities of unfiberized material. Strand type of operations, while effective for producing strand material, are not best suited for production of insulation type of fiber blanket and other similar types of products. Centrifuging, while effective for producing fiber insulation blanket has the disadvantage that the centrifuge must rotate at high speed, thus necessitating special working parts and maintenance, and further because the centrifuge is required to be formed of special alloys capable of withstanding the high temperatures.
Another general objective of the present invention is to provide a technique which overcomes various of the foregoing disadvantages or limitations of the prior art techniques referred to.
Moreover, the technique of the present invention provides for high production rates and utilizes only static equipment.
DETAILED DESCRIPTION OF THE INVENTION
The accompanying drawings illustrate, on an enlarged scale, a preferred embodiment of the present invention, and in these drawings
FIG. 1 is a fragmentary isometric view showing equipment including means for developing a blast, means for developing a series of secondary jets above the blast and directed downwardly toward the blast, together with means for establishing glass streams delivered by gravity from a region above the jets downwardly into the zone of influence of the jets and ultimately into the influence of the zone of interaction with the blast;
FIG. 2 is a vertical sectional view through equipment for establishing a single fiberizing station as arranged according to the present invention; and
FIG. 3 is a view similar to FIG. 2 but more diagrammatic and further illustrating certain dimensional relationships to be taken into account in establishing operating conditions in accordance with the preferred practice of the present invention.
In the drawings, the glass supply means includes a crucible or bushing 1 which may be supplied with molten glass in any of a variety of ways, for instance by means of the forehearth indicated at 2 in FIG. 3. Glass supply orifices 3 deliver streams of molten glass downwardly under the action of gravity as indicated at S.
A gaseous blast is discharged in a generally horizontal direction from the discharge nozzle 4, the blast being indicated by the arrow 5. The blast may originate in a generator, usually comprising a burner, so that the blast consists of the products of combustion, with or without supplemental air.
As will be seen from the drawings, the blast is directed generally horizontally below the orifices 3 from which the glass streams S are discharged.
At an elevation intermediate the crucible and the blast discharge device 4, jet tubes 6 are provided, each having a discharge orifice 7, the jet tubes receiving gas from the manifold 8 which in turn may be supplied through the connection fragmentarily indicated at 9.
The gases for delivery to and through the jet tubes 6 may originate in a gas generator taking the form of a burner and the products of combustion may serve for the jet, either with or without supplemental air. Preferably the combustion gases are diluted with air so as to avoid excessively high temperature of the gas delivered through the jet tubes.
Each jet tube 6 and its orifice 7 is arranged to discharge a gaseous jet downwardly at a point closely adjacent to the feed path of one of the glass streams S and preferably at the side of the stream S which, with respect to the direction of flow of the blast 5, is upstream of the glass stream. Moreover, each jet tube 6 and its orifice 7 is arranged to discharge the jet in a path directed downwardly toward the blast and which is inclined to the vertical and so that the projection of the paths of the glass stream and the jet intersect at a point spaced above the upper boundary of the blast 5.
It is contemplated that the vertical dimension of the blast and also the width thereof be considerably greater than the cross sectional dimensions of each secondary jet, so that adequate volume of the blast will be available for each jet to develop a zone of interaction with the blast. For this purpose also, it is further contemplated that the kinetic energy of the jet in relation to that of the blast, in the operational zone of the jet and blast, should be sufficiently high so that the jet will penetrate the blast. As pointed out in our applications Ser. No. 557,282 and Ser. No . 353,984, this requires that the kinetic energy be substantially higher than that of the blast, per unit of volume. Still further, the jet preferably has a velocity considerably in excess of the velocity of the glass stream as fed under the action of gravity downwardly toward the point of contact with the jet and sometimes also in excess of the velocity of the blast.
The operation of each fiberizing center is as follows:
From the drawings and especially from FIG. 2, it will be seen that the core C of the jet causes the induction of currents of air indicated by the lines A, the amount of air so induced progressively increased along the path of the jet. When the body of the jet, i.e. the gas of the core intermixed with the induced air, reaches the boundary of the blast, a zone of interaction is established in the region indicated by cross-lining marked I in FIG. 2.
As the stream S of molten glass descends and approaches the jet delivered from the orifice 7, the currents of air induced by the action of the jet cause the stream of glass to deflect toward the jet core as indicated at 10. Although the glass orifice 3 may be of substantially larger diameter or cross section than the jet orifice 7, the gravity feed of the glass stream S results in substantial reduction in diameter of the glass stream, so that when the stream meets the jet, the diameter of the stream is much smaller than the diameter of the glass orifice. With the higher velocity of the jet, as compared with that of glass stream, even when the glass stream meets the jet in the upstream region adjacent the jet core, the glass stream will not penetrate the jet core. However, because of the induced air currents surrounding the jet, the glass stream is caused to "ride" on the surface of the jet core within the surrounding sheath of induced air or to enter the body of the jet downstream of the jet core.
The action of the induced air in bringing the glass stream to the jet stabilizes the feed of the glass stream and will also assist in compensating for minor misalignment of the glass orifice with respect to the jet orifice. Because of the reliance upon induction effects of an isolated jet, the glass stream is brought into the mixing zone of the gas originating in the jet core and the induced air without subdivision or breakage of the stream or the fiber being formed. This action is enhanced by virtue of the fact that in the arrangement as above described and illustrated, the glass stream is not subjected to any sharp angled change in its path of movement before it has been subjected to some appreciable attenuation, thereby reducing its diameter and inertia.
In consequence of the glass stream being carried in the mixing zone of the jet, the glass stream is partially attenuated, this action representing the first stage of the two-stage attenuation above referred to. In turn, in consequence of this partial attenuation, the length of the embryonic fiber is increased, and this increase in length is accommodated by an undulating or whipping action, thereby forming loops, as indicated at 12. It is to be noted, however, that the glass stream remains intact, the loops of the embryonic fiber being carried downwardly in the mixing zone.
At the point where the blast 5 intercepts the jet, the jet penetrates the blast. This penetration of the blast by the jet establishes currents in the zone of interaction of the jet with the blast, which currents carry the partially attenuated glass stream into the interior of the blast and in consequence a second stage of attenuation occurs. This results in further increase in the length of the fiber being formed. The increase in fiber length is accommodated by additional undulating or whipping action, forming further enlarged loops as indicated at 13 within the blast. Notwithstanding this action, a typical fiber will remain intact and will be carried away by the blast flow in the form of a fiber of considerable length. Thus a single stream of molten glass is converted into a single glass fiber by a two-stage attenuation operation. It will be understood that in effecting this two-stage attenuation, the temperature of the glass and the temperature of the jet, as well as the temperature of the blast, are established at values which will retain the glass in attenuable condition throughout the first stage of attenuation and throughout the second stage until the attenuation has been completed in the zone of interaction between the jet and the blast.
In connection with the arrangement of the invention, it is to be understood that fiberizing centers may be arranged in multiple, as illustrated in FIG. 1. This is accomplished by employing a blast 5 which is broad or of large dimension in the direction perpendicular to the plane of FIG. 2, and by employing a similarly extended crucible 1 having a multiplicity of glass orifices, and further by employing a multiplicity of jet tubes 6 each having an orifice adjacent to one of the streams S of glass being delivered from the several glass orifices, all as shown in FIG. 1. Such a multiplicity of jet tubes may be supplied with the jet gas from a common manifold 8.
The disclosure of the above identified applications Ser. No. 557,282 and Ser. No. 353,984, may be referred to for further information in connection with the general arrangements providing for accommodation of multiple fiberizing centers and also for numerous other features, such, for example, as fiber collection means, glass feed systems and blast and jet generating and delivery systems, and including also information concerning the parameters involved in establishing a zone of interaction of a jet and blast.
In connection with various dimensional relationships involved in the equipment of the present invention, particular attention is directed to FIG. 3 on which certain symbols have been applied to identify some of the dimensions. These are identified in the following table which also gives an average or typical value in milimeters, as well as a usable range for each such value.
__________________________________________________________________________ VARIA- AVERAGE TION VALUE LIMITSFEATURE DIMENSION SYMBOL (mm) (mm)__________________________________________________________________________Bushing Diameter of glass d.sub.T 4 1 - 10 orifice Distance between 2 holes 10 5 →Jet Inner diameter of jet tube d.sub.t 1 0.3 - 3 Outer diameter of jet tube 1.5 0.7 - 5 Separation between 2 tubes 10 5 →Blast Vertical distance between 1.sub.B 25 10 - 50 the lips or thickness of the discharge section Width of the discharge 300 20 - 500 section__________________________________________________________________________
In addition to the foregoing dimensions, certain spacing relationships and also angular relationships should be observed, as indicated in the following table which gives an average or typical value in milimeters or degrees, as well as a usable range for each such value.
__________________________________________________________________________ AVERAGE VARIATION VALUE LIMITS (mm or (mm orFEATURES SYMBOL degree) degree)__________________________________________________________________________Vertical distance of jet discharge orifice Z.sub.JB 45 30 - 60to the upper boundary of flow of the blastVertical distance from the discharge Z.sub.JF 85 0 - 150opening of the glass stream to the jetdischarge orificeHorizontal distance from the axis of the X.sub.JF 5 1 - 15glass stream to the jet discharge orificeHorizontal distance from the axis of the X.sub.BF 5 0 - 30glass stream to the lip of the blastnozzleAngle of jet tube to the axis of glass αjf 10° 3° - 45°streamAngle of jet tube to the direction of αJB 80° 87° - 45°flow of the blast__________________________________________________________________________
With further reference to parameters of operation when employing the technique of the present invention, it is first pointed out that it is of course important that the glass be discharged from the glass orifice in a continuous stable stream. For this purpose, the rate of glass flow, the temperature of the bushing and the diameter of the glass discharge orifice should preferably be above certain predetermined limits. Thus, the pull rate of glass should be greater than 60 kg/hole for each 24 hour period; the bushing temperature should be greater than 1250° C., and the diameter of the glass discharge orifice should be greater than 2.5 milimeters. With at least certain types of glass formulations, observing these limits may assist in avoiding pulsations which have a tendency to accentuate until distinct droplets are formed. This phenomenon is incompatible with proper fiberization. In a typical or average working condition, the following values are appropriate; 100 kg/hole per day, bushing temperature 1400° C., glass orifice diameter 3 milimeters.
Additional operating ranges are as follows:
______________________________________Velocity jet 200 m/sec - 900 m/sec blast 200 m/sec - 800 m/secPressure jet .5 to 50 bars blast .05 to .5 barsTemperature jet 20° to 1800° C blast 1300° to 1800° CKinetic Energy Ratio - jet to blast 10/1 - 1000/1______________________________________
A typical operation according to the present invention may be carried out as given in the Example below.
EXAMPLE
______________________________________Glass formulation:SiO.sub.2 46.92Fe.sub.2 O.sub.3 1.62Al.sub.2 0.sub.3 9.20MnO 0.16CaO 30.75MgO 3.95Na.sub.2 O 3.90K.sub.2 O 3.50All parts by weight.Physical PropertiesViscosity 30 poises at 1310° C 100 poises at 1216° C 300 poises at 1155° CGlass orifice 3mm flow 100 kg/day per orificeBlast temperature 1550° C pressure .25 bar velocity 530 m/sJet temperature 20° C pressure 6 bar velocity 330 m/s orifice diameter 1 mmRatio of Kinetic energies ##STR1##Fiber diameter 6 microns______________________________________ | Method and apparatus are disclosed for converting a stream of attenuable material into a fiber by a two-stage attenuation technique, the two stages being effected sequentially by employment of a gaseous jet and a gaseous blast, thereby producing a single long fiber from each stream of attenuable material. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a machine which provides a resisting force for use in electronic- or computer-controlled equipment for exercise, training, or physical therapy.
Exercise has historically fallen into two categories: aerobic exercise and resistance exercise. Aerobic exercise is characterized by low resistance to the user's motion, but maintained at high speed for an extended period of time resulting in increased heartbeat and breathing rates. Resistance exercise, however, involves a greater resistance for shorter periods of time to intentionally break down and regenerate muscle tissue and lead to increased muscle bulk and strength. Equipment for both aerobic and resistance exercise have recently progressed into electronically enhanced versions.
The aerobic machines have progressed more rapidly into electronically enhanced versions due to two characteristics of this type of exercise: (1) relatively low resistance, and (2) intermittently or slowly varying resistance force levels over time.
This progression is evidenced by the recent introduction of electronically controlled rowing machines by Precor and AMF, and by the electronic stationary bicycles available from Bally, and by the computer-monitored moving staircase by Stainmaster.
The progress of electronically enhanced resistance equipment has progressed into mechanical machines of axles, pulleys, chains, wire rope, sprockets, and handlebars which could transmit the user's motion into the raising and lowering of stacks of weights. These machines made resistance exercise more convenient and could isolate individual muscle groups more effectively.
A mechanical enhancement of resistance equipment was patented by Jones [U.S. Pat. No. 3,858,873]. This invention added sophistication to weight-based machines by adding the capability of varying the resistance level as a function of the position of the user's moving member. This advancement is especially important where gravitational forces alone do not result in constant resistance throughout the exercise stroke, as in rotary exercises performed with free weights.
Later, electronic control of resistance began to enhance resistance exercise. Flavell (1973) discloses in U.S. Pat. No. 3,869,121 a machine that provides braking resistance in one direction through the use of an electric brake, and motion in the other direction using, for example, an electric motor or spring. Flavell later introduced [U.S. Pat. No. 4,184,678] an electromechanical machine that could regulate the user's motion against a desired, predetermined, force vs. speed characteristic, thereby creating a speed-programmable device. Still another of Flavell's U.S. patents, U.S. Pat. No. 4,261,562, advanced the speed-programmable device to include a motor with a wound stator interacting with rotating magnets to provide the resistance force. This resistance force is generated by the energy dissipated in an electrical loading of the stator windings. A similar exercise device was disclosed by Dorfman in U.S. Pat. No. 4,602,373 is which two electrically shorted commutator brushes are positioned against a rotating coil to regulate the resistance torque.
Bruder [U.S. Pat. No. 4,518,163] produced a machine that provided braking resistance levels as a stepwise function of the position of the user's moving member. With electronic control, the possibility of having random resistance levels, not predictable by the user, was reduced to practice by Sweeny in U.S. Pat. No. 4,358,105. Having resistance levels increase or decrease adaptively as a function of the user's performance was conceived by Jungerwith and such a machine was disclosed in his U.S. Pat. No. 4,323,237.
Electronic resistance also enables sophisticated monitoring of the user's performance during the exercise process. Barron patented a device [U.S. Pat. No. 3,984,666] which could accumulate and display calories expended during exercise using a resistance mechanism based on an alternator. Relyea [U.S. Pat. No. 4,408,613] extended this concept by having an audio-visual system instruct the user while controlling resistance through an electric brake. A motor-clutch combination was proposed as a resistance mechanism by Fulks in U.S. Pat. No. 4,569,518. The variable clutch selectively applies torque from the motor to the user during exercise.
The demand for the user himself or his trainer, coach, or therapist to program individualized resistance profiles as a function of position was partially fulfilled by Ariel, as revealed in his U.S. Pat. No. 4,354,676. The programmability of a resistance machine represented an advancement in flexibility of resistance exercise. This system could also accumulate and display characteristics and statistics of the user's exercise. A later U.S. Pat. No. 4,544,154 by Ariel employed feedback control circuitry, leaving the computer more computational time for monitoring and graphical display. This patent specified a hydraulic cylinder as the resistance device.
Although the Ariel machine is programmable, it does assume the availability of a resistance mechanism that can respond to electrical signals. Much less work is apparent in the provision of a generalized, electronic resistance device having the characteristics needed to (1) be adaptable to a broad range of exercise machines, even retrofitted to existing weight-based systems, and (2) be capable of interfacing to electronic or computer based control in a variety of exercise modes. To fulfill need (1) the resistance device must be capable of providing potentially high levels of resistance. To fulfill need (2) the electronics and mechanical system must have a short response time (i.e. the time between a force resistance level is commanded by a computer or electronic circuit and the time that the resistance force is actually available).
Fulfilling both of these needs simultaneously represents an engineering challenge due to electrical and mechanical inertia forces typically present in electric brakes or other force-generating devices. Mechanical inertia exists in the form of static and dynamic friction and rotational mass of the gear trains. Electrical inertia exists in the inductance of coils needed to generate electromagnetic forces. Although the Ariel patent does suggest using computer control to remove these anamolous forces, it does not discuss the fast response required of the resisting device.
The response-time problem was addressed in European patent application No. 0060302, by applicant Mitsubishi Kinzoku Kabushiki Kaisha, entitled "Muscle Training and Measuring Machine", filed on May 5, 1981. A solution to the problem, presented in the patent application, was the use of a hydraulic servo amplifier. The resulting invention was a hydraulic-based resistance mechanism capable of responding quickly to electrical signals. This patent application also revealed the necessity of quick response for most forms of sophisticated resistance exercise including isokinetic and isometric. This patent application also faulted motor- and brake-based resistance mechanisms for having resistance characteristics that are difficult to control, mentioning specifically friction and rotary mass of the rotor and gears. Although this invention claimed to solve the inertia problems for hydraulic-based resistance system, no known solution for brake-based systems is available. Brakes have advantages over hydraulics and motor based systems. Hydraulic cylinders contain a fluid that can leak and needs to be replaced periodically. Motors have a greater change of violating the user's safety than brakes. Motors create motion, but brakes only resist motion created by the user. If the user becomes weakened during exercise, a motor will continue to burden the user, possibly to the point of injury. Free weights as well as motors have this safety disadvantage relative to brakes.
Hence, the need does exist for a fast responding brake-based resistance mechanism, which is capable of high resistance forces and is adaptable to all modes of exercise in a safe manner. These needs are satisfied by the invention disclosed herein. This invention difers from the Flavell machine disclosed in U.S. Pat. No. 4,261,562 (previously mentioned) in that a brake is used to control forces directly rather than by varying the load on an electric motor acting as a generator. Load variation only permits varying the constant of proportionality between force and speed, whereas an electric brake can generate a force independent of, or arbitrarily dependent on, speed. This invention teaches a fast responding control system for a brake-based machine.
Three types of electric brakes are of common availability. The first type is the friction brake, in which an electric current flows through a coil of wire in the stationary portion (stator) producing a magnetic field which pulls the moving portion (rotor) in contact with the stator. The force of contact resists the motion of the rotor through friction properties of the material in contact.
The second type of electric brake is the hysteresis brake. In a hysteresis brake, an electric current flowing in a coil creates a large magnetic field in a cylindrically shaped gap. The rotor contains appreciable area which rotates within this gap. Motion of the rotor causes periodic magnetization and demagnetization of the rotor material. Each magnetization cycle involves an energy loss, and this loss generates a force resisting the motion of the rotor.
A third type of brake is the particle brake, which combines the features of the hysteresis and friction brakes. Small particles are present in the gap between the rotor and the stator. The resistance is produced by both friction of the particle motion and the repeated reverse magnetization of the particles. Greenhut disclosed in U.S. Pat. No. 4,620,703 a machine that employs a particle brake generating a resistance in both directions of exercise motion. Greenhut also mentioned the response time problem of brakes, and thereby proposed the more efficient particle brake combined with a transmission system having a high gear ratio.
The frictional properties of materials used in friction brakes tend to vary with rotor speed, making the force vs. current characteristic non-ideal. The difference between static and dynamic friction causes an undesirable jerky motion when exercising with a friction-brake-based resistance machine.
Hysteresis brakes tend to have a more constant force vs. velocity relationship, but the absence of material contact causes the hysteresis brake to be less efficient than the friction brake in producing a torque in response to a given input current. The loss of efficiency is regained in using larger coils, but this in turn increases the electrical inertia, or inductance, which is a problem when trying to change electrical current levels (and hence resistance force levels) quickly during the exercise process.
The desire to use smaller, lower cost, electric brakes can be fulfilled by using gear trains in the mechanical coupling of the user's motion to the rotary motion of the brake. The gear train causes the brake's rotor to rotate more quickly, hence magnifying the resistance apparent to the user. The gear train also introduces friction regardless of the type of brake used. Also, the rotary mass of large gears can be particularly noticeable at the start and end of the exercise stroke. At the start of the stroke, the user must exert more to bring the system up to a desired exercise speed. At the end of the stroke, the kinetic energy of the system, and not the user's exertion, keeps the system in motion. Hence, rotary mass interferes with the exercise process.
The problems discussed previously, i.e. those of inductance and rotary mass can be solved through the use of this invention. In addition, this invention can provide exercise modes not previously available from brake-based machines. The prior art brake-based resistance machines available from Paramount provide slowly varying forces, and hence is limited to a single mode of exercise (isotonic). This invention, with the addition of sensors and compensation circuits, further improves over the prior art by making possible brake-based resistance with additional exercise modes, including isokinetic, isometric, and viscous.
Isokinetic and isometric exercise modes are well known. Isokinetic means "constant speed", and isokinetic resistance machines resist the user's motion to the extent necessary (and no further) to maintain a constant speed of motion. In brake-based resistance systems, no resistance is applied until the user reaches the set speed, and is henceforth maintained at that speed. Isometric means "constant position" and isometric machines oppose the user's exerted force such that very little motion is produced. In practical brake-based resistance machines, isometric exercise is equivalent to a very slow isokinetic exercise. A single position cannot be maintained exactly due to the inability of the brake to produce motion. Viscous resistance is not as well known, but is also a desirable exercise mode. In viscous resistance, the resulting force is proportional to the speed of motion. This exercise mode is unique in the smoothness of motion created. Hydraulic cylinders, in which a fluid is pushed through a small hole produces viscous resistance naturally. This invention permits viscous resistance to be simulated accurately using an electric brake.
SUMMARY OF THE INVENTION
This invention relates to an apparatus consisting of an electric circuit that drives an electric current into an electric brake which accomplishes the following functions:
(1) generates braking forces nearly instantaneously in response to electrical command signals and provides a continuously varying resistance vs. position mode of operation during an exercise stroke,
(2) permits, with the addition of a compensation circuit, isokinetic, isometric, or viscous mode of resistance, and
(3) permits, with the addition of compensation circuits, cancellation of friction, gravitational or inertia forces associated with rotational mass anomalies in the mechanical drive train.
The invention is versatile and capable of any one of the mentioned exercise modes in (1) and (2) simultaneous with the compensations of (3).
The input signal to the circuit of the invention is a low voltage, possibly time varying, signal from a computer or other electronic circuit. The output function is a mechanical resistance force, large enough for meaningful exercise, but at all times closely proportional in magnitude to the voltage of the input signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a schematic diagram of a circuit controlling an exercise machine that embodies the invention.
FIG. 1(b) presents the response curve of the resistance force of the machine of FIG. 1(a) to a step increase in the desired resistance force signal.
FIG. 1(c) presents the response curve of the brake current and collector-emitter transistor voltage Vce to a step decrease in the desired resistance force signal.
FIG. 2 is a block diagram showing the invention being used to create isokinetic resistance.
FIG. 3 is a block diagram showing the invention being used to create viscous resistance.
FIG. 4 is a block diagram showing the invention being used to vary the resistance level as an explicit function of the position of the user's moving member.
FIG. 5 is a block diagram showing the invention being used to cancel the unwanted but known effects of friction, whose forces are a known function of velocity.
FIG. 6 is a block diagram showing the invention being used to cancel the unwanted problems of rotary mass typical of transmissions with large gear ratios.
FIG. 7 is a block diagram showing the invention being used to cancel friction and rotary inertia, and switch selectable modes for isotonic, isokinetic, and isometric resistance.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Refering to FIG. 1(a), there is shown an exercise machine having a mechanism 14 to engage and move under the force of a user's moving member. The user's motion is coupled to the rotor of an electrically activated brake 15 through a mechanical transmission system 16. Brake 15 provides a resistance torque to its rotor when an electrical current is flowing in the stationary coil. The rotational motion of the brake rotor is also coupled to a velocity sensor or tachometer 17 by transmission 16. The entire mechanical system is supported by a frame 13 to provide structural stability. The brake 15 is activated electrically by means of current flowing through a coil 5 shown schematically as resistor 6 (having a value R2) and an inductor 7 (having a value L).
An input voltage signal representative of the desired torque from a variable voltage source is provided at terminal 1. The variable voltage source could be a potentiometer producing a voltage level that varies between two limits, or it could be a digital computer capable of generating an analog voltage through a digital-to-analog converter. The voltage level from the voltage source is applied to terminal 1 of a high gain difference amplifier 2, which amplifies the magnitude of the voltage relative to a sensed voltage relative to ground across current-sensing resistor 12. The output signal of the difference amplifier 2 is switched to the base of transistor 3 by means of switch 21 in response to the output signal of the tachometer 17. When the velocity sensor 17 produces a signal having a voltage level that is greater than a set minimum level voltage signal applied to input terminal 19 of comparator 18, a logical one voltage signal is applied to line 22 which closes switch 21. Otherwise switch 21 remains open.
When the speed of the user's motion exceeds the speed represented by the velocity signal on terminal 19, difference amplifier 2 is able to energize a transistor 3, which is a current amplifier. Transistor 3 could be a bipolar transistor as shown, or it could be a Mosfet transistor with gate, source, drain connected the same way as the base, collector, emitter, respectively, of the bipolar transistor. A silicon controlled rectifier (SCR) could also be used in place of bipolar transistor 3 with the gate, anode, cathode connected the same way as the base, collector, emitter, respectively. For proper operation with an SCR, the power supply voltage applied to the anode must dip below the SCR's turn-off voltage periodically at a fast rate.
The degree to which transistor 3 is energized is controlled by the magnitude of the difference between the signals on the non-inverting and inverting input terminals of amplifier 2, i.e. the difference between the desired level of resistance force and the resistance force provided by the brake.
Difference amplifier 2 is selected to have a high gain such that servo action causes the voltage signal representative of the brake current sensed by resistor 12 to stabilize quickly to the voltage level on terminal 1. The end result is that the resistance force generated by the brake follows the desired resistance force represented on the input terminal 1. The servo action is explained in more detail below.
The current flowing in the coil 5 and in resistor 12 is produced by a voltage difference existing between a DC voltage on line 23 and ground 20. This DC voltage is derived from an available AC voltage source 11 that is isolated from the remainder of the circuit of the present invention by an isolation transformer 10, and then rectified by a rectifier 9. Resistor 8 (having value R1) is inserted between rectifier 9 and coil 5 to limit the maximum current flow possible in the coil 5 to a safe level. A voltage clamping device 4 is connected between the emitter and collector of transistor 3. Device 4 has a very low electrical resistance when voltage across it exceeds a particular "clamping" voltage level, otherwise it has a high serial resistance. Metal oxide varistors and zener diodes exhibit this variable resistance characteristic, and either could be used as the clamping device. The clamping device 4 protects the transistor 3 from unusually high voltages that occur in circuits with a large inductance, e.g. coil 5 having inductive component 7 (L).
Resistor 12 is used to sense the current flowing in the brake during exercise motion. This current is related to the torque being exerted by the user, and hence resistor 12 voltage is a measure of the exerted torque. The exerted torque can also be measured, or sensed, by a pressure transducer mounted somewhere in the mechanical coupling of the user's force. The output of the pressure transducer is a voltage proportional to the user's force, which can be substituted for the voltage across resistor 12. Also, a strain guage could sense the user's torque if mounted on a portion of the mechanical system that is strained by the user's force. A strain guage produces a voltage proportional to the user's torque, which can be substituted for the voltage across resistor 12.
The important characteristic of the circuit diagrammed in FIG. 1(a) is its fast response time, which can be quantified in two parts: the rise time and the fall time. The rise time, Tr, is the elapsed time needed for the brake current to reach its maximum value Imax. When current Imax is flowing in the coil 5, the maximum resistance force is available from the brake. The fall time Tf is the elapsed time required for the current in the brake to drop to zero from Imax. The rise time and fall time are ideally much shorter than a typical exercise stroke, so that varying resistance levels are possible within the stroke. A typical exercise stroke lasts about 1 to 2 seconds.
FIG. 1(b) shows a very demanding input voltage (applied as a voltage level at terminal 1 in FIG. 1(a) from the exercise control system, namely to increase the brake current from zero to its maximum value. The time required to generate this current is the rise time Tr which will now be computed. FIG. 1(b) shows the current waveform in response to the step input voltage signal. This curve begins with an exponential rise with an exponential time constant of z=L/R, where L is the value of the inductor 7 of the brake coil 5 and R=R1+R2+R3, the total resistance in the path from the supply voltage to ground. When the maximum current, Imax, is reached, the exponential behavior ceases, and the amplifier 2 components and feedback work only to maintain the current at the level of Imax. The rise time, Tr, and maximum current, Imax, are related by the following equation:
Vs/R [1-e.sup.-Tr/z ]=I.sub.max (1)
where z=L/R. Tr can be calculated by rearrangement of equation (1) as follows:
T.sub.r =-L/R log[1-I.sub.max R/Vs] (2)
A rise time Tr of 0.083 seconds was achieved in our prototype apparatus in which Imax=0.6 amps corresponded to 200 lbs or equivalent force resistance. In this system L=11 henries, R=R1+R2 +R3=100+22+5 ohms, respectively and Vs=120 volts of rectified household electricity. Hence, the brake current could increase from zero to 0.6 amps in 0.083 seconds, and hence the corresponding resistance force could increase from zero to 200 lbs in the same time duration, and this was demonstrated to be sufficient for high-quality force resistance control in a vareity of exercise modes.
Another very demanding input voltage is illustrated in FIG. 1(c) as a step decrease from its maximum value to zero. The fall time, Tf, is the time required for the force resistance to reach zero, or equivalently when current through coil 5 ceases to flow. It is assumed that the input signal on terminal 1 remains at the maximum value for a long time prior to t=0, and that the maximum resistance force had been reached. The current through coil 5 ceases to flow when all energy stored in the magnetic field of inductor 7 coil is dissipated. The fall time is to be calculated by indicating the time required to dissipate all energy stored in the brake. Transistor 3 in FIG. 1(a) will not dissipate an appreciable amount of energy because no current flows from its collector to emitter when the voltage on the base is low. The components that dissipate energy are resistors 8, 6, and 12 and voltage clamping device 4.
When the input voltage level on termnal 1 drops to zero, transistor 3 turns off and no current flows from its collector to emitter, attempting to halt the current flow. However, because the voltage across the inductive portion 7 of the brake coil 5 is proportional to the derivative of the current, the brake voltage will become negative very rapidly. The voltage clamping device 4 will allow current to flow between its terminals when the voltage across it reaches its clamping voltage Vclamp. Furthermore, the clamping device 4 will continue to let current flow through it until the voltage across it decreases to a level less than Vclamp. While voltage level Vclamp is maintained by the clamping device, the brake current will decay exponentially as shown in FIG. 1(c).
The power dissipated in clamping device 4 is the maintained voltage, Vclamp, multiplied by brake current I(t). Resistors 8, 6, and 12 will dissipate power equivalent to RI(t), where R=R1+R2+R3. The integral value of the total power dissipated over time should be equal to the energy stored in the brake coil inductor 7 prior to time zero, and this energy value is (1/2) L Imax. Hence, the fall time can be calculated from the expression ##EQU1##
Rearranging the equation ##EQU2##
A simplifying approximation can be made if Vclamp is assumed to be much greater than i(t) R for most of the time. This approximation is valid for our apparatus. Substitute i(t)=Imax (1-exp(-t/z) where z=L/R and exp() is the natural exponential function. Making the approximation gives ##EQU3## or equivalently
V.sub.clamp [T.sub.f +Z(e.sup.-Tf/z -1)]=1/2L I.sub.max (6)
where Tf can be found through numerical iteration. For our prototype apparatus Vclamp=360 volts, z=L/R=0.0866 seconds, L=11 henries, and Imax=0.6 amps. Under these conditions Tf=0.045 seconds, calculated from equation (6).
The rise time of 0.083 seconds and the fall time of 0.045 seconds are much shorter than the duration of a typical exercise stroke which is typically 1-2 seconds. Hence, our apparatus is capable of a wide variety of exercise modes, and indeed has been so demonstrated.
The importance of high voltage circuitry is critical in achieving these fast rise and fall times. The rise time is heavily dependent on the power supply voltage level being much larger than would ordinarily be required to generate Imax in steady state. In fact, for our apparatus, only 12 volts is needed to achieve Imax in steady state, but 120 volts is needed for a satisfactory response time.
The fall time is heavily dependent on the clamping voltage being large in value as indicated by equation (6). Because the rate of energy dissipation of the clamping device 4 is proportional to the clamping voltage, the brake current can be brought to zero quickly when the clamping voltage is high.
Normally high voltage components increase the cost of a circuit significantly. In our design, the high voltage power supply in FIG. 1(a) is simply an isolation transformer 10, i.e. a transformer with a one-to-one voltage ratio, and a rectifier 9 coupled to the power already available from the utility company. This power supply does not require regulation, and the absence of regulation lowers the cost normally incurred by high voltage power supplies. Because the brake has such a large inductance, its presence in the circuit serves to filter the power supply voltage in the circuit of FIG. 1(a), although some "ripple" in the brake current is produced. However, this ripple is of too high a frequency (50 to 60 cycles per second) to be noticed by the user. Also, since a brake does not produce motion, no vibrations are created by the presence of the ripple. This represents an economic advantage of brake-based exercise machines based on this invention over prior-art motor-based machines. A motor-based machine would almost certainly require a tightly regulated power supply to reduce ripple-induced vibrations to an acceptable level.
Therefore, the combination of all features designed into our apparatus makes possible a low-cost brake-based exercise machine that is capable of high performance through fast response.
FIGS. 2 through 7 show additional embodiments of the invention with the force driver 25 representing the circuit of FIG. 1(a). In FIGS. 2 through 7, single line connections indicate electrical connections and line pairs indicate mechanical linkages.
FIG. 2 shows the use of the circuit of FIG. 1(a) to achieve isokinetic resistance. The force driver circuit 25 provides a current to electric brake 15, the rotor of which is mechanically coupled to the exercise machine 13. A velocity sensor 17 coupled to the exercise machine 13 converts the mechanical speed of the user's motion into a proportional electric voltage. This voltage is subtracted from a desired set point voltage on terminal 29 of a high gain difference amplifier 30. Amplifier 30 is used as a feedback compensator to increase current flow to the brake by means of the force driver 25 when the user's speed, as measured by the voltage produced by the velocity sensor 17, is greater than the desired set point voltage on terminal 29.
FIG. 2 also shows how the circuit of FIG. 1(a) may be used to achieve isometric resistance. It is functionally equivalent to the isokinetic system, except that the desired velocity signal on terminal 29 is set to zero.
FIG. 3 shows how the circuit of FIG. 1(a) may be used to achieve viscous fluid type resistance. In this system, the top row of elements are the same and interconnected in the same way as in FIG. 2 with the signal representative of the desired force set proportional to the user's speed. The user's speed is sensed by the velocity sensor 17. The constant of proportionality (the viscous damping coefficient) is adjustable through the use of a gain stage 32. A digital computer could also accept the signal from the velocity sensor by means of an analog-to-digital converter and could output the proportional voltage level to terminal 1 by means of a digital-to-analog converter.
FIG. 4 shows how the circuit of FIG. 1(a) may be used to achieve a desired force vs. position profile, or variable resistance. In this exercise system, the top row of elements are again as those in FIG. 2 with a position sensor 34 in place of the velocity sensor 17. The position sensor 34 senses the position of the user's moving member by providing a voltage signal representative thereof. For example, a potentiometer with a fixed voltage across the two outer electrotrodes will produce such a signal on the third electrode if its shaft is coupled to the rotor of brake 15. The voltage signal from the position sensor 34 is applied to a look-up table 35 to determine the desired level of resistance force for each sensed position. The look up table could represent a resistance vs. position profile recommended by a coach, therapist, or the user. It could also be defined by a digital computer that can read the output of the position sensor and provide a corresponding voltage level to terminal 1.
FIG. 5 shows how the circuit of FIG. 1(a) may be used to cancel the unwanted, but known, effects of friction. In this embodiment, the top row of elements is as shown in FIG. 2 with a subtracter 37 added preceeding force driver 25. The velocity sensor 17 senses the velocity of the user's motion, and the look up table 27 is used to determine the level of frictional force represented by the signal on line 38 known to be generated by the mechanical system at each level of velocity. This estimate is subtracted from the desired force (represented by the input voltage on terminal 39 of subtracter 37) by the voltage subtracter 37. The force driver 25 thereby generates a force which equals the desired force minus the frictional force. The frictional force in the mechanical system is therefore cancelled. A digital computer could also accept the signal from the acceleration sensor and output the proper signal to terminal 1 and achieve the same result.
Because the brake can only resist motion, the desired force level must be greater than or equal to the frictional force at all times for true cancellation to occur. The desired force level represented by voltage on terminal 39 could be identical to the force level specified in FIG. 2, 3, or 4, depending on which exercise mode is desired.
FIG. 6 shows how the circuit of FIG. 1(a) may be used to cancel the unwanted forces generated by the rotary mass of the drive train 16 and other mechanical components. The top row in this FIG. is as in FIG. 5 with an acceleration sensor 40 replacing the velocity sensor 17. The force generated by the rotary mass of the drive train is proportional to the rotary acceleration. The rotary acceleration is sensed by acceleration sensor 40 and a gain stage 41 amplifies the signal therefrom such that the inertia force signal on line 42 represents the force due to rotary acceleration. Cancellation is achieved by voltage subtracter 37. A signal representative of the desired force level (terminal 39) in this system could be identical to the force level specified in FIGS. 2, 3, or 4 depending on which exercise mode is desired. Again, a digital computer could accept the signal from the acceleration sensor and output the proper voltage to terminal 1. Because the brake can only resist motion, the desired force level must be greater than or equal to the force generated by the rotary mass at all times for true cancellation to occur.
FIG. 7 shows how the circuit of FIG. 1(a) may be used to simultaneously cancel inertia and friction with the exercise mode selectable as isokinetic, viscous, or resistance vs. position. Subtractor 37, force driver 25, brake 15, and exercise machine 13 are the same and are interconnected in the same way as in FIGS. 5 and 6. The sensors 34, 17, and 40 are now simultaneously coupled to exercise machine 13, rather than individually. Gain stage 41 produces a signal representative of the rotary inertia in the same way as in FIG. 6. Look-up table 27 produces a signal representative of the frictional forces in the same way as FIG. 5. Voltage summer 44 produces a signal representative of the total force to be canceled from the desired force by subtractor 37. When the mode selector switch 43 is in the top, middle, or bottom position, the desired force is equal to the force necessary for isokinetic resistance, viscous resistance, or resistance vs. position, respectively. These signals generate the desired force level in the same way as FIGS. 2, 3, and 4 when the switch is in the top, middle, or bottom position, respectively. A digital computer could perform many of the functions illustrated in FIG. 7 by accepting the signals from the sensors and providing the proper voltage level at terminal 1.
All of the exercise modes outlined (isokinetic, isometric, viscous, and force vs. position) and the compensations (for friction and inertia) perform well only when the machine generating the resistance force has a fast response time.
In isokinetic exercise, the machine must resist the user's varying exertion precisely to achieve a truly constant speed of motion. If the speed is maintained precisely, then the user's exertion level is represented accurately by the current flowing in the brake at all times. This current can be sensed easily by a computer or other monitoring device (e.g. by means of an analog-to-digital converter) to record an accurate measure of the user's exertion force at every position. If the user is exerting to his maximum potential, then the sensed current flowing in the brake measures the user's strength, and this information is valuable to athletic strength trainers or physical therapists analyzing an injury. Without the fast response time, the velocity would vary during the measurement. These variations in velocity represent acceleration and deceleration, making it impossible to separate the user's exertion force and the forces generated by the acceleration/deceleration. Hence, a fast response time is required to accurately sense the user's exertion during isokinetic exercise.
In the viscous resistance mode, the desired level of resistance is proportional to speed. Because the speed can vary quickly at the discretion of the user, a fast response time is required to produce a truly viscous resistance characteristic. The truely viscous nature of the resistance leads to a smoother and often more pleasant exercise.
In the force vs. position exercise mode, a fast response is required if the resistance force generated is to follow the desired force vs. position profile. This profile can be generated intelligently by a computer as outlined in the U.S. Pat. No. 4,354,676 by Gideon Ariel.
The strong dependence of frictional forces on speed again leads to a fast response requirement to achieve adequate cancellation. The strong dependence of inertia-related forces on acceleration lead to the same requirement for cancellation. | Motion of a user exercising acts against an electric brake. The current flowing in the coil of the brake is controlled by an electronic circuit in accordance with a specified function from a computer or another electronic circuit. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for the production of corrugated paper, and more particularly to a method which corrugates the paper with longitudinal ridges and grooves, rather than transverse corrugations.
2. Description of the Prior Art
Various methods and equipment have been proposed in the prior art for the production of corrugated paper. In U.S. Pat. No. 2,257,428, issued to Ruegenberg on Sept. 30, 1941, there is described a method and apparatus for making folds for crinkles in paper. The Ruegenberg method is described as useful with an all-around extensible and elastic paper or production of crepe paper or the like. This patent describes the use of a series of straight rollers positioned in parallel to make increasing depth to the folds.
A similar process and machine are described in U.S. Pat. No. 2,901,951, issued to Hochfeld on Sept. 1, 1959. The Hochfeld patent also describes the use of a series of parallel, straight line rollers which give increasing depth to the paper folds. In both the Ruegenberg and Hochfeld patents, it is significant that the use of the straight line rollers requires that the paper take different length paths depending on its location relative the rollers. This is one difficulty in the prior art which is overcome by the present invention.
In U.S. Pat. Nos. 2,276,737, issued to Plewes et al. on Mar. 17, 1942 and 1,975,548, issued to Ives on Oct. 2, 1934, there are described methods and devices for crimping and fluting paper at an angle to the direction of travel of the paper. Typical devices for crimping paper transverse of its direction of travel are disclosed in U.S. Pat. Nos. 1,896,037, issued to Boeye on Jan. 31, 1933 and 2,974,716, issued to Fourness on Mar. 14, 1961.
SUMMARY OF THE INVENTION
Briefly described in one aspect of the present invention there is provided a method for producing corrugated paper which includes feeding the paper over a first, arcuate roller such that the paper leaves the arcuate roller in the plane of the roller, making several longitudinal folds in the paper, passing the folded paper over a second arcuate roller, the second arcuate roller having about the same center of curvature as the first arcuate roller, and unfolding the paper to yield the corrugations.
It is an object of the present invention to provide a method for the production of corrugated paper.
Another object of the present invention is to provide a method for corrugating paper to yield uniform and well shaped corrugations.
It is a further object of the present invention to provide a method for producing corrugated paper with the ridges and grooves of the corrugation extending parallel to the direction of travel of the paper, rather than transverse to that direction.
A further object of the present invention is to provide a method for corrugating paper to accurately control the shape and position of corrugations, reduce the amount of paper and glue used, and increase the structural strength of the ultimate paper.
Another object of the present invention is to provide an apparatus for the production of corrugated paper, and particularly one which meets the above purposes.
Further objects and advantages of the present invention will become apparent from the description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side, partially schematic drawing of an apparatus for producing corrugated paper in accordance with the present invention.
FIG. 2 is a top, plan view of a portion of the apparatus of FIG. 1, and particularly showing the two arcuate rollers
FIG. 3 is a side, elevational view of the first arcuate roller useful in the present invention.
FIG. 4 is a front view of a portion of the first arcuate roller and associated row of folding discs.
FIG. 5 is a side, elevational view of a second row of folding discs.
FIG. 6 is a front, elevational view of a portion of the second set of folding discs.
FIG. 7 is a front, elevational view of a portion of the third set of folding discs.
FIG. 8 is a front, elevational view of a portion of the sliding tabs used to unfold the folded paper after passing over the second arcuate roller.
FIG. 9 is a partial, front, elevational view of a pair of crimping rollers useful with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Before proceeding with the detailed description of the present invention, a general summary of the process will be provided. Referring in particular to FIG. 1, there is show a paper corrugator 10 constructed in accordance with and useful in the present invention. As is customary, the apparatus utilizes a continuous sheet of paper 11 received for example from a roll 12. The apparatus 10 includes a first arcuate roller 13 and a second arcuate roller 14. The two arcuate rollers lie in about the same plane 15 and have a common center of curvature 16 lying in that plane. The paper 11 is passed over the first arcuate roller 13 to move from that roller in about the plane 15. Successive folding members 17-19 provide longitudinal ridges and grooves in the paper 11 and then fold the paper over for passage over the second arcuate roller 14. The paper moves to the roller 14 in the plane 15, and then passes from the roller at about a 90° angle from the plane 15. In the preferred embodiment, the paper then passes over a straight roller 20 to again change direction by about 90°, the folds are separated by the members 21 and crimping rollers 22 provide additional corrugations.
A particular embodiment of the paper corrugator 10 is shown in FIG. 1. In this embodiment, a main frame 23 is supported on legs 24 and in turn supports through an arm 25 a subframe 26. The paper roll 12 is received on a suitable axle 27 which is in turn received by the frame 23 for rotation. Alternatively, the axle 27 is fixed to the frame 23 and the roll is permitted to rotate about the axle. The paper passes upwardly over a directional roller 28 supported by upstanding arms 29. In this fashion, the paper moves vertically downward to the first arcuate roller 13 and thereafter passes horizontally in the plane 15 of the arcuate rollers.
As will be described in detail with respect to the later drawings, the various folding and unfolding members, such as folding discs 18, are provided in pairs mounted upon suitable supports, such as 30 and 31. Typically, one set of the discs is positioned above the paper and the other set is positioned below the paper, thus providing for the desired folding or shaping of the paper as it passes therebetween.
Also as shown in FIG. 1, the paper passes vertically downward from the second arcuate roller 14 to a straight, directional roller 20, from which it passes in the horizontal plane. It will however be appreciated that the orientation of the rollers and paper is not fixed, but may be modified as desired. It has been found to be desirable to have the arcuate rollers 13 and 14 in a horizontal plane, and thus the directional roller 28 is useful to direct the paper to the first arcuate roller in the proper direction. It will also be appreciated that the invention is described herein as including paper which passes at about 90° angles to or from the arcuate rollers. It will be appreciated that this angle is variable, particularly depending upon the size and nature of the paper being used.
In accordance with the present invention, the first step is in feeding the continuous sheet of paper 11 over a first arcuate roller 13. The paper is fed to the first arcuate roller preferably at an angle about 90° to the plane 15 of the first arcuate roller. The paper passes from the first arcuate roller 13 in about the plane 15. The next step is to make several longitudinal folds in the paper as it moves in the plane 15 to the second arcuate roller 14.
Referring in particular to FIG. 2, this first section of the apparatus 11 is shown from a top view. The first arcuate roller 13 includes several cylindrical rollers 32 received upon a shaft 33. The shaft has an arcuate configuration, and is supported by several brackets 34 mounted to an upper support member 35. The upper support member 35 is secured to a lower support member 36A which is in turn attached to the frame 23. On each side of the apparatus there is included a pair of threaded rods 37 and 38 which extend through aligned apertures in the support members 35 and 36A. As shown in FIG. 3, nuts such as 39 and 40 and washers such as 41 and 42 are received upon the rods 37 and 38 on opposite sides of the upper and lower support members to provide for positioning of the support members. In this fashion, the distance between the upper and lower support members may be varied as desired, depending upon the operating characteristics which are required for the apparatus.
As discussed, there are several longitudinal folds made in the paper as it passes from the first arcuate roller 13 to the second arcuate roller 14. These folds are prepared by first forming several longitudinal and parallel ridges 43 and grooves 44. A first set of folding members 45 are provided adjacent the first arcuate roller 13. As shown particularly in FIGS. 3 and 4, the first folding members comprise several folding discs 46 received on parallel curved shafts 47 and 48. The shaft 47 is mounted to the upper support member 35 by means of a bracket 49 attached to the upper support member by means of a screw 50. Similarly, the lower shaft 48 is secured to the lower support member 36B by means of a bracket 51 secured by a screw 52. As shown in FIG. 4, the folding discs 46 are positioned on the respective shafts to provide a beginning shaping of the paper 11.
It is desired to provide the ridges and grooves at equal but alternating spacings so that the material eventually can be laid over upon itself to reduce its width by a certain amount, such as by one-half. It will be appreciated that if the ridges and grooves were equally spaced along the width of the paper, then any folding of the paper would result in reducing the paper down to a very small size, particularly the width of the spacings of the ridges and grooves. Alternatively, only certain ones of the folds could be used if a greater width of the paper was desired. To avoid these two alternatives, the present invention positions the ridges and grooves at spacings such that each of the ridges can be folded over on the adjacent paper to reduce the width of the paper by only a desired amount, such as one-half.
Thus as shown in FIG. 4, it is desirable in the preferred embodiment to locate the discs 46 on the respective shafts 47 and 48 such that the distance from a particular ridge to the groove on one side is relatively short and to the groove on the other side is relatively long. In forming these creases or folds in the paper, the discs 46 are used and they preferably are rotatable about the shafts such that they will rotate with the paper as it is moved therebetween. To position the discs and to provide for such rotation, there is preferably included a series of spacers 83 which are cylindrical and are received over the shafts 47 and 48 between each successive pair of discs to maintain their location as desired.
As previously noted, the shafts 47 and 48 are mounted to the upper and lower support members 35 and 36B. As previously indicated, the position of the upper support member 35 is variable with respect to the frame 23. The lower support member 36B which carries the lower disc shaft 48 is mounted to the frame 23. Thus, the relative spacing between the shafts 47 and 48, and the discs carried thereon, may be varied by appropriate adjustment of the upper support member 35.
Referring to FIGS. 5 and 6, there is shown a second set of folding members 18, which again preferably comprise folding discs such as 53. The folding members 18 are constructed almost identically with the folding members 17 shown earlier. Upper support members 54 are mounted to lower support members 55 which in turn are secured to the frame 23. The upper support member is mounted by means of rods, such as 56, mounted with nuts 57 and washers 58 in the same manner as previously described to provide for vertical adjustment of the upper support member. The folding discs 53 are mounted on shafts 59 and 60 which are in turn mounted to the respective support members such as by brackets 61 and screws 62. Spacing sleeves 63 are included on the respective shafts between associated discs to provide for proper spacing of the discs and rotation thereof. As shown in FIG. 6, particularly in comparison with FIG. 4, it is apparent that the function of the second folding members 18 is to provide a further depth of fold in the paper 11.
In FIG. 7 there is shown the third set of folding discs 19. A pair of support members 64 and 65 are secured to the frame 23 in the fashion, for example, as previously described. Attached to the support members are several mounting members 66 to which are rotatably attached the folding discs 67. These folding discs 67 provide for positioning the paper in the folded over condition prior to passage over the second arcuate roller 14. As previously described, the folds are made such that the spaces between ridges and grooves are equal alternating distances. In other words, referring in particular to FIG. 7 it is shown that the distance from ridge 43A to groove 44A is the same distance as from the ridge 43B to groove 44B. At the same time, the distance from ridge 43A to groove 44B is about the same distance as from ridge 43B to groove 44C. However, the distance for example from ridge 43A to groove 44A is substantially shorter than the distance from ridge 43A to groove 44B. In this fashion, the paper may be folded over in the manner indicated in FIG. 7 to yield a flat sheet of paper having the several folds shown.
Referring in particular to FIG. 2, it is shown that the various folding members 17-19 are configured and oriented in a fashion to make the respective ridges and grooves pass generally along radial lines from the center of curvature of the arcuate rollers 13 and 14. In this fashion, the ridges and grooves, and more generally the various portions of the paper 11 are caused to move along paths of identical length from the first arcuate roller to the second arcuate roller. Unlike the prior art, this achieves a folding of the paper without causing binding or other undesirable stresses on the paper due to different portions of the paper travelling different distances. It will also be appreciated that various types of rollers and folding members may be used in performing this invention. In the preferred embodiment, however, the arcuate rollers comprise several cylindrical rollers on an arcuate shaft, and the folding members are rotating discs as described.
As shown in FIG. 1, the paper passes over the second arcuate roller 14 and then vertically downward to a straight, directional roller 20. As shown, the straight roller 20 is mounted through a shaft 68 to a support member 69, which is in turn secured to the sub-frame 26.
From the straight roller 20 the paper passes through unfolding members 21. Support members 70 and 71 are mounted to the sub-frame 26 in the same fashion as previously described. Although folding discs could be used as in the earlier description, the unfolding members may suitably comprise sliding tabs 72 secured by screws 73 to the respective support members. These tabs are positioned to simply raise the folds such that the paper can be delivered in the unfolded, corrugated condition.
Also in the preferred embodiment there is provided a pair of crimping rollers 22 which provide additional corrugations in the paper. The crimping rollers are shown particularly in FIG. 9. The rollers include several ridges 74 and grooves 75 which provide comparable folds in the paper 11. The rollers are mounted on shafts 76 which are received in bearings 77 mounted to the support members 78. The support members 78 are attached to the sub-frame 26. Passage of the paper between the crimping rollers provides the additional corrugations more comparable to that associated with corrugated paper.
As thus described, the paper corrugator 19 is useful in the production of corrugated paper. It is a particular aspect of the present invention that the paper is passed over arcuate rollers 13 and 14, with folds being formed in the paper between the two rollers and along radial lines extending from the center of curvature for the rollers. The paper is thereafter unfolded, and preferably is crimped to provide additional corrugations. It is a particular aspect of the present invention that the paper is thereby reduced in width from the initial sheet width to a reduced width corresponding with the width of the ultimate corrugated paper. This width reduction is accomplished along radial lines to permit all portions of the paper to move about the same distance in the area in which the folds are created.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A method for the production of corrugated paper comprising the steps of feeding a continuous sheet of paper over a first arcuate roller, making several folds in the paper along lines of radius of the first arcuate roller, passing the paper over a second arcuate roller which has the same center of curvature as the first arcuate roller, and unfolding the paper folds to yield the corrugated paper. The paper preferably turns about 90° in passing over the first and second arcuate rollers, and after being unfolded there is provided additional corrugations by use of crimping rollers or the like. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/330,581, filed Dec. 19, 2011, which is a continuation of U.S. application Ser. No. 13/089,099, filed Apr. 18, 2011 (abandoned), which is a continuation of U.S. patent application Ser. No. 12/632,608, filed Dec. 7, 2009 (abandoned), which is a continuation of U.S. patent application Ser. No. 11/821,259, filed Jun. 21, 2007, now U.S. Pat. No. 7,645,580, which is a continuation of U.S. patent application Ser. No. 11/244,331, filed Oct. 4, 2005 (abandoned), which is a continuation of U.S. patent application Ser. No. 09/910,183, filed Jul. 20, 2001, now U.S. Pat. No. 7,087,380, which is a continuation of U.S. patent application Ser. No. 09/706,525, filed Nov. 3, 2000 (abandoned), which is a continuation of U.S. patent application Ser. No. 09/498,567, filed Feb. 4, 2000 (abandoned), which is a continuation of U.S. patent application Ser. No. 09/107,029, filed Jun. 29, 1998 (abandoned), which claims priority to United Kingdom Application No. 9713597.4, filed Jun. 28, 1997, which for purposes of disclosure are each incorporated herein by specific reference in their entireties.
This application contains a Sequence Listing which has been submitted in ASCII format via EFS-Web and is hereby incorporated by reference in its entirety. Said ASCII copy, created on Jan. 23, 2013, is named 0051 — 0092_US10_Sequence Listing.txt and is 10776 bytes in size.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention is concerned with improvements in and relating to forensic identification, particularly where based on DNA profiling.
2. The Relevant Technology
DNA profiling offers a versatile identification technique for a wide variety of applications including, anthropological, paternity and other forensic environments. The use of such profiling is significant in determining links, or their absence, between samples. Such samples might include those taken from known individuals and/or those taken from the scene of or linked to a crime.
DNA profiling based on the use of short tandem repeats (STR) or micro satellite loci is used in such applications. STR's are a class of polymorphic markers which consist of simple randomly repeated sequences of between 1 and 6 base pairs in length. STR's in the non-coding part of the genome are generally considered.
In the human genome STR's occur every 6 to 10 kilo bases along the DNA. The length, however, varies greatly between individuals due to mutation and provides identifying characteristics as a result.
A variety of DNA profiling systems exist, including single locus analysis and multiple locus analysis where a number of STR loci are simultaneously amplified.
In analyzing the results from an unknown sample it is generally considered against a ladder marker consisting of alleles derived from actual samples. The allelic ladder provides a reference point and allows correspondence of alleles to be identified clearly.
SUMMARY OF THE INVENTION
The present invention provides new alleles and new ladders incorporating them for a variety of loci. The present invention offers an improved range and coverage of markers as a result. The ladders include a number of rare alleles offering improved identification of the alleles in an unknown sample.
According to a first aspect of the invention we provide an allelic ladder mixture comprising one or more of the following allelic ladders:
i) an allelic ladder for locus HUMVWFA31/A comprising one or more of alleles comprising or consisting of sequences:
(SEQ ID NO: 1) TCTA TCTG TCTA (TCTG) 4 (TCTA) 3 ; (SEQ ID NO: 2) TCTA (TCTG) 4 (TCTA) 7 ; or (SEQ ID NO: 3) (TCTA) 2 (TCTG) 4 (TCTA) 3 TCCA (TCTA) 3
or at least 75% homologous thereto;
ii) an allelic ladder for locus HUMTHO1 comprising or consisting of sequence:
(SEQ ID NO: 4) (TCAT) 4 CAT (TCAT) 7 TCGT TCAT;
or at least 75% homologous thereto;
iii) are allelic ladder for locus D8S1179 comprising one or more of alleles:
(SEQ ID NO: 5) (TCTA) 8 ; (SEQ ID NO: 6) (TCTA) 2 TCTG(TCTA) 16
or at least 75% homologous thereto;
iv) an allelic ladder for locus HUMFIBRA/FGA comprising one or more of alleles comprising or consisting of the sequences:
(SEQ ID NO: 7) (TTTC) 3 TTTT TTCT (CTTT) 5 T (CTTT) 3 CTCC (TTCC) 2 ; (SEQ ID NO: 8) (TTTC) 3 TTTT TTCT (CTTT) 13 CCTT (CTTT) 5 CTCC (TTCC) 2 ; (SEQ ID NO: 9) (TTTC) 3 TTTT TTCT (CTTT) 16 CCTT (CTTT) 5 CTCC (TTCC) 2 ; (SEQ ID NO: 10) (TTTC) 4 TTTT TT (CTTT) 15 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 11) (TTTC) 4 TTTT TT (CTTT) 16 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 12) (TTTC) 4 TTTT TT (CTTT) 17 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 13) (TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 4 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 14) (TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 15) (TTTC) 4 TTTT TT (CTTT) 11 (CTGT) 3 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 16) (TTTC) 4 TTTT TT (CTTT) 10 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 17) (TTTC) 4 TTTT TT (CTTT) 12 (CTGT) 5 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; or (SEQ ID NO: 18) (TTTC) 4 TTTT TT (CTTT) 14 (CTGT) 3 (CTTT) 14 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ;
or at least 75% homologous thereto;
v) an allelic ladder for locus D21S11 comprising one or more of alleles comprising or consisting of sequences:
(SEQ ID NO: 19) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA(TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 6 TCGTCT; (SEQ ID NO: 20) (TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT; (SEQ ID NO: 21) (TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT; (SEQ ID NO: 22) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 8 TCGTCT; (SEQ ID NO: 23) (TCTA) 5 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT; (SEQ ID NO: 24) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT; (SEQ ID NO: 25) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT; (SEQ ID NO: 26) (TCTA) 6 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT; (SEQ ID NO: 27) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT; (SEQ ID NO: 28) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TA TCTA TCGTCT; (SEQ ID NO: 29) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 3 TCCATA (TCTA) 12 TA TCTA TCGTCT; (SEQ ID NO: 30) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TA TCTA TCGTCT; (SEQ ID NO: 31) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 14 TATCTA TCGTCT; (SEQ ID NO: 32) (TCTA) 10 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT; (SEQ ID NO: 33) (TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT; (SEQ ID NO: 34) (TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TCGTCT; or (SEQ ID NO: 35) (TCTA) 13 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT;
or at least 75% homologous thereto;
vi) an allelic ladder for locus D18551 comprising an allele comprising or consisting of sequence:
(AGAA) 8 (SEQ ID NO: 36); or at least 75% homologous thereto.
Preferably the mixture includes allelic ladders for a plurality of loci. It is particularly preferred that the mixture include allelic ladders for at least four loci. Preferably the mixture includes allelic ladders for a plurality of loci selected from HUMVWFA31/A, HUMTHO1; D8S1179, HUMFIBRA/FGA, D21511 and D18551. Preferably the mixture includes allelic ladders for at least four of these loci. In its most preferred form the mixture includes allelic ladders for all of these loci.
Preferably the mixture includes an amelogenin sex test.
Preferably one or more of the allelic ladders in the mixture includes at least 7 alleles and more preferably at least 12 alleles. Preferably a plurality, and particularly all, of the allelic ladders of the mixture include at least 8 and more preferably at least 10 alleles.
Preferably one or more or all of the ladders, if present in the mixture may be provided such that: the HUMVWFA31/A allelic ladder includes at least 9, more preferably 11 and ideally 12 alleles; the HUMTHO1 allelic ladder includes at least 7, more preferably 9 and ideally 10 alleles; the D8S1179 allelic ladder includes at least 9, more preferably 12 and ideally 13 alleles; the HUMFIBRA/FGA allele ladder includes at least 18, more preferably OQ 26 and ideally 28 alleles or is present as HUMFIBRA/FGA/LW and HUMFIBRA/FGA/HW with the HUMFIBRA/FGA/LW ladder including at least 16 more preferably 18 and ideally 20 alleles, the HUMFIBRA/FGA/HW ladder including at least 6, more preferably at least 7 and ideally 8 alleles; the D21511 allelic ladder includes at least 14, more preferably 16 and ideally 17 alleles; and the D18S51 ladder includes at least 15, more preferably 19 and ideally 20 alleles.
Preferably one or more of the allelic ladders in the mixture comprises at least 4 pairs of alleles 4 base pairs from each other. More preferably at least 10 pairs, and ideally at least 12 pairs of alleles are so provided. Preferably one or more or all the allele ladders, if present in the mixture, may be provided such that: the HUMVWFA31/A allele ladder includes at least 7, more preferably 10 and ideally 11 pairs of alleles 4 base pairs from each other; the HUMTHO1 allele ladder includes at least 5, more preferably 6 and ideally 7 pairs of alleles 4 base pairs from each other; the D8S1179 allelic ladder includes at least 8, more preferably 11 and ideally 12 pairs of alleles 4 base pairs from each other; the HUMFIBRA/FGA allele ladder includes at least 17, more preferably 20 and ideally 23 pairs of alleles 4 base pairs from each other; the D21S11 allele ladder includes at least 3 and ideally 4 pairs of alleles 4 base pairs from each other; and the D18S51 ladder includes at least 13, more preferably 18 and ideally 19 pairs of alleles 4 base pairs from each other. The D21S11 allele ladder may, or may further include, at least 8, more preferably 11 and ideally 12 pairs of alleles 8 base pairs from each other.
Preferably the allele sequences have at least 85% homogeneity with the listed sequences. More preferable levels of even 90% or at least 95% may be provided. Ideally the exact sequences listed are included within the alleles. In their most preferred form the alleles consist of the listed sequences.
The alleles may further include flanking sequences, i.e., between the primer and STR.
Preferably the HUMVWFA31/A ladder includes alleles ranging from 130, more preferably 126 and ideally 122 base pairs upwards and/or from 166 base pairs downwards. Preferably the HUMTHO1 ladder includes alleles ranging from 150 base pairs upwards and or 189 base pairs downwards. Preferably the D8S1179 ladder includes alleles ranging from 157 base pairs upwards and/or 201, and more preferably 205 base pairs downwards. Preferably the HUMFIBRA/FGA ladder includes alleles ranging from 173 base pairs upwards and/or 298, more preferably 302 and ideally 310 base pairs downwards. Preferably the D21S11 ladder includes alleles ranging from 203 base pairs upwards and/or 255 or more preferably 259 base pairs downwards. Preferably the D18S51 ladder includes alleles ranging from 270 or more preferably 266 base pairs upwards and/or 326 or 330 or 334 or 338 or even 342 downwards.
According to a second aspect of the invention we provide an allelic ladder mixture comprising an allelic ladder for one or more of the following loci, with lowest molecular weight allele and/or uppermost molecular weight allele as follows
Locus
Low MW allele
High MW allele
a) HUMVWFA31/A
10
21
b) HUMTH01
4
13.3
c) D8S1179
7
19
d) HUMFIBRA/FGA
16.1
50.2
e) D21S11
53
81
f) D18S51
8
27
Preferably one or more of the loci ladders have both the upper and lower limits specified. Preferably all the loci ladders have the full ranges listed.
Preferably the mixture includes allelic ladders for a plurality of loci. It is particularly preferred that the mixture include allelic ladders for at least four loci. Preferably the mixture includes allelic ladders for a plurality of loci selected from HUMVWFA31/A, HUMTHO1, D8S1179, HUMFIBRA/FGA, D21S11 and D18S51. Preferably the mixture includes allelic ladders for at least four of these loci. In its most preferred form the mixture includes allelic ladders for all of these loci.
The intervals of alleles in the ladders and/or number of alleles in the ladders may be as specified in the first aspect of the invention. This aspect may include any of the other features specified elsewhere in the application.
The ladder mixtures of the first and/or second aspect of the invention may further include one or more of PARR buffer, primer(s), or Tag polymerase.
According to a third aspect of the invention we provide a method of analysing one or more samples comprising: —
a) obtaining genomic DNA from the sample;
b) amplifying the DNA;
c) obtaining an indication of one or more of the constituent parts of the sample; and comparing the indications with an allelic ladder mixture comprising one or more of the following allelic ladders:
i) an allelic ladder for locus HUMVWFA31/A comprising one or more of alleles comprising or consisting of sequences:
(SEQ ID NO: 1)
TCTA TCTG TCTA (TCTG) 4 (TCTA) 3 ;
(SEQ ID NO: 2)
TCTA (TCTG) 4 (TCTA) 7 ;
or
(SEQ ID NO: 3)
(TCTA) 2 (TCTG) 4 (TCTA) 3 TCCA (TCTA) 3
ii) an allelic ladder for locus HUMTHO1 comprising or consisting of sequence:
(SEQ ID NO: 4)
(TCAT) 4 CAT (TCAT) 7 TCGT TCAT;
iii) an allelic ladder for locus D8S1179 comprising one or more of alleles comprising or consisting of sequences:
(SEQ ID NO 5)
(TCTA) 8 ;
or
(SEQ ID NO: 6)
(TCTA) 2 TCTG (TCTA) 16 ;
iv) an allelic ladder for locus HUMFIBRA/FGA comprising one or more of alleles comprising, or consisting of the sequences:
(SEQ ID NO: 7)
(TTTC) 3 TTTT TTCT (CTTT) 5 T (CTTT) 3 CTCC (TTCC) 2 ;
(SEQ ID NO: 8)
(TTTC) 3 TTTT TTCT (CTTT) 13 CCTT (CTTT) 5 CTCC (TTCC) 2 ;
(SEQ ID NO: 9)
(TTTC) 3 TTTT TTCT (CTTT) 16 CCTT (CTTT) 5 CTCC (TTCC) 2 ;
(SEQ ID NO: 10)
(TTTC) 4 TTTT TT (CTTT) 15 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 11)
(TTTC) 4 TTTT TT (CTTT) 16 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 12)
(TTTC) 4 TTTT TT (CTTT) 17 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 13)
(TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 4 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 14)
(TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 15)
(TTTC) 4 TTTT TT (CTTT) 11 (CTGT) 3 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 16)
(TTTC) 4 TTTT TT (CTTT) 10 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ;
(SEQ ID NO: 17)
(TTTC) 4 TTTT TT (CTTT) 12 (CTGT) 5 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ;
or
(SEQ ID NO: 18)
(TTTC) 4 TTTT TT (CTTT) 14 (CTGT) 3 (CTTT) 14 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ;
v) an allelic ladder for locus D21S11 comprising one or more of alleles comprising or consisting of sequences:
(SEQ ID NO: 19)
(TCTA) 4 (TCTG) 6 (TCTA) 3 TA(TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 6 TCGTCT;
(SEQ ID NO: 20)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT;
(SEQ ID NO: 21)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT;
(SEQ ID NO: 22)
(TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 8 TCGTCT;
(SEQ ID NO: 23)
(TCTA) 5 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT;
(SEQ ID NO: 24)
(TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT;
(SEQ ID NO: 25)
(TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT;
(SEQ ID NO: 26)
(TCTA) 6 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT;
(SEQ ID NO: 27)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT;
(SEQ ID NO: 28)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TATCTA
TCGTCT;
(SEQ ID NO: 29)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TATCTA
TCGTCT;
(SEQ ID NO: 30)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TATCTA
TCGTCT;
(SEQ ID NO: 31)
(TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 14 TATCTA
TCGTCT;
(SEQ ID NO: 32)
(TCTA) 10 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT;
(SEQ ID NO: 33)
(TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT;
(SEQ ID NO: 34)
(TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TCGTCT;
or
(SEQ ID NO: 35)
(TCTA) 13 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT;
vi) an allelic ladder for locus D18551 comprising an allele comprising or consisting of sequence:
(AGAA) 8 ;
(SEQ ID NO: 36)
including allelic ladders or alleles 75% homologous thereto.
The allelic ladder mixture may possess other features specified in the first or second aspects of the invention or elsewhere in this application.
Preferably the DNA sample is one or more of a sample taken from the scene of a crime, a sample associated with the scene of a crime, a sample obtained from a suspect, a sample obtained from a human under consideration (for instance for paternity or maternity analysis) or a reference sample. The sample may be in the form of blood, hair, skin or bodily fluid.
Preferably the sample is amplified using a polymerase chain reaction. Preferably primers for one or more of loci HUMVWFA31/A, HUMTHO1, D8S1179, HUMFIBRA/FGA, D21511 or D18551 are employed. The primers may be dye or otherwise labelled.
According to a fourth aspect of the invention we provide one or more alleles comprising or consisting of sequences:
(SEQ ID NO: 1) TCTA TCTG TCTA (TCTG) 4 (TCTA) 3 ; (SEQ ID NO: 2) TCTA (TCTG) 4 (TCTA) 7 ; (SEQ ID NO: 3) (TCTA) 2 (TCTG) 4 (TCTA) 3 TCCA (TCTA) 3 ; (SEQ ID NO: 4) (TCAT) 4 CAT (TCAT) 7 TCGT TCAT; (SEQ ID NO: 5) (TCTA) 8 ; (SEQ ID NO: 6) (TCTA) 2 TCTG (TCTA) 16 ; (SEQ ID NO: 7) (TTTC) 3 TTTT TTCT (CTTT) 5 T (CTTT) 3 CTCC (TTCC) 2 ; (SEQ ID NO: 8) (TTTC) 3 TTTT TTCT (CTTT) 13 CCTT (CTTT) 5 CTCC (TTCC) 2 ; (SEQ ID NO: 9) (TTTC) 3 TTTT TTCT (CTTT) 16 CCTT (CTTT) 5 CTCC (TTCC) 2 ; (SEQ ID NO: 10) (TTTC) 4 TTTT TT (CTTT) 15 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 11) (TTTC) 4 TTTT TT (CTTT) 16 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 12) (TTTC) 4 TTTT TT (CTTT) 17 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 13) (TTTC) 4 TTTT TT (CTTT) 8 (CTGT)4 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 14) (TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 15) (TTTC) 4 TTTT TT (CTTT) 11 (CTGT) 3 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 16) (TTTC) 4 TTTT TT (CTTT) 10 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 17) (TTTC) 4 TTTT TT (CTTT) 12 (CTGT) 5 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 18) (TTTC) 4 TTTT TT (CTTT) 14 (CTGT) 3 (CTTT) 14 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4 ; (SEQ ID NO: 19) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA(TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 6 TCGTCT; (SEQ ID NO: 20) (TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT; (SEQ ID NO: 21) (TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT; (SEQ ID NO: 22) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 8 TCGTCT; (SEQ ID NO: 23) (TCTA) 5 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT; (SEQ ID NO: 24) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT; (SEQ ID NO: 25) (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT; (SEQ ID NO: 26) (TCTA) 6 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCCA) 2 TCCATA (TCTA) 11 TCGTCT; (SEQ ID NO: 27) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT; (SEQ ID NO: 28) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TATCTA TCGTCT; (SEQ ID NO: 29) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TATCTA TCGTCT; (SEQ ID NO: 30) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TATCTA TCGTCT; (SEQ ID NO: 31) (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 14 TATCTA TCGTCT; (SEQ ID NO: 32) (TCTA) 10 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT; (SEQ ID NO: 33) (TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT; (SEQ ID NO: 34) (TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TCGTCT; (SEQ ID NO: 35) (TCTA) 13 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA)2 TCCATA (TCTA) 12 TCGTCT; or (SEQ ID NO: 36) (AGAA) 8 ;
or at least 75% homologous thereto.
/Preferably the alleles are provided purified from alleles other than those of HUMVWFA31/A HUMTHO1, D8S1179, HUMFIBRA/FGA, D21511, D18551 or AMG loci.
According to a fifth aspect of the invention we provide the use of an allelic ladder according to the first aspect of the invention and/or an allele according to the fourth aspect of the invention for comparison with a DNA analysis result.
The analysis may be a DNA profile of a sample. The profile may be based on analysis of one or more loci, in particular including one or more of HUMVWFA31/A, HUMTHO1, D8S1179, HUMFIBRA/FGA, D21511, D18551 or AMG. The sample may be from the scene of a crime, associated with the scene of a crime or comprise a bodily fluid sample. The sample may be used to compare two or more individuals, or samples arising therefrom, for instance in paternity and/or maternity analysis.
According to a sixth aspect of the invention we provide a method of producing an allelic ladder or mixture thereof by subjecting the ladders of the first, second or fourth aspects of the invention to PCR.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example only, and with reference to the accompanying figure in which:
FIGS. 1 a and 1 b illustrates the locus, allele designation and size for an embodiment of the invention;
FIG. 2 a shows an electrophoretogram of the allelic ladder for Amelogenin (AMG);
FIG. 2 b shows an electrophoretogram of the allelic ladder for HUMVWFA31/A;
FIG. 2 c shows an electrophoretogram of the allelic ladder for HUMTHO1;
FIG. 2 d shows an electrophoretogram of the allelic ladder for D8S1179;
FIG. 2 e shows an electrophoretogram of the allelic ladder for HUMFIBRA, low and high molecular weights;
FIG. 2 f shows an electrophoretogram of the allelic ladder for D21511;
FIG. 2 g shows an electrophoretogram of the allelic ladder for D18551;
FIG. 3 a shows the sequence of selected alleles forming the HUMVWFA31/A ladder (SEQ ID NOS 1-2 and 39, respectively, in order of appearance);
FIG. 3 b shows the sequence of selected alleles forming the HUMTHO1 ladder (SEQ ID NO: 4);
FIG. 3 c shows the sequence of selected alleles forming the D8S1179 ladder (SEQ ID NOS 5-6, respectively, in order of appearance);
FIG. 3 d shows the sequence of selected alleles forming the HUMFIBRA ladder (SEQ ID NOS 7-18, respectively, in order of appearance);
FIG. 3 e shows the sequence of selected alleles forming the D21S11 ladder (SEQ ID NOS 19-35, respectively, in order of appearance); and
FIG. 3 f shows the sequence of selected alleles forming the D18S51 ladder (SEQ ID NO: 36).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An allelic ladder mixture illustrative of the present invention is provided for loci HUMTHO1, D21S11, D8S1179, HUMVWFA31/A, HUMFIBRA/FGA and amelogenin sex test. The loci nomenclature is standard, corresponding to that used in the GENEBANK database.
The ladder mixture includes a significant number of alleles fair each locus so as to provide a base line for comparison across a wide range. The loci, allelic designation and base pair sizes for the mixture are shown in FIGS. 1 a and 1 b . The nomenclature for the loci is discussed in Gill et al. 1996 Int. Journal Leg. Med. 109 14-22.
The allelic ladder mixture was presented in PARR buffer (containing Tris and 1.5 mM Mg ions at pH8.0) obtained from Cambio, primers obtained from Oswell and Taq polymerase from Perkin Elmer.
Electrophoretograms for the allelic ladders are shown in FIGS. 2 a to 2 g with the allelic number designations shown.
FIGS. 3 a to 3 f show the sequences for the alleles identified in FIGS. 2 a to 2 g.
The allelic ladder mixture discussed above was produced according to the following techniques. Buccal swabs and/or bloodstains were used as the sample sources. The genomic DNA was extracted using the chelex procedure described by Walsh et al. 1991 Bio. Techniques 1 91-98.
The recovered DNA was quantified by dot hybridisation using a higher primate specific probe, as disclosed in Walsh et al. 1992 Nucleic Acids Res. 20 5061-5065.
Each sample was then amplified according to the conditions set out below in Table 1 with unlabelled oligonucleotide primers, the sequences for which are disclosed in Urquhart et al. 1995 Bio Techniques 18 116-121 and Oldroyd et al. 1995 Electrophoresis 16 334-337.
TABLE 1
D18
95° C. for 60 seconds
D1
94° C. for 30 seconds
60° C. for 60 seconds
58° C. for 60 seconds
72° C. for 60 seconds
72° C. for 30 seconds
Method: 28 CYCLES + 72° C.
Method: 26 cycles + 72° C.
for 10 minutes then hold at 4° C.
for 10 minutes then hold at 4° C.
D8
94° C. for 30 seconds
TH01
94° C. for 45 seconds
60° C. for 60 seconds
and
60° C. for 60 seconds
72° C. for 60 seconds
VWA
72° C. for 60 seconds
Method: 30 cycles + 72° C.
Method: 28 cycles + 72° C.
for 10 minutes then hold at 4° C.
for 10 minutes then hold at 4° C.
FGA
93° C. for 60 seconds
Amelo
93° C. for 30 seconds
60° C. for 60 seconds
58° C. for 75 seconds
72° C. for 60 seconds
72° C. for 15 seconds
Method: 30 cycles + 72° C.
Method: 30 cycles + 72° C.
for 10 minutes then hold at 4° C.
for 10 minutes then hold at 4° C.
Individual alleles were then isolated and sequence analysis was carried out according to the methods of Barber et al. 1996 Int. Journal Leg. Med. 108 180-185 and Barber and Parkin 1996 Int. Journal. Leg. Med. 109 62-65. Both DNA strands of each allele reported were sequenced and the sequences provided in FIGS. 3 a to 3 g are the consensus (7 results for this.
The illustrations of the alleles provided in FIGS. 3 a to 3 g follow the nomenclature recommended by the DNA commission of the International Society of Forensic Haemogenetics 1994 lot. Journal Leg. Med. 107 159-160 where the complete number of tandem repeats observed are designated by the digit. The longhand version of these sequences is provided at the end of the specific description.
To prepare the ladder cocktail amplification of the alleles is necessary. This process was performed by amplifying the purified single alleles described above using a labelled primer in each case. For the locus HUMFIBRA/FGA the ladder was produced from two separate mixes, discussed in more detail below. The primers used are disclosed in Urquhart et al. 1995 Bio Techniques 18 116-121 and Oldroyd et al. 1995 Electrophoresis 16 334-337 and were employed according to the conditions set out above in Table 1.
The singleplexs produced in this way were analysed on an Applied Biosystems 377 automated sequencer to confirm the sequences. The sequences obtained from the profiling system are one base longer than those determined form the DNA sequencing technique initially discussed above. This is due to the ability of DNA polymerase from Thermus aquaticus to catalyse a non-template mediated addition of a deoxyribonucleotide to the 3′ hydroxyl of PCR products. This is generally known as the “n+1” product and can be generated in preference to the “n” product. The results reported here, however, refer to the “n” product rather than the “n+1” product for which the labelled primer PCR conditions have been optimised to produce.
The products of the amplification process for each locus were then diluted, mixed with one another and reanalysed to produce a single ladder for each loci having even peak heights. An initial level of 1000 Arbitary Units, AU, was increased to 1000-5000 AU to give greater signal strength and volume for the ladder.
The single ladders produced in this way were then mixed together to give the cocktail discussed above. The proportions of each ladder used are controlled to give balanced peak areas. The cocktail was then validated using Applied Biosystems 373A and Applied Biosystems 377 automated sequencers with Genescan and Genotyper software.
Allelic ladders according to the invention can be prepared by applying PCR amplification techniques to a pre-existing sample of the allelic ladder mixture. Alternatively the allelic ladders can be constructed from the sequence information provided herein.
The new ladders disclosed above significantly extends the range of alleles which can be identified in any DNA profiling system.
The allelic ladder mixture is used as a control sample alongside samples from known or unknown individuals which are then segregated according to size in a gel. Alleles in the sample under test can be designated by the known alleles in the control if they are within 0.5 bases of one another. Alleles falling outside this range are estimated based on their position relative to the ladder.
Using the standard nomenclature discussed above, the ladder range for each locus, defined by the extreme low molecular weight and extreme high molecular weight alleles are:
Locus
Low MW allele
High MW allele
a) HUMVWFA31/A
10
21
b) HUMTH01
4
13.3
c) D8S1179
7
19
d) HUMFIBRA/FGA
16.1
50.2
e) D21S11
53
81
f) D18S51
8
27
The allelic ladders also enable the identification of certain rare and hence highly discriminatory alleles in DNA profiling, thus increasing the profiling systems power.
For the various locus certain alleles are of particular significance as follows:
Locus HUMTHO1
The primers used for this locus were labelled with 6-FAM. The polymorphic region of this locus is based around a tetranucleotide motif repeat, (TCAT) n , where n=4 to 13. Particular alleles provided by the present invention include 4, 9.3, 10 and 13.3. The 9.3 and 13.3 alleles were found to have a deletion of a thiamine nucleotide at either the last base of the 4th repeat unit or the first base of the 5th repeat unit. The 13.3 allele notably possesses a non-consensus tetranucleotide (TCGT) at the 13th repeat,
Locus D21S11
The primers for this locus were also labeled with 6-FAM. The allele range extends from 53 to 81 and significantly includes alleles 53, 56, 57, 79 and 81. The polymorphic region of the D21S11 alleles is relatively complex in structure and is based around the tetranucleotide TCTR, where R is A or G (following the ambiguity codes of the Nomenclature Committee of the International Union of Biochemistry), as well as containing invariant hexa-, tri- and di-nucleotides. Both allele 54 and allele 56 deviate from this general structure in that they possess a deletion of a 14 base pair TA(TCTA) 3 (SEQ ID NO: 37) unit immediately prior to the invariant TCA tetranucleotide.
Locus D18S51
Again primers with a 6-FAM label were used. The ladder extends to 20 distinct alleles with particularly significant alleles at 8, 9, 23, 24, 45, 26 and 27. The polymorphic region is based around a simple tetranucleotide repeat motif (AGAA), (SEQ ID NO: 38), where n is 8 to 27.
Locus D8S1179
The primers used for this locus were labeled with TET. The ladder extends from alleles 7 to 19, based on 13 separate alleles. Significant alleles include 7, 15, 18 and 19. A Different generalized structures were observed between the upper and lower molecular weight ends of the ladder. In the lower molecular weight area, 161 to 177 base pairs, a simple repeat region based on the tetranucleotide TCTA exists. In the higher weight region, 181 to 201 base pairs, a compound repeat region composed of the tetranucleotide TCTR was found.
Locus HUMVWFA31/A
HEX labeled primers were used for this locus. The ladder covers alleles between 10 and 21, based on 12 alleles in total. Noteworthy alleles 10, 11 and 12 are included. The polymorphic unit is generally composed of a compound repeat following the pattern (TCTR)n. For the 13 and 14 alleles a non-consensus TCCA tetranucleotide at the 10th and 11th repeats was found.
Locus HUMFIBRA/FGA
This locus also employed HEX labelled primers. As mentioned above this ladder was constructed in two separate components. A low molecular weight and high molecular weight mix was used to produce the overall ladder. The low molecular weight mix ranges from allele 16.1 to 34.2 and the high molecular weight mix from allele 42.2 to 50.2.
The low MW mix includes significant alleles 16.1, 28, 30, 30.2, 31.2, 32.2, 33.2 and 34.2. The high MW mix includes noteworthy alleles 42.2, 43.2, 44.2, 45.2, 47.2, 48.2 and 50.2.
In general the HUMFIBRA/FGA alleles have a polymorphic unit based around the compound repeat YYBY, with the alleles in the upper part of the weight range being more complex in structure than those in the lower part. Within the general framework, allele 16.1 has a T nucleotide addition in the repeat region and allele 27 has a C to T transition in the 19th repeat unit (CTTT to CCTT). The upper MW allele range includes a stutter peak which is 4 base pairs smaller than the 50.2 allele. This artifact corresponds to allele 49.2 which has not currently been determined.
Amelogenin
Primers for this locus were once again labeled with 6-FAM. The sequence data revealed an X specific product of 105 base pairs and a Y specific product of 111 base pairs.
HUMTHO1 Allele Sequences (SEQ ID NO: 4) 13.3 (TCAT) 4 CAT (TCAT) 7 TCAT D21S11 Alleles Sequences (SEQ ID NO: 19) 53 (TCTA) 4 (TCTG) 6 (TCTA) 3 TA(TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 6 TCGTCT (SEQ ID NO: 20) 54 (TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT (SEQ ID NO: 21) 56 (TCTA) 5 (TCTG) 6 (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT (SEQ ID NO: 22) 57 (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 8 TCGTCT (SEQ ID NO: 23) 59 (TCTA) 5 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 9 TCGTCT (SEQ ID NO: 24) 61 (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 10 TCGTCT (SEQ ID NO: 25) 63 (TCTA) 4 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT (SEQ ID NO: 26) 65 (TCTA) 6 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TCGTCT (SEQ ID NO: 27) 67 (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT (SEQ ID NO: 28) 68 (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 11 TATCTA TCGTCT (SEQ ID NO: 29) 70 (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TATCTA TCGTCT (SEQ ID NO: 30) 72 (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TATCTA TCGTCT (SEQ ID NO: 31) 74 (TCTA) 5 (TCTG) 6 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 14 TATCTA TCGTCT (SEQ ID NO: 32) 75 (TCTA) 10 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT (SEQ ID NO: 33) 77 (TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT (SEQ ID NO: 34) 79 (TCTA) 11 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 13 TCGTCT (SEQ ID NO: 35) 81 (TCTA) 13 (TCTG) 5 (TCTA) 3 TA (TCTA) 3 TCA (TCTA) 2 TCCATA (TCTA) 12 TCGTCT D18551 Allele Sequences (SEQ ID NO: 36) 8 (AGAA) 8 D8S1179 Allele Sequences (SEQ ID NO: 5) 7 (TCTA) 8 (SEQ ID NO: 6) 19 (TCTA) 2 TCTG (TCTA) 16 HUMVWAF31/A Allele Sequences (SEQ ID NO: 1) 10 TCTA TCTG TCTA (TCTG) 4 (TCTA) 3 (SEQ ID NO: 2) 12 TCTA (TCTG) 4 (TCTA) 7 (SEQ ID NO: 3) 13 (TCTA) 2 (TCTG) 4 (TCTA) 3 TCCA (TCTA) 3
(Note also that the allele has an atypical 3′ flanking sequence. The usual sequence is TCCA TCTA T. In this allele the sequence is (TCCA)2T.
HUMFIBRA(FGA) Allele Sequences
(SEQ ID NO: 7)
16.1
(TTTC) 3 TTTT TTCT (CTTT) 5 T (CTTT) 3 CTCC (TTCC) 2
(SEQ ID NO: 8)
27
(TTTC) 3 TTTT TTCT (CTTT) 13 CCTT (CTTT) 5 CTCC (TTCC) 2
(SEQ ID NO: 9)
30
(TTTC) 3 TTTT TTCT (CTTT) 16 CCTT (CTTT) 5 CTCC (TTCC) 2
(SEQ ID NO: 10)
31.2
(TTTC) 4 TTTT TT (CTTT) 15 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 11)
32.2
(TTTC) 4 TTTT TT (CTTT) 16 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 12)
33.2
(TTTC) 4 TTTT TT (CTTT) 17 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 13)
42.2
(TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 4 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 14)
43.2
(TTTC) 4 TTTT TT (CTTT) 8 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 15)
44.2
(TTTC) 4 TTTT TT (CTTT) 11 (CTGT) 3 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 16)
45.2
(TTTC) 4 TTTT TT (CTTT) 10 (CTGT) 5 (CTTT) 13 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 17)
47.2
(TTTC) 4 TTTT TT (CTTT) 12 (CTGT) 5 (CTTT) 14 (CTTC) 3 (CTTT) 3 CTCC (TTCC) 4
(SEQ ID NO: 18)
48.2
(TTTC) 4 TTTT TT (CTTT) 14 (CTGT) 3 (CTTT) 14 (CTTC) 4 (CTTT) 3 CTCC (TTCC) 4
(1) GENERAL INFORMATION:
(i)
APPLICANT:
(A) NAME: Griffiths, Rebecca A. L.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Barber, Michael D.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE.: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Johnson, Peter E.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(F) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Gillbard, Sharon M.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY; Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Haywood, Marc D.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Smith, Carolyn D.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Arnold, Jennifer
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Burke, Trudy
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Urquhart, Andrew J.
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(A) NAME: Gill, Peter
(B) STREET: c/o The Forensic Science Service, Priory House, Gooch St.
(C) CITY: Birmingham
(D) STATE: W Midlands
(E) COUNTRY: United Kingdom
(F) POSTAL CODE (ZIP): B5 6QQ
(ii)
TITLE OF INVENTION: Improvements in and relating to forensic identification
(iii)
NUMBER OF SEQUENCES: 36
(iv)
COMPUTER READABLE FORM:
(A) MEDIUM TYPE: Floppy disk
(B) COMPUTER: IBM PC compatible
(C) OPERATING SYSTEM: PC-DOS/MS-DOS
(D) SOFTWARE: PatentIn Release #1.0, Version #1.30 (EPO)
(vi)
PRIOR APPLICATION DATA:
(A) APPLICATION NUMBER: GB 9713597.4
(B) FILING DATE: 28 Jun. 1997
(2) INFORMATION FOR SEQ ID NO: 1:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 40 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 1:
TCTATCTGTC TATCTGTCTG TCTGTCTGTC TATCTATCTA
(2) INFORMATION FOR SEQ ID NO: 2:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 48 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 2:
TCTATCTGTC TGTCTGTCTG TCTATCTATC TATCTATCTA TCTATCTA
(2) INFORMATION FOR SEQ ID NO: 3:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 52 base pairs
(B) TYPE: nucleic acid.
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 3:
TCTATCTATC TGTCTGTCTG TCTGTCTATC TATCTATCCA TCTATCTATC TA
(2) INFORMATION FOR SEQ ID NO: 4:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 55 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 4:
TCATTCATTC ATTCATCATT CATTCATTCA TTCATTCATT CATTCATTCG TTCAT
(2) INFORMATION FOR SEQ ID NO: 5:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 32 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 5:
TCTATCTATC TATCTATCTA TCTATCTATC TA
(2) INFORMATION FOR SEQ ID NO: 6:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 76 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 6:
TCTATCTATC TGTCTATCTA TCTATCTATC TATCTATCTA TCTATCTATC
TATCTATCTA
TCTATCTATC TATCTA
(2) INFORMATION FOR SEQ ID NO: 7:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 65 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 7:
TTTCTTTCTT TCTTTTTTCT CTTTCTTTCT TTCTTTCTTT TCTTTCTTTC TTTCTCCTTC
CTTCC
(2) INFORMATION FOR SEQ ID NO: 8:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 108 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 8:
TTTCTTTCTT TCTTTTTTCT CTTTCTTTCT TTCTTTCTTT CTTTCTTTCT
TTCTTTCTTT
CTTTCTTTCT TTCCTTCTTT CTTTCTTTCT TTCTTTCTCC TTCCTTCC
(2) INFORMATION FOR SEQ ID NO: 9:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 120 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 9:
TTTCTTTCTT TCTTTTTTCT CTTTCTTTCT TTCTTTCTTT CTTTCTTTCT
TTCTTTCTTT
CTTTCTTTCT TTCTTTCTTT CTTTCCTTCT TTCTTTCTTT CTTTCTTTCT
CCTTCCTTCC
(2) INFORMATION FOR SEQ ID NO: 10:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 126 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 10:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTTCT TTCTTCCTTC CTTCCTTTCT TTCTTTCTCC
TTCCTTCCTT
CCTTCC
(2) INFORMATION FOR SEQ ID NO: 11:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 130 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 11:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTTCT TTCTTTCTTC CTTCCTTCCT TTCTTTCTTT
CTCCTTCCTT
CCTTCCTTCC
(2) INFORMATION FOR SEQ ID NO: 12:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 134 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 12:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT CTTCCTTCCT TCCTTTCTTT
CTTTCTCCTT
CCTTCCTTCC TTCC
(2) INFORMATION FOR SEQ ID NO: 13:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 170 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 13:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTGTCT
GTCTGTCTGT CTTTCTTTCT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTCCTTC CTTCCTTCCT TTCTTTCTTT CTCCTTCCTT CCTTCCTTCC
(2) INFORMATION FOR SEQ ID NO: 14:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 174 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 14:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTGTCT
GTCTGTCTGT CTGTCTTTCT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTC CTTCCTTCCT TCCTTTCTTT CTTTCTCCTT CCTTCCTTCC TTCC
(2) INFORMATION FOR SEQ ID NO: 15:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 178 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 15:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTGT CTGTCTGTCT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTCCT TCCTTCCTTT CTTTCTTTCT CCTTCCTTCC
TTCCTTCC
(2) INFORMATION FOR SEQ ID NO: 16:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 182 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 16:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTGTCTGT CTGTCTGTCT GTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTCCT TCCTTCCTTC CTTTCTTTCT TTCTCCTTCC
TTCCTTCCTT
CC
(2) INFORMATION FOR SEQ ID NO: 17:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 190 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 17:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTGTCTGTCT GTCTGTCTGT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTTCT TTCTTTCTTC CTTCCTTCCT TTCTTTCTTT
CTCCTTCCTT
CCTTCCTTCC
(2) INFORMATION FOR SEQ ID NO: 18:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 194 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 18:
TTTCTTTCTT TCTTTCTTTT TTCTTTCTTT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTTCT GTCTGTCTGT CTTTCTTTCT TTCTTTCTTT
CTTTCTTTCT
TTCTTTCTTT CTTTCTTTCT TTCTTTCTTC CTTCCTTCCT TCCTTTCTTT
CTTTCTCCTT
CCTTCCTTCC TTCC
(2) INFORMATION FOR SEQ ID NO: 19:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 113 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 19:
TCTATCTATC TATCTATCTG TCTGTCTGTC TGTCTGTCTG TCTATCTATC
TATATCTATC
TATCTATCAT CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCG TCT
(2) INFORMATION FOR SEQ ID NO: 20:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 115 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 20:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATCAT
CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCT ATCTATCTAT CGTCT
(2) INFORMATION FOR SEQ ID NO: 21:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 119 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 21:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATCAT
CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCT ATCTATCTAT
CTATCGTCT
(2) INFORMATION FOR SEQ ID NO: 22:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 121 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 22:
TCTATCTATC TATCTATCTG TCTGTCTGTC TGTCTGTCTG TCTATCTATC
TATATCTATC
TATCTATCAT CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCT
ATCTATCGTC
T
(2) INFORMATION FOR SEQ ID NO: 23:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 125 base pairs
(B) TYPE; nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 23:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTATCTATC
TATATCTATC
TATCTATCAT CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CGTCT
(2) INFORMATION FOR SEQ ID NO: 24:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 129 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 24:
TCTATCTATC TATCTATCTG TCTGTCTGTC TGTCTGTCTG TCTATCTATC
TATATCTATC
TATCTATCAT CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCGTCT
(2) INFORMATION FOR SEQ ID NO: 25:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 133 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 25:
TCTATCTATC TATCTATCTG TCTGTCTGTC TGTCTGTCTG TCTATCTATC
TATATCTATC
TATCTATCAT CTATCTATCC ATATCTATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCG TCT
(2) INFORMATION FOR SEQ ID NO: 26:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 137 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 26:
TCTATCTATC TATCTATCTA TCTATCGTC TGTCTCTCTG TCTGTCTATC
TATCTATATC
TATCTATCTA TCATCTATCT ATCCATATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCT ATCGTCT
(2) INFORMATION FOR SEQ ID NO: 27:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 141 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 27:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATATC
TATCTATCTA TCATCTATCT ATCCATATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCT ATCTATCGTC T
(2) INFORMATION FOR SEQ ID NO: 28:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 143 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 28:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATATC
TATCTATCTA TCATCTATCT ATCCATATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCT ATATCTATCG TCT
(2) INFORMATION FOR SEQ ID NO: 29:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 147 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 29:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATATC
TATCTATCTA TCATCTATCT ATCCATATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCT ATCTATATCT ATCGTCT
(2) INFORMATION FOR SEQ ID NO: 30:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 151 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 30:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATATC
TATCTATCTA TCATCTATCT ATCCATATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCT ATCTATCTAT ATCTATCGTC T
(2) INFORMATION FOR SEQ ID NO: 31:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 155 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 31:
TCTATCTATC TATCTATCTA TCTGTCTGTC TGTCTGTCTG TCTGTCTATC
TATCTATATC
TATCTATCTA TCATCTATCT ATCCATATCT ATCTATCTAT CTATCTATCT
ATCTATCTAT
CTATCTATCT ATCTATCTAT CTATATCTAT CGTCT
(2) INFORMATION FOR SEQ ID NO: 32:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 157 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 32:
TCTATCTATC TATCTATCTA TCTATCTATC TATCTATCTA TCTGTCTGTC
TGTCTGTCTG
TCTATCTATC TATATCTATC TATCTATCAT CTATCTATCC ATATCTATCT
ATCTATCTAT
CTATCTATCT ATCTATCTAT CTATCTATCT ATCGTCT
(2) INFORMATION FOR SEQ ID NO: 33:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 161 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 33:
TCTATCTATC TATCTATCTA TCTATCTATC TATCTATCTA TCTATCTGTC
TGTCTGTCTG
TCTGTCTATC TATCTATATC TATCTATCTA TCATCTATCT ATCCATATCT
ATCTATCTAT
CTATCTATCT ATCTATCTAT CTATCTATCT ATCTATCGTC T
(2) INFORMATION FOR SEQ ID NO: 34:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 165 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 34:
TCTATCTATC TATCTATCTA TCTATCTATC TATCTATCTA TCTATCTGTC
TGTCTGTCTG
TCTGTCTATC TATCTATATC TATCTATCTA TCATCTATCT ATCCATATCT
ATCTATCTAT
CTATCTATCT ATCTATCTAT CTATCTATCT ATCTATCTAT CGTCT
(2) INFORMATION FOR SEQ ID NO: 35:
(i)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 169 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 35:
TCTATCTATC TATCTATCTA TCTATCTATC TATCTATCTA TCTATCTATC
TATCTGTCTG
TCTGTCTGTC TGTCTATCTA TCTATATCTA TCTATCTATC ATCTATCTAT
CCATATCTAT
CTATCTATCT ATCTATCTAT CTATCTATCT ATCTATCTAT CTATCGTCT
(2) INFORMATION FOR SEQ ID NO: 36:
(I)
SEQUENCE CHARACTERISTICS:
(A) LENGTH: 32 base pairs
(B) TYPE: nucleic acid
(C) STRANDEDNESS: single
(D) TOPOLOGY: linear
(ii)
MOLECULE TYPE: DNA (genomic)
(iii)
HYPOTHETICAL: NO
(iv)
ANTI-SENSE: NO
(vi)
ORIGINAL SOURCE:
(A) ORGANISM: Homo sapiens
(I) ORGANELLE: Mitochondrion
(xi)
SEQUENCE DESCRIPTION: SEQ ID NO: 36:
AGAAAGAAAG AAAGAAAGAA AGAAAGAAAG AA
The present 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. 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. | The invention provides allelic ladder mixtures and individual alleles suitable for use in such mixtures. The allelic ladder mixtures give improved identification and distinguishing capabilities, particularly suitable in forensic investigations. | 2 |
FIELD OF THE INVENTION
The invention relates to a compressed-air piston engine, in particular for paint-spraying devices, dosing pumps, grease guns and the like, including a working piston with a piston rod, which working piston can be moved by alternately loading the surfaces of the piston, and thus it oscillates in a piston cylinder driven by compressed air on its two piston surfaces by means of a slide control, which piston rod is axially guided in a cylinder head and/or a cylinder bottom, in each an inlet/outlet is provided for the compressed-air supply or discharge into/out of the piston cylinder, whereby the slide control has a control piston movable in a control cylinder, and control openings are provided in the control cylinder, which control openings fluidly connect a supply/discharge pipeline or vent pipelines for the compressed air to the control cylinder, and are controlled by the control piston. Furthermore, the invention relates to a compressed-air piston engine with a switch valve for the compressed air in the cylinder head and the cylinder bottom, which can be operated by the working piston and switches the slide control, whereby the switch valves have a valve piston rod projecting into the piston cylinder and operable by the working piston of the compressed-air piston engine.
BACKGROUND OF THE INVENTION
A single acting compressed-air piston engine is already known and can also be designed to be double acting without much effort, wherein a working device is connected to each face of the compressed-air piston engine. The piston cylinder can thereby be constructed in one piece with the cylinder head or the cylinder bottom, however, it is advantageous when both the cylinder head and also the cylinder bottom are manufactured separately from the piston cylinder, and the parts are subsequently assembled, as this is, for example, done in Patent DE 33 42 388 C3 so that the necessary machining on the parts can be kept to a minimum.
The slide controls, which are needed for switching the linear movement of the working piston and are provided outside of the piston cylinder, are independent of this in such compressed-air piston engines and are placed so that the axes of the associated control piston of the control cylinder extend parallel to the axis of the working piston.
The slide control is either laterally attached to the piston cylinder and, if necessary, designed in one piece with same, or it is provided just like in the arrangement corresponding to DE 33 42 388 C3 above the cylinder head, or, if necessary, also below the cylinder bottom; the slide control can be structurally integrated into these structural parts. Both arrangements are unfavorable.
In the first case, it is not possible to change the working stroke of the working piston without having to exchange at the same time the entire slide control, which in each case is designed only for a specific working stroke and thus for a specific height of the piston cylinder. Since very different working strokes are needed for the various uses, the manufacturer of such a compressed-air piston engine must have many differently dimensioned slide controls in storage; an adapting of the working stroke by the user is not possible or only possible with great difficulties.
In the second case, the structural length of the compressed-air piston engine is significantly increased solely by the slide control because even if the control piston can be kept shorter than the working piston, it does require significant additional space in the axis extending direction of both pistons at the same time, which space is added to the required space for the working piston.
It is also already known to initiate the switching of the working piston through the initially-mentioned switch valves, in each case the valve piston rod moves a valve piston against the force of a return spring when it is carried along by the working piston in its working direction on the last portion of its working stroke; after the working stroke has been switched the return spring moves the valve piston including the valve piston rod again into its initial position.
The purpose of the invention is to overcome the above-described disadvantages of the known compressed-air piston engines of the type identified in detail above and to mount a slide control space-savingly and fittingly with respect to various working strokes of the working piston. Moreover, a further purpose of the invention is to design the needed mountings in such a compressed-air piston engine simply and to limit same to few structural parts.
SUMMARY OF THE INVENTION
The purpose is attained according to the invention, first, in such a manner that the slide control is provided in/on the cylinder head or in/on the cylinder bottom, in such a manner that the axes of the control piston and of the working piston are positioned approximately vertically above one another.
It is entirely sufficient for the slide control to extend in the direction of its axis only so far that it does not, or does not significantly, exceed the outer circumference of the cylinder head or bottom, the slide control axis extending transversely with respect to the piston cylinder, so that through the slide control merely the structural height of the cylinder head or bottom increases slightly. However, the increase of this structural height due to inclusion of the integrated slide control can now be limited to a minimum dimension since the extent of such a slide control extending transverse with respect to its axis can be kept small compared with its extent in the axial direction.
The change of the working stroke of a compressed-air piston engine designed in this manner results--essentially--merely in a corresponding change of the piston cylinder, which can be easily exchanged. It is remarkable that this advantage does not require any additional compressed-air guides, since in comparison with the conventional arrangements, fewer rather than more structural parts must be used, and, in particular, the significant ones, namely cylinder head and bottom, are designed independently of the structural length of the piston cylinder.
It is thereby particularly advantageous when the axis of the control piston is spaced from the axis of the working piston because the piston rod can then be supported at both ends and/or can be guided both through the cylinder head or also through the cylinder bottom without being thereby hindered by the slide control.
A preferred embodiment of such a compressed-air piston engine of the invention using a switch valve in the cylinder head and the cylinder bottom, which switch valve can be operated by the working piston, consists of each of the switch valves being provided with a differential slide, which consists of a first valve piston of a larger piston surface and a second valve piston of a smaller piston surface, which are fastened at a fixed distance in alignment on the valve piston rod in such a manner that the air pressure from a branch pipeline standing in the valve housing moves the differential slide into a first end position, in which its valve piston rod projects partially into the piston cylinder. The differential slide is in connection with the constantly standing air pressure in the preferred first end position, from which it can be moved solely under the action of the working piston on its valve piston rod into a second end position--against the force from the air pressure, which force acts on the differential slide piston. A return spring is in this manner not needed, when merely care is taken that the piston surfaces of the differential piston are continuously exposed to the compressed air.
In detail, it is particularly advantageous when the switch valve is axis-parallel with respect to the working piston, and a circular-cylindrical passage for supporting the differential slide is provided in the cylinder head/bottom, whereby the passage is blocked off against the piston cylinder best by means of a preferably elastic closure, through which penetrates the valve piston rod, and against which the first valve piston can be placed under the action of the compressed air, thus the first valve piston slightly resiliently abuts against the elastic closure so that noise and wear are kept low. On the other side, on its side opposite this air blocking, the passage has advantageously a threaded bushing set by means of a locking screw, in which threaded bushing the second valve piston is guided, which blocks a supply/discharge pipeline leading into the switch valve as long as the first valve piston rests on the closure. With this it is assured that the differential slide is in the first end position, independent of the air pressure standing in the supply/discharge pipeline, as long as it is not moved out of same by the working piston.
Such an operation of the switch valves in connection with the working piston is guaranteed when at least one control opening for the supply/discharge pipelines from the switch valves, a main pipeline from the compressed-air source, and a vent pipeline from the compressed-air piston engine into the environment are provided in the control cylinder; furthermore, when in/outlets, which are connected to the slide control through working pipelines, for the compressed air in the piston cylinder are controlled on both sides of the working piston each by one of the switch valves, which is connected through a branch pipeline through the main pipeline to the compressed-air source and influences one of the supply/discharge pipelines to and from the control cylinder; still furthermore, when the control piston can be moved axially oscillatingly by the compressed air alternately flowing through these supply discharge pipelines; finally, when control chambers are provided on the control piston, which control chambers influence the control openings so that the main pipeline is connected alternately to an inlet/outlet, and at the same time an outlet to the environment; and finally, when branch pipelines from the main pipeline are branched off and are unblocked. The control chambers are advantageously constructed such that the compressed-air source is fluidly connected through the main pipeline at all times to one of the in/outlets.
Compressed-air connections between the cylinder head and cylinder bottom can be accomplished in a simple manner by fixed pipe sections clamped between both, which in a suitable manner connect their compressed-air guides; they must be exchanged together with the piston cylinder when the working stroke is changed. It is thereby, for example, advantageous when one of the branch pipelines, one of the working pipelines for the in/outlets, and/or the supply/discharge pipeline of one of the switch valves are guided with the slide control through a pipe section clamped between the cylinder head and the cylinder bottom outside of the piston cylinder.
In detail, it is furthermore advantageous when the control cylinder is closed on the front end face by locking parts so that it can be designed as a bore passing through the cylinder head/bottom; screw caps are best used for the locking parts. When elastic stops are preferably provided on the front end face on the control piston, which stops alternately strike the locking parts, then the control piston itself is protected; the elastic design of the stops extends the lifetime of the control piston and reduced noise generation.
The supply/discharge pipelines from the switch valves end in the vicinity of the locking parts so that they cannot be influenced by the control piston, and same is subjected to the air pressure of the compressed-air source alternately on its two end faces.
A structurally particularly simply design of the control piston occurs when on same a second control chamber is provided on both sides of the first control chamber, and is fluidly connected alternately with one associated outlet.
All in all, a remarkable improvement of its service-free lifetime has been achieved beyond the structural simplification of the compressed-air piston motor and its reduced spacial requirements, because the otherwise required return springs often break down or must be replaced due to spring breakage at the usually high working frequency of the compressed-air piston motor and its switch valves and the high dynamic stress related thereto. The switch times for the working piston are thereby very short because the differential slide is subjected at all times to the full switching force by the continuously supplied air pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be discussed hereinafter in connection with one exemplary embodiment and the drawings, in which:
FIG. 1 illustrates a compressed-air piston engine of the invention in an essentially center longitudinal cross-sectional view in a position of use,
FIG. 2 is a side view of FIG. 1 corresponding to cross-section II--II of FIG. 1,
FIG. 3 is a slightly enlarged top view of FIG. 2 corresponding to cross-section III--III of FIG. 2,
FIG. 4 is also a slightly enlarged top view of FIG. 2 corresponding to cross-section IV--IV of FIG. 2, and
FIG. 5 shows a detail D of FIG. 1, still further enlarged, all illustrated schematically simplified.
DETAILED DESCRIPTION
A compressed-air piston engine according to the invention consists in accordance with FIG. 1 essentially of a piston cylinder 1, a cylinder head 2, a cylinder bottom 3 and a working piston 4 and also the necessary control devices and compressed-air pipelines.
The pipe-shaped piston cylinder 1 is clamped between the circular-disk-shaped cylinder head 2 and the similarly shaped cylinder bottom housing 3, and is locked centrally on these by concentric coupling plates 21, 31, which are provided on first faces 22, 32 of the cylinder head 2 and of the cylinder bottom 3, each in one piece with these, which first faces face one another. A pipe-shaped air filter 5 is fittingly inserted into an annular groove 23 on the other (second) face 24 of the cylinder head 2 and is otherwise closed off by a filter lid 51. Three clamping screws 6 clamp together the filter lid 51 with the air filter 5, the cylinder head 2, the piston cylinder 1, and the cylinder bottom 3 so that the air filter 5 and the piston cylinder 1 are thereby tightly tensioned together. FIGS. 1 and 2 each indicate one clamping screw 6, FIG. 3 shows the orientation of all three clamping screws 6.
The longitudinal cross section in the area of the cylinder head 2 is shown in FIG. 1, deviating from the otherwise (axial) cross-sectional extent, also through a switch valve 7, which is also provided in the cylinder bottom 3 in the same manner and is shown enlarged in FIG. 5. Both switch valves 7, the position of which, spaced from the main axis HA of the compressed-air piston engine, is shown in FIGS. 3 and 4, have essentially the same design and are provided in a respective circular-cylindrical passage 25, 33 in the cylinder head 2 or in the cylinder bottom 3, which passage 25, 33 is partly smooth-walled and partly provided with a thread. The passages 25, 33 are connected on the one side through an associated branch pipeline ZL1, ZL2 to a main pipeline HL for the compressed air, which in turn is supplied with compressed air from a compressed-air source, which is not shown in the drawings and is merely indicated by a directional arrow Q; the arrangement is such that the compressed air stands at all times in the passages 25, 33. The branch pipeline ZL2 bridges outside of the piston cylinder 1 the free space between the cylinder head 2 and the cylinder bottom 3 with the help of a straight pipe section RS3, which has parallel axes with respect to the piston cylinder 1, is clamped between both.
Both switch valves 7, which work as slides, are in turn arranged axially parallel with respect to the piston cylinder 1 and have a differential slide member 71, which consists of a first valve piston 71a of a larger diameter and a second valve piston 71b of a smaller diameter, which are fixedly mounted at a distance "a" from one another on a common valve piston rod 71c, and the two alternately assumed end positions of which are indicated in FIGS. 1 and 5, where the first end position is shown in full line and the second in dashed lines. The passages 25, 33 are pneumatically separated from the piston chamber 10 of the piston cylinder 1 by an elastic closure 72, which is fastened in the cylinder head 2 or the cylinder bottom 3 and has a guide bore 72a, in which the valve piston rod 71c is axially movably supported. It can project into the piston chamber 10 so that its free surface 71d is then in the working range of the working piston 4.
The passages 25, 33 are furthermore separated from the environment U by a locking screw 73 with a central vent opening 73a. An aligned threaded bushing 74 with a guide cylinder 74a rests on the locking screw 73, in which guide cylinder 74a the second, smaller valve piston 71b is guided easily longitudinally movably. Supply/discharge pipelines Z1, Z2 end in the guide cylinder 74a and are connected to a slide control 8 provided in the cylinder head 2. The first, larger valve piston 71a is guided directly on the smooth cylinder surface of the passage 25, 33. While the supply/discharge pipeline Z1 ends directly in the slide control 8, in the case of the supply/discharge pipeline Z2 extending into and out of the cylinder bottom 3 a straight (third) pipe section RS1 bridges the free space between the cylinder head 2 and the cylinder bottom 3 and is clamped between both.
FIG. 1 indicates furthermore that the working piston 4 has a piston rod 41, which is supported centrally and slightly so as to be longitudinally movable in the cylinder head 2 and the cylinder bottom 3. A working device can be coupled to its end (here the lower); this is possible at both ends in the case of double-acting devices.
Each combined inlet/outlet port 26, 34 for the compressed air in the cylinder head 2 and the cylinder bottom 3 is provided in accordance with FIG. 2 on both sides of the working piston 4 in the piston chamber 10. The inlets/outlets 26, 34 are pneumatically connected to the slide control 8 by means of working pipelines AL1, AL2, whereby the working pipeline AL2 bridges the free space between the cylinder head 2 and the cylinder bottom 3 through a (second) straight pipe section RS2, which is clamped between both. Directional arrows R1 (FIG. 2) indicate the oscillating loading of the working piston 4.
All pipe sections RS1-3 and their spacial arrangement can be easily recognized in FIG. 4.
The slide control 8 can be best recognized in FIG. 3, in which it is illustrated centrally cross-sectioned. A control piston 82 is guided axially easily movably in a control cylinder 81 inserted in the form of a bushing into the cylinder head 2. The control cylinder 81 extends thereby transversely with respect to the main axis HA of the compressed-air piston motor and is (FIG. 1) spaced from same by the dimension "e" in such a manner that the piston rod 41 is not tangent to the axial position of the control cylinder. Two screw caps act as locking parts 83 and axially lock the control cylinder 81 in direction of its control axis SA (FIG. 2). Elastic stops 84 are respectively mounted on the end faces of the control piston 82, which stops 84 resiliently strike the adjacent locking part 83 during movement of the control piston 82.
The supply/discharge pipelines Z1, Z2 out of the switch valves 7 end near the locking part 83 so that they are not blockable and can always alternately load one associated face of the control piston 82 with compressed air. Whereas the working piston 4 and the two valve pistons 71a, 71b are each equipped with only one piston ring on their outer surfaces, a total of five areas, which are to be sealed off against one another, exist in the slide control 8; these areas are pneumatically separated from one another by four piston rings in corresponding annular grooves 82a, which piston rings are provided on the control piston 82 and are arranged at approximately equal axial distances from one another. Annular control chambers 82b, 82c are recessed between the sealing piston rings on the outer surface of the control piston 82, which control chambers 82b, 82c fluidly connect two adjacent control openings 81a, 81b, 81c with one another, into which the main pipeline HL, the working pipelines AL1, AL2 and the vent pipelines EL end; the vent pipelines EL on the other hand lead through the air filter 5 to the environment U, indicated by directional arrows R2 (FIG. 2).
The operation of the arrangement can be easily read without any difficulties from the drawings.
The differential slides 71 rest under the influence of the air pressure from the main pipeline HL, which air pressure is continuously supplied through the branch pipelines ZL1, ZL2, so long with its first valve piston 71a on the closure 71 as the associated valve piston rod 71c, which projects into the piston chamber 10, is not pressed by the working piston 4. The respective supply/discharge pipelines Z1, Z2 are in this first end position of the differential slide 71, which end position is shown in full lines, separate from the associated branch pipelines ZL1, ZL2 and vent through the vent openings 73a.
When the working piston 4 moves the differential slide 71 into the second end position indicated by dashed line, the compressed air then reaches into the supply/discharge pipelines Z1, Z2 so that the control piston 82 moves axially into its other end position, and the vent openings 73a are blocked. The supply/discharge pipelines Z1, Z2, which accordingly act as venting discharge pipelines in the first end position of the differential slide 71, end on both sides of the control piston 82 and not able to be influenced by same in the control cylinder 81 (FIG. 3).
The control piston 82 connects with its first control chamber 82b, as indicated in FIG. 3, the control opening 81a connected to the main pipeline HL to one of the control openings 81b, in which one of the working pipelines AL1, AL2 ends. The control chamber 82b is thus always guiding fluid pressure. One of the second control chambers 82c connects at the same time the other control opening 81b to one of the control openings 81c, into which the vent pipelines EL end, whereas the respective other second control chamber 82c is inactive and blocks any air flow.
The working piston 4 is in this manner moved out of its one end position, and the slide control 8 is switched as soon as the valve piston rod 71c, which extends freely into the piston chamber 10, is reached; the associated switch valve 7 switches then again the slide control 8.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A compact transportable compressed-air piston engine for paint-spraying devices, dosing pumps, grease guns or the like, makes it possible, without much effort, to carry out various length working strokes of a working piston. A compact engine is obtained by mounting the control in/on the cylinder head or in/on the cylinder bottom with axes extending transversely with respect to a main axis so that stroke changes can be achieved solely by the working piston contacting the valve piston rods of switch valves. In addition, return springs are not needed in the switch valves, which are required for reversing and are operated by the working piston. | 5 |
The present invention relates to a disc brake for a motor vehicle.
More specifically, the present invention relates to a disc brake of the type which comprise: a disc which has an inboard face and an outboard face, this disc rotating about a transverse axis in a direct sense of rotation when the vehicle is travelling forward; a carrier comprising an upstream branch and a downstream branch straddling the disc and secured to a common base which is fixed to the vehicle facing the inboard face of the disc, the downstream branch following on from the upstream branch in the direct sense of rotation of the disc, and each branch having an inboard housing and an outboard housing which are situated one on each side of the disc; a caliper straddling the disc and mounted so that it can slide relative to the carrier in a transverse direction parallel to the transverse axis, this caliper comprising a jaw pointing towards the outboard face of the disc, and a cylinder closed by a piston and pointing towards the inboard face of the disc; first and second guide means provided respectively on the carrier and on the caliper, one of the guide means consisting of a first bore, and the other consisting of a first pin sliding in the first bore; and a pair of friction pads, this pair being formed of an inboard pad and of an outboard pad placed respectively, in the transverse direction, between the piston and the inboard face of the disc, and between the outboard face of the disc and the jaw of the caliper, the inboard pad having an upstream end and a downstream end which are mounted so that they can slide in the respective inboard housings of the upstream and downstream branches, and the outboard pad having an upstream end and a downstream end which are mounted so that they can slide in the respective outboard housings of the upstream and downstream branches, the inboard and outboard pads bearing, between their respective ends, respective friction linings pointing towards the inboard and outboard faces of the disc and by means of which each pad is urged by the disc in the direct sense of rotation in the event of braking while the vehicle is travelling forwards, a first and a second at least of the inboard and outboard housings of the upstream and downstream branches forming stops for the respective ends of the pads, these stops being capable of opposing a movement of the inboard and outboard pads in the direct sense of rotation.
Disc brakes of this type are well known in the prior art, as shown, for example, in Patent Documents PCT/FR96/00615, PCT/FR94/00174, and EP-0,694,133.
One of the many problems which arise when designing disc brakes lies in the difficulty of absorbing the dragging forces transmitted to the pads by the disc, without the carrier deformations which necessarily result from this causing resistance that opposes the satisfactory sliding of the caliper relative to the carrier, as such a resistance itself generates abnormal wear and unevenness of the pads, risks of brake seizure, increase in brake-fluid absorption, noise, etc.
SUMMARY OF THE INVENTION
The invention falls within this context and its purpose is to propose a disc brake capable of deforming without appreciable functional anomaly.
To this end, the brake of the invention which in other respects conforms to the above preamble, is essentially characterized in that when the pads are urged in the direct sense of rotation, just a first of the inboard and outboard housings of the upstream branch forms an upstream stop for the upstream end of just a first one of the inboard and outboard pads, while just a second one of the inboard and outboard housings of the downstream branch forms a downstream stop for the downstream end of just a second one of the inboard and outboard pads, in that the upstream branch has a first stiffness for a force applied to the upstream stop, in that the downstream branch has a second stiffness for a force applied to the downstream stop, and in that the ratio between the first and second stiffnesses is between 0.80 and 1.25.
In other words, the disc brake of the invention is such that each of the upstream and downstream branches offers a stop to one of the inboard and outboard pads, that each of the pads abuts against just one of the branches, and that the upstream and downstream branches have stiffnesses which are at least similar, the ratio between these stiffnesses moreover preferably being between 0.95 and 1.05.
In one possible embodiment of the invention, the first housing is the inboard housing of the upstream branch whereas the second housing is the outboard housing of the downstream branch, and the upstream end of the inboard pad has a retaining profile via which this upstream end is caught onto the upstream stop of the inboard housing of the upstream branch, the downstream end of the outboard pad for its part bearing against the downstream stop of the outboard housing of the downstream branch.
Bearing in mind the geometry generally adopted for the carrier, and according to which the upstream and downstream branches are connected to the base of the carrier by respective upstream and downstream bridges, it may be advantageous according to the invention to make provision for the bridge, which connects to the base of the carrier that branch one of whose housings forms a stop for the inboard pad, to have a cross-section which is smaller than the cross-section of the bridge which connects to the base of the carrier that branch one of whose housings forms a stop for the outboard pad.
If the lower end of the upstream bridge is defined as being that end adjoining the base of the carrier and if the upper end of the upstream bridge is defined as being that end which is distant from the base, it is also advantageous to contrive for the first guide means to be located at the upper end of the upstream bridge.
As a preference, the first pin enters the first bore via an opening in the first bore which is in a half-space, delimited by the disc, in which the upstream stop is situated.
The disc brake of the invention may also comprise a third and a fourth guide means provided respectively on the carrier and on the caliper and one of which is a second bore and the other of which is a second pin sliding in the second bore, the second pin entering the second bore via an opening of the second bore which is in the same half-space as the downstream stop.
Finally, it may also be useful to contrive for the upstream and downstream branches only to be connected together by the base of the carrier.
Other features and advantages of the invention will emerge clearly from the description thereof given hereafter by way of non-limiting indication with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view from above and partially in section of a disc brake of the type to which the present invention is applicable;
FIG. 2 is a diagrammatic view from above illustrating the behaviour of the pads and of the disc in a disc brake of the prior art;
FIG. 3 is a diagrammatic front-on view of a disc brake in accordance with the invention, seen from the vehicle on which it is mounted;
FIG. 4 is a diagrammatic view from above of a disc brake in accordance with the invention;
FIG. 5 is a perspective view of a carrier of a disc brake in accordance with the invention, seen from the vehicle on which this brake is mounted; and
FIG. 6 is a perspective view of a carrier of a disc brake in accordance with the invention, seen from outside the vehicle on which this brake is mounted.
DETAILED DESCRIPTION OF THE INVENTION
As FIG. 1 shows, the invention relates to a disc brake for a motor vehicle, of the type which comprise, in a known way, a disc 1, a carrier 2, a caliper 3, guide means 41, 42, 43, 44 provided on the carrier 2 and on the caliper 3, and a pair of friction pads formed of an inboard pad 51 and of an outboard pad 52.
The disc 1 has an inboard face 11 and an outboard face 12 and is driven, with a wheel of the vehicle, in rotation about a transverse axis X in a direct sense of rotation D when the vehicle is travelling forward.
The carrier 2 comprises an upstream branch 21 and a downstream branch 22 both of which straddle the disc 1 and are secured to a common base 23 of the carrier, the latter being fixed to the vehicle facing the inboard face 11 of the disc, for example using screws inserted in orifices 231 and 232.
By convention, the downstream branch 22 is here defined as being the one which follows on from the other, known as the "upstream branch 21", in the direct sense of rotation D of the disc.
Furthermore, as better shown by FIGS. 5 and 6, each branch has an inboard housing 211, 221 and an outboard housing 212, 222 which housings lie on each side of the disc 1.
The caliper 3 which also straddles the disc 1 is mounted so that it can slide relative to the carrier 2, in a transverse direction T parallel to the transverse axis X.
This caliper 3, which acts like a gripper, essentially comprises a jaw 32 pointing towards the outboard face 12 of the disc, and a cylinder 31 situated on the inboard face 11 side of the disc and closed by a piston 311.
The guide means 41, 42, 43 and 44 are made up of pairs, each pair comprising a bore and a pin mounted so that it can slide in this bore.
As FIG. 1 shows, the guide means 41 and 43 provided on the carrier may consist of pins, the guide means 42 and 44 provided on the caliper 3 then consisting of bores.
However, it is also possible to contrive for the guide means 41 and 43 provided on the carrier to consist of bores, as shown in FIGS. 5 and 6, the caliper then being equipped with pins, or alternatively to contrive for the carrier and the caliper each to have one bore and one pin.
However, the layout of these guide means relative to the housings 211, 221, 212, 222 may, according to the invention, be optimized in a way which will be described later.
The inboard pad 51 is placed, in the transverse direction T, between the piston 311 and the inboard face 11 of the disc, and has an upstream end 511 and a downstream end 512 which are mounted so that they can slide in respective inboard housings 211, 221 of the upstream and downstream branches 21, 22.
Similarly, the outboard pad 52 is placed between the outboard face 12 of the disc and the jaw 32 of the caliper, and has an upstream end 521 and a downstream end 522 which are mounted so that they can slide in the respective outboard housings 212, 222 of the upstream and downstream branches 21, 22.
Furthermore, the inboard and outboard pads 51, 52 bear, between their respective ends, friction linings 510, 520, the lining 510 of the inboard pad pointing towards the inboard face 11 of the disc 1, and the lining 520 of the outboard pad pointing towards the outboard face 12 of the disc.
When pressurized brake fluid is injected into the cylinder 31 and pushes the piston 311 towards the disc 1, this piston presses the pad 51 against the inboard face 11 of the disc, the result of this being that the cylinder 31 is forced away from the disc until the jaw 32 presses the outboard pad 52 against the outboard face 12 of the disc with an equivalent force.
If, during this operation, the vehicle is travelling forwards, the pads 51 and 52 are therefore urged, by the disc, and via their linings 510 and 520 which rub against the latter, in the direct sense of rotation D.
A defect which is commonplace in known disc brakes is that of leading, at least when this urging is relatively strong, to a deformation of the disc, as illustrated, intentionally exaggerated, in FIG. 2.
What happens is that as the forces received from the disc by the pads have ultimately to be transmitted to the vehicle chassis via the carrier, and as the latter is fixed to the vehicle only on the inboard pad 51 side, the natural tendency of the carrier and of the caliper is to pivot about an imaginary axis of rotation R on the same side as the vehicle.
This movement, which is accompanied by a greater movement of the outboard pad 52 than of the inboard pad 51 in the direct sense D causes elastic warping of the disc, which has a tendency to worsen by positive retroaction of the phenomenon and to deform the brake in such a way that the sliding of the caliper relative to the carrier thereby becomes degraded.
Be that as it may, as the carrier's special purpose is to hold the pads relative to the disc, and therefore in this case to offer elastic resistance to the movement of the pads in the direct sense of rotation D, each pad then necessarily bears against the carrier, either because its upstream end is retained by the corresponding housing of the upstream branch 21, or because its downstream end is retained by the corresponding housing of the downstream branch 22, or again because each of its ends is retained by the corresponding housing of the corresponding branch, as recommended, for example, in the Patent Document EP-0,694,133 cited in the preamble.
The disc brake of the invention can be distinguished from the prior art especially in the fact that for an urging of the pads in the direct sense of rotation D, just a first one of the inboard and outboard housings 211, 212 of the upstream branch 21 forms an upstream stop 611 for the upstream end of just a first of the inboard and outboard pads 51, 52, whereas just a second one of the inboard and outboard housings 221, 222 of the downstream branch 22 forms a downstream stop 622 for the downstream end of just a second one of the inboard and outboard pads 51, 52.
In other words, each of the upstream and downstream branches 21, 22 offers a stop to one of the inboard and outboard pads 51, 52, and each of these pads bears only against one of these branches.
These features are illustrated symbolically in FIG. 4, which contains two types of pictorial symbol, namely a pictorial symbol P traction formed of an arrow pulling a bolt engaged in a hook, this pictorial symbol being, for example, the one associated with the upstream stop 611, and a pictorial symbol P thrust formed of an arrow pressing against a wall, this pictorial symbol being, for example, the one associated with the downstream stop 622.
The pictorial symbol P traction symbolizes the method of transmission of force by catching as illustrated by FIG. 3 in the case of the upstream end 511 of the inboard pad 51, the latter having a retaining profile 513 via which this upstream end 511 is caught on the upstream stop 611 of the inboard housing 211 of the upstream branch 21.
The pictorial symbol P thrust for its part symbolizes a method of transmitting a force by pressing, more specifically the means which in this case applies to the downstream end 522 of the outboard pad 52, which presses against the downstream stop 622 of the outboard housing 222 of the downstream branch 22 when this outboard pad is dragged by the disc 1 in the direct sense of rotation D.
The pictorial symbols P traction and P thrust visible in FIG. 4 can be distinguished from one another in a further way by additional graphics, namely the sense of their arrow, and the nature of the line (solid line or broken line) depicting them, these graphics having the sole purpose of allowing a complete understanding of the invention.
Bearing all of these conventions in mind, one of the major aspects of the invention is that the methods of transmission of force depicted by pictorial symbols in solid line are incompatible with the methods of transmission of force depicted by pictorial symbols in broken line, that is to say they must not be used in the same brake, pictorial symbols shown in solid line, however, being mutually compatible, as are pictorial symbols shown in broken line.
Furthermore, if we restrict ourselves for the time being to the pictorial symbols shown in solid line, those in which the arrow points in the direct sense D illustrate the method of transmission of force between the pads and the carrier when the disc 1 is turning in the direct sense D, whereas those in which the arrow faces in the opposite sense to the direct sense D illustrate the method of transmitting force between the pads and the carrier when the disc 1 is turning in the opposite sense to the direct sense D, the significance of the sense of the arrows obviously being the same in the case of the pictorial symbols in broken line.
Bearing in mind, however, that the maximum speed of a vehicle travelling forwards is very much higher than the maximum speed of the same vehicle travelling backwards, the invention is essentially interested only in the methods of transmitting force for the direct sense of rotation D of the disc, that is to say when the vehicle is travelling forwards, the choice of methods for transmitting force when the vehicle is travelling backwards being less critical.
To sum up, FIG. 4 therefore shows:
that in a first possible embodiment of the invention, the inboard pad 51 needs to be caught via its upstream end 511 in the upstream inboard housing 211 without its downstream end 512 pressing against a stop of the downstream inboard housing 221, whereas the outboard pad 52 needs to press via its downstream end 522 against a stop 622 of the downstream outboard housing 222 without its upstream end 521 being caught on the upstream outboard housing 212;
that in a second possible embodiment of the invention, the outboard pad 52 needs to be caught via its upstream end 521 on the upstream outboard housing 212 without its downstream end 522 pressing against a stop of the downstream outboard housing 222, whereas the inboard pad 51 needs to press via its downstream end 512 against a stop of the downstream inboard housing 221 without its upstream end 511 being caught on the upstream inboard housing 211;
that in the first embodiment of the invention, it is furthermore possible to contrive for the outboard pad 52 to be caught via its end 522 on the outboard housing 222 when the vehicle is travelling backwards, without its end 521 pressing against a stop of the outboard housing 212, while the inboard pad 51 presses via its end 511 against a stop of the inboard housing 211 without its end 512 being caught on the inboard housing 221; and
that in the second embodiment of the invention, it is also possible to contrive for the inboard pad 51 to be caught via its end 512 on the inboard housing 221, when the vehicle is travelling backwards, without its end 511 pressing against a stop of the inboard housing 211, while the outboard pad 52 presses via its end 521 against a stop of the outboard housing 212 without its end 522 being caught on the outboard housing 222.
Another essential aspect of the invention is that if K1 denotes the stiffness of the upstream branch 21 for a force applied to the upstream stop 611, and if K2 denotes the stiffness of the downstream branch 22 for a force applied to the downstream stop 622, then the ratio K1/K2 between these stiffnesses must be between 0.80 and 1.25, that is to say that the upstream and downstream branches must have at least similar stiffnesses, these stiffnesses preferably being as similar as possible to one another, and for example such that their ratio K1/K2 is rather between 0.95 and 1.05.
Thanks to these features, which give the inboard pad 51 mobility comparable with that of the outboard pad 52 as far as their common dragging by the disc 1 is concerned, and which therefore guarantee a simultaneous and equivalent movement of these pads under braking, the phenomenon described with reference to FIG. 2, and all of its negative consequences, can be avoided.
As FIGS. 5 and 6 show, the upstream and downstream branches 21, 22 are connected to the base 23 of the carrier by respective upstream and downstream bridges 241, 242.
A first of these bridges, in this case the upstream bridge 241 in the figures, serves to connect to the base 23 of the carrier that branch one housing of which forms a stop for the inboard pad 51, that is to say, in this case, the upstream branch 21 the housing 211 of which bears the stop 611.
The second of the upstream and downstream bridges, in this case the downstream bridge 242 in the figures, serves to connect to the base 23 of the carrier that branch one of the housings of which forms a stop for the outboard pad 52, that is to say, in this case, the downstream branch 22 the housing 222 of which bears the stop 622.
This being the case, as the outboard stop 622 is, by construction, further from the vehicle than the inboard stop 611, an advantageous way of satisfying the condition that the ratio K1/K2 has to satisfy, at least if the carrier is made out of just one material, consists in giving the first and second bridges cross-sections S1 and S2 which differ, and which are such that the cross-section S2 of the second bridge is greater than the cross-section S1 of the first bridge (see FIG. 3).
In the embodiment illustrated in FIGS. 3, 5 and 6, and in which the upstream bridge 241 has a lower end 241a adjoining the base 23 of the carrier and an upper end 241b distant from the base 23, the guide means 41 provided on the carrier, in this case the bore 41, is advantageously situated at the upper end 241b of the upstream bridge 241 so that the caliper can follow the movement of the inboard pad 51, without any lead or lag.
Another advantageous feature of the invention can be defined by considering (see FIG. 4) that the disc 1 delimits, for example via its mid-plane 13, two half-spaces E+, E-, each of which points towards a corresponding face 11, 12 of the disc.
This being the case, it is preferable for the first pin, that is to say that one of the first and second guide means which is a pin, to enter the first bore via an opening of the first bore which is in the same half-space as the upstream stop.
For example, in the embodiment of FIGS. 3, 5 and 6, which envisages for the first guide means 41, that is to say the guide means associated with the carrier 2, is a bore, and that the second guide means 42, that is to say the one associated with the caliper 3, is a pin, it is preferable for the pin 42 to enter the bore 41 via an opening 411 which is in the same half-space E- as the upstream stop 611.
Similarly, when the disc brake of the invention comprises, by way of additional guide means, a second bore 43 and a second pin 44 sliding in this second bore 43, it is preferable for this second pin 44 to enter the second bore 43 via an opening 431 therein which is in the same half-space E+ as the downstream stop 622.
Finally, as FIGS. 5 and 6 show, it is also advantageous to make provision for the upstream and downstream branches 21, 22 to be joined together only by the base 23 of the carrier, so as to make the carrier easier to design and avoiding any strong interaction between the movement of the upstream stop 611 and the movement of the downstream stop 622. | A disc brake for a motor vehicle including a disc (1), a carrier fixed to the vehicle and inboard (51) and outboard (52) pads. The respective ends (511,512,521,522) of the inboard (51) and outboard (52) pads slide in an upstream branch (21) and a downstream branch (22) of housings (211,221,212,222) of the carrier. Each of the upstream and downstream branches (21,22) of the carrier provides a stop (611,622) to one of the inboard and outboard pads (51,52) however, each of the pads (51,52) only comes into abutment against one of the upstream and downstream branches. The upstream and downstream branches (21,22) being connected to a base (23) different cross-sections and correspondingly different stiffness in a ratio of between 0.80 to 1.25 to resist forces applied to the stop (611,622) without appreciable degradation in the operational performance of the disc brake. | 5 |
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the machine of the invention;
FIG. 2 is a top plan view of the carriage of the machine;
FIG. 3 is a face view of a program card for the machine;
FIG. 4 is a face view of a display provided on the carriage of the machine;
FIG. 5 is a somewhat diagrammatic bottom plan view of the carriage showing needle actuating cams arranged for fair-isle knitting;
FIG. 6 is a view similar to FIG. 5 showing the camming arranged for punch-lace knitting;
FIG. 7 is an enlarged somewhat schematic fragmentary bottom plan view of the carriage showing an electromagnetic needle actuator and associated needle-butt detector;
FIG. 8 is a view taken on the plane of the line 8--8 of FIG. 7;
FIG. 9 is a schematic view in perspective of the pulse generator of the machine;
FIG. 10 (A and B) are diagrams showing the signal outputs of components of the pulse generator;
FIG. 11 is a block diagram showing the principal components of the machine and indicating their interrelationship;
FIG. 12 (A, B and C) are circuit diagrams showing electronic components of the card reader of the machine;
FIG. 12D is a schematic representation indicating the location on the program card of strobe signals with respect to ruled columns in the design area of the card;
FIG. 13 is a circuit diagram showing a digital adapter and thresholding circuit components associated with the reader;
FIG. 14A is a circuit diagram showing the electronic components of needle butt circuitry;
FIG. 14B is a wave shape diagram illustrating the operation of the circuitry of FIG. 14A;
FIGS. 15A and 15B are diagrams showing electronic drive components for the liquid crystal display on the machine;
FIG. 15C is a wave shape diagram illustrating the operation of the circuitry of FIG. 15A;
FIG. 16A is a diagram showing actuator duty cycle and time-out circuitry;
FIG. 16B is a wave shape diagram illustrating the operation of the circuitry of FIG. 16A;
FIG. 17A is a circuit diagram showing the interface between the computer and input/output circuitry;
FIG. 17B is a truth table for the Off-Program-Knit switch of the machine;
FIG. 18 is a circuit diagram showing a voltage level comparator;
FIG. 19 is a listing of computer subprograms and subroutines;
FIGS. 20 through 47 are flow diagrams; and
FIGS. 48 and 49 is a glossary of terms used in the flow charts of FIGS. 20 through 47.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is embodied in preferred form in the machine of the drawings and is an integral part thereof along with other inventions which are the subject of copending applications bearing Ser. Nos. 627,173, 627,178 and 627,446 respectively, all filed on Oct. 30, 1975. Referring to FIGS. 1 and 2 of the drawings, reference characters 10 and 12 designate the bed and carriage respectively of such home knitting machine. The carriage is slidably mounted on a guide rail 14 affixed to the bed, and includes handles 16 and 18 which an operator may grasp and utilize to move the carriage back and forth on the bed. Knitting needles 20 are slidably supported in side by side relation in the bed 10 as shown. The carriage includes needle actuating camming hereinafter described and includes left and right electromagnetic actuators 22 and 24 respectively by means of which the needles may be caused to enter one or another of alternate cam paths and knit a single yarn, two different yarns, or a yarn and thread into fabric in a prescribed manner.
A general purpose minicomputer 26, of Texas Instrument Co. P/N Model 960A, programmed as hereinafter indicated, is provided for controlling the needle actuators 22 and 24 pursuant to instructions on a program card 28 as detected by a reader 30 located on the carriage and/or the condition of various electrical switches also located on the carriage. As shown, the computer 26 connects by a multi-wired cable 32 with an input-output box 34 and the input-output box connects by another such cable 36 with the carriage 12. Cable 36 extends through a slot 38 in a table 40 which supports the bed 10 on one side of the slot 38 and a compartmentalized housing 42 for accessories on the other side. The cable 36 is of such length as to permit it to move freely with the carriage 12 as the carriage is moved along the bed. The input-out box includes an input power line 44 and a switch 46 by means of which power supplied over line 44 may be connected to or disconnected from the carriage. Power is supplied to the computer 26 over line 48.
Electrical switches located on the carriage and operatively connected to the computer 26 via input output box 34 include an O.P.K. switch 50, needle one switch 52, motifing switch 53, automatic and row repeat switch 54, row advance 56, row descent switch 58, design inversion switch 60, left-right reverse switch 62 and check-digit switch 63. A pulse generator 64 mounted on the carriage for rotation in timed relation to movement of the carriage and a liquid crystal display 66 on the carriage also operatively connect with the computer 26 via the input-output box 34.
The O.P.K. switch 50 is a three position switch which an operator of the machine may move into one position (O) to turn the machine off, another position (P) to put the machine in a PROGRAM MODE, and still another position (K) to place the machine in a KNIT MODE. The switch remains in whatever position it is placed until moved again. Motifing switch 53 is a three position switch similar to switch 50 and has an off position (O) as well as two motifing positions (M+) and (M-). The automatic and row repeat switch 54 is movable into either of two positions (A or R). Design inversion switch 60 and left-right reverse switch 62 are also two position switches. Each of the switches 54, 60 and 62 remains in whatever position it is placed until moved again. The other switches, that is, needle one switch 52, row advance switch 56, row descent switch 58 and check digit switch 63 are on-off switches which remain on only so long as they are depressed. The motifing switch 53, automatic and row repeat switch 54, design inversion switch 60, row advance switch 56, row descent switch 58 and left-right reverse switch 62 are dual function switches in that each serves one purpose when the machine is in the KNIT MODE and another purpose when the machine is in the PROGRAM MODE.
A stand 68, centrally located with respect to ends of the needle bed 10 is provided with yarn guides 70 and 72, and with tension devices 74 and 76 enabling one yarn, two yarns or a yarn and thread to be fed in a controlled fashion to the needles of the machine and to be knit into fabric.
Program card 28 which may be best seen in FIG. 3, is used to instruct the computer concerning the manner in which fabric is to be knit on the machine. As shown, the card includes mutually perpendicular lines which define a design area of rectangles 78 that extend in numbered columns (1 through 36) and numbered rows (1 through 20). The rectangles 78 correspond to stitches and the numbered columns and numbered rows to wales and courses respectively which may be knit in a fabric pursuant to instructions on the card. Preferably the width and height of each rectangle 78 are such as to substantially correspond to the width and height of a typical stitch. The card includes two rows of strobe markings 80 (strobe A) and 82 (strobe B), a row of size delineating ellipses 84 aligned with the numbered columns 2 through 36, and a column of size delineating ellipses 86 aligned with the numbered rows all as shown in the drawing. In addition the card includes a column of ellipses 88 in association with symbolically expressed textless instructions, that is, the ellipses 88a, 88b, 88c and 88d having to do with selvedge, mirror imaging, horizontal multiplication and vertical multiplication, respectively.
The reader 30 includes a thumb wheel 90 by means of which the program card may be easily moved through the device after having been inserted in the entrance slot 92 on the carriage. As will be explained hereinafter in more detail, the reader is adapted to detect, as the card moves through it, the strobe marks on the card and any marks made on it by an operator in particular rectangles in the design area or in particular ellipses outside the design area.
As previously noted, the pulse generator rotates in timed relation to movement of the carriage 12. The device (FIG. 9) includes photo-interrupter modules 94 and 96 in association with a toothed disc 98 affixed on one end of a shaft 100. Each module includes a light emitting diode (LED) on one side of the disc 98 and a phototransistor on the other side as shown for the module 94 at 102 and 104 respectively and for module 96 at 106 and 108 respectively. A toothed pulley 110 is affixed to the shaft 100 and a timing belt 111 connects the toothed pulley with a pinion 112 which is rotatable in the carriage and meshes with a rack 114 on the bed 10 of the machine (FIG. 2). As the carriage 12 is moved on the bed, pinion 112 is rotated by reason of its engagement with the rack 114 and the timing belt 111 is caused to drive pulley 110 and shaft 100. Disc 98 is rotated by shaft 100 in synchronism with the carriage and equally spaced teeth 116 on the wheel intermittently interrupt light between the LED and phototransistor in each of the photointerrupter modules causing the modules to produce output pulses. Modules 94 and 96 are so located and the number of teeth 116 on disc 98 is such as to cause module 94 to produce a pulse (FIG. 10A) each time the carriage passes from one needle area of the bed to the next, and module 96 to produce pulses (FIG. 10B) which lead the pulses from module 94 by 90° when the carriage is moved in one direction (to the right) and which lag the pulses from module 94 by 90° when the carriage is moved in the other direction (to the left).
The liquid crystal display 66 (FIG. 4) is comprised of a background plane 118 and fourteen segments which may be turned on selectively to provide meaningful indications to an operator of the knitting machine. One such segment in the shape of the numeral two is located at the left end of the display, and another of the segments, formed as the unit integer is located next to it. Two segments, one in the shape of an arrow pointing upward and the other also in the shape of an arrow but pointing downward, are located at the right end of the display. Four vertically aligned rectangularly shaped elements which define three of the segments (the two centrally located elements being electrically connected to constitute one segment) are located next to the arrows, and seven segments, selected combinations of which can represent any number from zero to nine, are disposed between the three segments formed by the four vertically aligned rectangular elements and the single segment formed as the unit integer.
Needle actuating camming is provided in conjunction with the left and right needle actuators 22 and 24, and left and right butt detectors 118 and 120 on the underside of the carriage 12 (FIGS. 5, 6 and 2). Such camming which is symmetrical about the transverse center line of the carriage includes fixed left and right separator cams 122 and 124, knit cams 123 and 125, fixed center cams 126 and 128, fixed upper elongated guide cam 130, fixed left and right elongated lower guide cams 132 and 134, free floating left and right check cams 136 and 138, spring biased left and right gate cams 140 and 142, left and right fair-isle gate cams 144 and 146 adjustable by cam lever 148, left and right knit-tuck gate cams 150 and 152 adjustable by the cam lever 148, left and right knit-in cams 154 and 156 also adjustable by cam lever 148, and russel cams 158 and 160 adjustable by cam levers 162 and 164 all as embodied in Model 321 of a home knitting machine sold by The Singer Co. under its registered trademark "Memo-Matic."
The camming is shown in FIG. 5 with the adjustable cams in positions enabling the camming in conjunction with suitably controlled actuators 22 and 24 to cause the needles 20 as the carriage traverses the bed of the machine to move in a well known manner suited to Fair-Isle knitting wherein two yarns 166 and 168 of different colors are knitted into a pattern. Alternate paths as selectively determined for the needles by the actuators pursuant to instructions specified by an operator of the machine prescribe the particular form of the pattern. The alternate paths for movement of the carriage 12 in the direction indicated as determinable by the one actuator 24 appear at 170 and 172.
In FIG. 6 the camming is shown with the adjustable cams disposed to enable the camming in conjunction with suitably controlled actuators 22 and 24 to cause the needles, as the carriage is moved back and forth on the bed, to knit Punch Lace, in a well known manner, into a pattern prescribed by the operator of the machine with a wool or synthetic yarn 174 and nylon thread 176. Alternate paths for needles through the camming in FIG. 6 as selectively determinable by actuator 24 during movement in one direction is shown at 180 and 182.
With the adjustable cams disposed for either Fair-Isle Knitting or Punch Lace knitting and with the actuators 22 and 24 out of action (i.e. in the absence of control signals to these devices) all needles are caused to follow one path through the camming as the carriage 12 is moved in one direction or another along the bed 10 (in FIG. 5, path 170 for the direction indicated; and in FIG. 6, path 180 which is the same as path 170). The needles in both instances are caused to move in the bed in the same way and Stockinet knitting is performed in a manner well known.
Butt detector 120 as may be best seen in FIG. 7 includes a contact element 184 mounted in a fixed cam 186 and another contact element 188 in the form of a spring which in addition to serving as a contact, functions as a biasing means for a side cam 190. The butts 20a of needles 20 passing between cams 186 and 190 successively bridge the gap between contact elements 184 and 188 thereby closing an open circuit between them and causing a signal to be transmitted to the computer 26. Butt detector 118 is similar to and functions in the same manner as butt detector 120.
The width of a fabric to be knitted is defined prior to knitting by an operator positioning those needles which are to be on the fabric in one or more positions on the bed as required for the knitting of the particular cloth such that they can be influenced by the camming in the carriage as it is moved back and forth across the bed, and positioning those needles at opposite end portions of the bed which are to be off the fabric in positions such that can not be acted upon by the camming in the carriage. For automatic pattern knitting the way in which the needles to be on the fabric are preliminarily disposed is always such that as the carriage is moved on the bed no more than two such needles in succession can pass by the leading butt detector before a needle butt enters the device and is detected. Therefore, regardless of the type of pattern knitting no more than three needle spaces can be traversed by the carriage without a signal from a butt detector before it is certain that the butt detector has reached the end of the fabric. The computer 26 takes note of the absence of three butt detector signals during automatic pattern knitting and causes the actuator to operate so as to cause needles, beginning with the first of a number of needles to enter the actuator 24 in advance of the first of the three needles missing the butt detector, to knit a plurality of like stitches as selvedge. Cam lever 148 (FIG. 2) which is used in adjusting the carriage camming for Punch Lace knitting closes a switch 191 when moved into its Punch lace position and causes a signal to be transmitted to the computer 26 effective to provide for the formation of selvedge with both the wool or synthetic yarn and thread (174 and 176 respectively in FIG. 6) used in this type of knitting rather than with the thread alone. One, two or three selvedge stitches as prescribed by the operator may be knit at each edge of the fabric with the machine as shown and described herein.
Needle selector 24 (FIGS. 7 and 8) includes a permanent magnet 192 fastened against the upper limb 194 of a C-shaped channel of magnetic material having a lower limb 196. The upper and lower limbs 194 and 196 of the channel define a gap 198 which diverges toward the left as viewed in FIG. 7 and presents north and south magnetic poles as indicated. A hole 200 formed in the upper limb 194 adjacent to the narrowest portion of the gap 198 reduces the strength of the upper or north pole of the opposed magnetic poles as developed by the permanent magnet 192. A magnetizable core 202 is attached to limb 194 and a coil 204 is provided about the core.
Needle butts 20a moving through the selector 24 are attracted in the narrowest part of gap 198 to the north pole on the upper limb 194 or the south pole on lower limb 196 depending upon whether or not coil 204 is energized. A deenergized coil causes a needle butt to be drawn to the lower or south pole against limb 196 and to thereafter continue along the limb because of the divergence of the poles. However an energized coil produces a strong electromagnetic pole on the core 202 at the upper limb 194 of the same polarity as that produced by the permanent magnet on such limb and causes a needle butt in the gap 198 to be drawn to the north pole against limb 194. The needle butt thereafter travels along limb 194 because of the divergence of the poles. Needle selector 22 is constructed and functions in the same manner as needle selector 24.
The knitting machine of the invention is programmed for pattern knitting with the OPK switch 50 in the P position. The card 28 may be used to instruct the machine concerning the pattern to be knit or instructions may be obtained from a pattern pre-programmed into computer 26 by the operator flipping a switch 206 on the computer. The computer may, if desired, be preprogrammed to include a plurality of different patterns each of which may be specified for reproduction upon the operation of an appropriate switch.
Marks in the design area of the card and in ellipses outside the design area define a pattern to be knitted. A preprinted card defining the pattern could be used to instruct the machine but if the operator wishes to prescribe a pattern not preprinted on a card or not stored in the computer he must mark the card 30 with a pencil or other marker (preferably one leaving an erasable mark) as required for the pattern desired.
An operator marks out a design configuration of his own for reproduction in a fabric, as for example the duck on the card in FIG. 3, by selectively darkening rectangles in the design area as shown. Boundaries for a unit design area to be repetitively reproduced each with the design configuration is specified by the operator darkening one of the size delineating ellipses 84 adjacent to a selected numbered column and another one of the size delineating ellipses 86 adjacent a selected numbered row as in FIG. 3. If he inadvertently darkens more than one column aligned ellipse or more than one row aligned ellipse, only the one aligned with the lowest numbered column or row is given effect by the control electronics when the card is read. If no size delineating ellipse is darkened the ellipses adjacent column 36 and row 20 which are preprinted black serve to prescribe the boundaries of the unit design.
In addition to specifying a design configuration on the card and selecting size delineators, an operator may prescribe one, two or three wales to be knit as selvedge with like stitches by darkening one of the ellipses 88a, call for mirror imaging of the unit design horizontally or vertically or both by darkening one or both of the ellipses 88b, specify a two, three or four fold increase in the unit design horizontally by darkening one of the ellipses 88c, specify a two, three or four fold increase in the unit design vertically by darkening one of the ellipses 88d. The machine is capable of executing any combination of the instructions pertaining to mirror imaging, multiplication, or selvedge which are not inconsistent due to more than one of the ellipses 88a, 88c or 88d having been darkened.
Instructions on the card are imparted to the machine by feeding the card through the reader 30 with thumb wheel 90. The reader includes various light emitting diodes and phototransistors which are multiplexed into paired relationship as the card passes through the reader, and they serve to detect the presence of marks within the design area defining the design configuration and marks outside the design area whether imprinted on the card as in the case of strobe marks and the delineator marks adjacent row 21 and column 36, or marks added for the purpose of selecting one of the design options (selvedge, mirror imaging, multiplications).
Signals representing the instructions on the card pertaining to the pattern to be knitted as denoted by the marks in the rectangles and ellipses and detected by the reader in conjunction with associated circuitry are transmitted to the computer and retained in memory until recalled to control operation of the actuators 22 and 24 during the knitting of fabric. The manner in which the reader functions to detect markings reliably on the card and the manner in which the computer functions concerning such instructions and others is discussed in detail hereinafter. It is here merely noted that the reader is adapted to recognize reverse movements of the card and control the recording of signals in the computer accordingly so that it is not essential for an operator to painstakingly avoid all reverse movements while feeding a card through the reader, that the reader is further adapted to detect when a skewed card is fed into the reader, that the reader and computer are adapted to determine when a card is fed too fast through the reader for the accurate reading of instructions on the card, that the strobe markings on the card are arranged to maximize the permissable speed of the card, and that the reader and computer are adapted to determine the total number of dark marks on the card.
After the card has been read and while the machine is in the PROGRAM MODE an operator can:
1. Designate a particular needle (needle one) to form column 1 of the unit design on the program card;
2. Specify a motifing sequence;
3. Call for a reversal in the fabric of the left - right orientation of the unit design on the program card.
Such instructions can be prescribed singly or in combination in varying order. Also, the operations specified in 2 and 3 above can, if desired, be performed prior to the reading of a card.
The overall position of the pattern in fabric to be knit on the machine is determined by the needle one selection. The designation is made by the operator moving the carriage 12 to a position wherein its transverse center line is in alignment with a needle to be selected and then momentarily depressing the needle one switch 52. A motifing sequencing is prescribed by the operator moving the carriage across portions of the needle bed with motifing switch 53 in its M- position, the effect of which is to schedule those needles traversed while the switch is so positioned to knit background only and nothing of the design configuration on the program card. By traversing needles with switch 53 in the M+ position, the operator may at any time void any of the selections made with the switch in the M- position. A reversal in the fabric of the left - right orientation of the unit design as it appears on the card is prescribed by the operator setting the left - right reversing switch in its reversing position.
While the machine is in the PROGRAM MODE, the operator can utilize switches on the carriage to prescribe mirror imaging and/or multiplication not called for on the program card, or to override and change such option or options specified on the card. Switch 54 may be so used for horizontal mirror imaging, switch 60 for vertical mirror imaging, switch 58 for horizontal multiplication and switch 56 for vertical multiplication. Switches 54 and 60 which may have been left in the option selecting position prior to the time the O.P.K. switch was moved to the P position must be moved out of that position and returned to it to effect a selection.
A momentary depression of switch 58 causes the display 66 to show, with an appropriate number of its rectangular elements, the horizontal multiplication factor in the computer at that time and continued depression of the switch causes the display to cycle through the multiplication factors. When the switch is released, the multiplication factor in view at the time is retained on the display and that factor is programmed into the computer. A momentary depression of switch 56 causes the display to show an up arrow, and with its rectangular elements the vertical multiplication factor then in effect. Continued depression of the switch causes cycling on the display of the vertical multiplication factors any one of which may be selected for the computer and retained on the display by the operator releasing the switch when the factor appears.
After the machine has been programmed the operator must before proceeding to knit fabric move the O.P.K. switch 50 into the K-position to place the machine in the KNIT MODE. Assuming the machine was properly programmed the display 66 will be caused to show at least a 1 standing for row 1 on the design card and either the up or the down arrow when the switch is moved to the K position. If the machine was programmed for vertical mirror imaging the down arrow will show, otherwise the up arrow will be displayed. If the machine was programmed for vertical multiplication a single rectangle will also come into view, otherwise none appear.
Fabric is knit with the machine in the KNIT MODE by the operator moving the carriage back and forth across the bed to actuate the needles. The first course of fabric is knit pursuant to the instructions read from row 1 of the program card, and while the row is being knit the display shows the numeral 1 brought into view when the O.P.K. switch was moved into the K position. Thereafter, higher numbered rows on the card are knit sequentially without repetition up through the highest numbered row of the unit design as delineated on the card (row 15 in FIG. 3), provided the automatic and row repeat switch 54 is in its A position (normal position) and vertical multiplication was not prescribed. After the highest numbered row of the unit design has been knit the rows of the unit design are knit again beginning with row 1 unless vertical mirror imaging was programmed into the computer in which case the rows are knit downward from the highest numbered row of the unit design. After each new row is completed and the carriage has been reversed, as determined by the computer 26 in response to signals from the butt detectors 118 and 120, the display is updated to show the row being knit. The display shows a 1 C during movement of the carriage across the needle bed each time the transverse center line of carriage passes over the needle one position.
The operator can knit a design row out of sequence if he first selects the particular row he wishes to knit with the row advance switch 56 or row descent switch 58. These switches are so operable anytime the carriage is in the KNIT MODE provided the carriage is not in the midst of knitting a course of fabric. With the row advance switch depressed the display steps upwardly from the row showing, slowly at first and then more rapidly, and cycles through the unit design rows on the card. With the row descent switch depressed the display steps downwardly, initially at a slow pace, and then rapidly from the row showing, and cycles through the unit design rows. The operator selects the row he wishes to knit by releasing the row advance or row descent switch when the number of the row he wishes to knit appears. He can then knit the selected row by moving the carriage across the bed of the machine after which the unit design rows will again be knit sequentially as the operator continues to move the carriage on the machine reversing its direction at each end of the fabric, and the display will be updated accordingly to show the row being knit. A momentary depression of switch 56 or 58 causes the display to immediately step up or down one design course row.
The operator can cause a particular row to be knit repeatedly any number of times and the number of the row to be displayed during this process. This is accomplished by the operator moving the automatic and row repeat switch 54 into its R position and leaving it there until he has knit that row the desired number of times.
If vertical multiplication was perscribed, the machine knits each unit design row two, three or four times (as was specified for the multiplication factor) as the carriage 12 is moved back and forth across the bed 10, and the display is caused to show whether a row is being knit for the first, second, third or fourth time with a corresponding number of rectangles. The number of the particular design row being knit at any time is also in evidence on the display.
An operator can, by placing the design inversion switch 60 in the inverting position, reverse the design configuration and background of a unit design being knitted on the machine. He can, for example, change from knitting a black duck on a white background to knitting a white duck on a black background.
With the motifing switch 53 in an off position the unit design is knitted all across the fabric as the carriage is moved on the bed of the machine. However the operator may at any time, by placing the switch in the M+ or M- position, cause the motifing instructions (if any) presecribed in the PROGRAM MODE to be executed as the carriage is moved to knit fabric. With switch 53 placed in the M+ position and switch 60 in its inverting position design inversion is effected during knitting only in wales of the unit design. Design inversion is effected in all wales of the fabric with switch 53 in the M- position and switch 60 in its inverting position.
If selvedge stitches were presecribed on the program card, the number of wales designated for selvedge with no pattern are formed in fabric being knitted. If no selvedge was specified on the card and the operator wishes selvedge he may provide for it with switch 62, or if he wishes to change the number of wales of selvedge previously specified he may do so with this switch. Depression of switch 62 causes the number of wales (0, 1, 2 or 3) of selvedge in effect to appear on the display along with the up and the down arrow, and continued depression of the switch causes the display to slowly cycle through all the possible number of wales of selvedge. The operator selects a desired number of wales merely by moving the switch down until that number appears and then reversing it.
Various indications which may be caused to appear on the display 66 have already been mentioned. In addition the display is capable of indicating to the operator the occurrence of certain errors. If the check digit switch 63 is depressed at any time after a program card has been read either while the machine is in the PROGRAM MODE or in the KNIT MODE the display will show only the last digit of the total number of marks within the rectangles and ellipses which were detected by the reader as the card passed through it. A discrepancy between the number of such marks detected and the number on the card suggests to the operator that the card was misread, that he should make any corrections required, as for example, by erasing smudges or darkening some of the marks, and once again (with the machine in the PROGRAM MODE) feed the card through the reader.
When the operator switches the machine from the PROGRAM MODE to the KNIT MODE the letter E for error appears on the display if the program card was read too fast or moved through the reader in a skewed fashion. If the operator failed to make a needle one selection in the PROGRAM MODE, 1 E appears on the display when the O.P.K. switch is moved to the K position. Assuming the card was read properly, the display is caused to show 2 E when the machine is switch to the KNIT MODE if during the PROGRAM MODE an excessive number of design options for horizontal multiplication, vertical multiplication or for selvedge were prescribed. The actuators 22 and 24 will not operate and the machine can not knit patterns while any one of the error indications E, 1 E, or 2 E is in evidence on the display. Pattern knitting is possible only after the error is corrected by reprogramming.
While the machine is in the KNIT MODE the display is caused to flash if the power supply drops below a predetermined value somewhat greater than that required to operate the needle actuators 22 and 24 pursuant to programmed instructions. If the power drops further to a value no longer sufficient to operate the needle actuators the display shows a 0.
The operator may switch the machine from the KNIT MODE into the PROGRAM MODE at any time and prescribe some or all new instructions for the knitting of fabric. A new card may be fed into the reader, and/or one or more of the switches effective in the PROGRAM MODE may be operated to prescribe new instructions. Feeding a new card through the reader has the effect of prescribing anew all of the kinds of instructions which may be specified on a card. Instructions previously prescribed by the left - right reverse switch 62 or motifing switch 53 are not affected by the reading of a new card. However, if the operator desires he may use these switches as hereinbefore described to change such instructions. If a new card is fed through the reader or the operator changes the left - right multiplication instructions, left - right reverse instructions or left - right mirror imaging instructions, the old needle one selection is voided and needle one must be reselected. To reselect the old needle one, the operator need only move the transverse center line of the carriage across that needle while in the PROGRAM MODE. To select a new needle 1 he must align the transverse center line of the carriage with the needle to be selected and momentarily depress the needle one switch 52.
A simplified system block diagram of the electrical control portion of the subject knitting machine is shown in FIG. 11 wherein the carriage 12, described hereinabove in conjunction with FIG. 3 is shown in block diagram form. The programmed minicomputer 26, which is described hereinbelow in detail, interacts with the carriage 12 by means of an input-output box 34 (hereinafter referred to as the I/O box 34), bus 506, bus 508, bus 510, bus 512 and bus 514.
Signals generated at the carriage 12, such as by manipulation of the various switches, operation of the card reader 30 and/or by movement of the carriage 12 as described supra, are applied to the programmed minicomputer 26 by way of the bus 506, I/O box 34 and bus 508. As is described hereinbelow in detail, one or more of these signals may be modified within the I/O box 34 before being applied to the programmed computer 26. Not all inputs to the minicomputer 26 originate on the carriage. For example, an oscillator (not shown) located within the I/O box 34 provides a real time clock signal for the computer 26 on the bus 510 as will be apparent to those skilled in the art. However, the oscillator can just as well be located in the carriage 12. The signals generated by the computer 26 for controlling the subject knitting machine are applied to the various components of the carriage 12, such as the display 66, card reader 30, actuators 22 and 24 and the like, by way of the bus 512, I/O box 34 and bus 514. As is described hereinbelow in detail, various ones of these signals are acted upon or modified within the I/O box 34.
Before considering the programmed computer 26 in more detail, it will be beneficial to consider the various signals supplied to and provided by the computer 26.
As described supra in conjunction with FIGS. 9 and 10 photo-interrupter modules 94 and 96 provide two carriage position indicating signals in quadrature. Hereinafter the signal provided by module 94 will be referred to as PIP A and the signal provided by module 96 will be referred to as PIP B. As discussed above, these signals go through a complete cycle as the carriage 12 traverses each needle position 20. The programmed computer 26 in conjunction with circuits in the I/O box 34 utilizes these PIPer signals A and B to monitor the carriage 12 position on the needle bed 10 and to time the firing of the actuators 22 and 24 (FIG. 2). For example, as the carriage 12 is moved from left to right PIP A will go low while PIP B is high (FIG. 10). The programmed computer 26 senses these conditions to increment an up down counter or register (not shown) located therein to keep track of the carriage 12 location on the needle bed 10. Conversely, when the carriage is moved from right to left PIP A will go high while PIP B is high as shown by a perusal of FIG. 10. The programmed computer 26 will sense these conditions to decrement the counter or register (not shown) within the computer 26. When the subject knitting apparatus is first turned on, the computer 26 will assign the number zero to the then current carriage position and then increment or decrement this count as the carriage is moved to the right or left to keep track of the location of the carriage 12 on the needle bed 10 at all times. Incrementing or decrementing, i.e., updating of the carriage 12 position counter (not shown) within the computer 26 takes place when PIP A undergoes a transition and PIP B is low. Once the carriage 12 position counter (not shown) has been updated, the programmed computer 26 will determine if an actuator 22 or 24 is to be fired when the carriage 12 is in the current position on the needle bed 10. An actuator 22 or 24 is fired only when PIP B is high and PIP A undergoes a transition from high to low or low to high. To insure proper operation when patterning data is entered and when needle one is designated, it is necessary to adjust the position of the photo-interrupter modules 94 and 96 so that the carriage position counter (not shown) updates occur when the carriage 12 center is over a sinker; i.e., when the carriage 12 center is halfway between needle positions.
As described above, knitting design information is entered into the computer 26 by means of the card reader 30. As described above in conjunction with FIG. 3 strobe channels A and B are located at opposite sides of the program card 28. For purposes of clarity, those strobe channels are illustrated in FIG. 12D as being adjacent a single information row on the program card 28 in order to show their phase relationship and their location with respect to the various columns of information on the program card 28. As shown by FIG. 12D the strobe channels A and B comprise alternating black and white (card background) portions with the first black segment in strobe channel A being of extended length. Like the PIPer signals A and B discussed above, the strobe channels A and B are in quadrature; i.e., ninety degrees out of phase. Additionally, one complete strobe cycle is associated with each of the columns on the program card 28.
When moving from right to left as seen in FIG. 12D, strobe A will go from black to white while strobe B is black. Conversely, when moving from left to right, strobe A will go from white to black while strobe B is black. The programmed computer 26 can sense these changes to determine whether the program card 28 is passing through the card reader 30 or being withdrawn therefrom. In accordance with the present invention, as strobe A goes from black to white while strobe B is black the program card 28 information in the associated information column is read and a column count register (not shown) or a column up-down counter (not shown) within the computer 26 is incremented. Conversely, when strobe A goes from white to black while strobe B is black, the column count is decremented and no column information is read. The program card 28 information read time occurs during the white portion of strobe A. As illustrated in FIG. 12D, strobe A goes white over the far right hand portion of column one and extends well over the left portion of column 2. Because the strobe A and B sensing devices are located to the right of the card information sensing devices, as is described below in conjunction with FIG. 12A, the information sensing devices will be located in the left portion of column 1 when strobe A first goes from black to white and will be located in the right portion of column 1 when strobe A subsequently goes from white to black. The same is true of the remaining columns of the program card.
The electrical portion of the card reader 30 is illustrated in FIG. 12A as including 21 design information reading stations 534 - 574 corresponding to the 21 rows on the program card 28. As will be apparent, more or less than the twenty-one design information reading stations 534 - 574 can be utilized depending upon the layout of the program card 28. Located above and offset to the right of the design information reading stations 534 - 574 is a strobe B reading station 530, while located below the information reading stations and offset to the right is a strobe A reading station 532. The 23 illustrated reading stations 530 - 574 are activated by means of five light emitting diodes 520, 522, 524, 526 and 528 and five phototransistors 582, 584, 586, 588 and 590 which are interconnected by means of a plurality of light pipes to form a matrix.
Any one of the light emitting diodes (LED's) 520, 522, 524, 526 and 528 can be enabled by means of a signal supplied by the computer 26 appearing on leads 520.6, 522.6, 524.6, 526.6 or 528.6, respectively. Each of the first four of the light emitting diodes 520, 522, 524 and 526 are coupled to five consecutive reading stations by means of light pipes. For example, light emitting diode 520 is coupled to the first five reading stations 530 (strobe B), 534, 536, 538 and 540 by means of the light pipes 520.1, 520.2, 520.3, 520.4 and 520.5. The next light emitting diode 522 is coupled to the next five reading stations 542, 544 546, 548 and 550 by means of the light pipes 522.1, 522.2, 522.3, 522.4 and 522.5, respectively. The next two light emitting diodes 524 and 526 are connected to five consecutive reading stations in a like manner. Since a total of twenty-three reading stations are utilized, only three reading stations 572, 574 and 532 (strobe A) are associated with the fifth light emitting diode 528.
Any one of the phototransistors 582, 584, 586, 588 and 590 can be enabled by means of a signal supplied by the computer 26 appearing on leads 582.6, 584.6, 586.6, 588.6, or 590.6, respectively. The output signal from each phototransistor 582, 584, 586, 588 and 590 appearing on leads 582.7, 584.7, 586.7, 588.7, and 590.7 respectively, is connected to a common output lead 580, amplified by an amplifier 592 and applied to a comparator 596 (FIG. 13) by way of lead 594. Each of the phototransistors is coupled to a corresponding one of the five reading stations associated with each of the first four light emitting diodes 520, 522, 524 and 526 by means of a plurality of light pipes. For example, the first phototransistor 582 is coupled to the first reading station 530 (strobe B) associated with the light emitting diode 520, the first reading station 542 associated with the light emitting diode 522, the first reading station 552 associated with the light emitting diode 524, the first reading station 562 associated with the light emitting diode 526 and the first reading station 572 associated with the light emitting diode 528 by means of the light pipes 582.1, 582.2, 582.3, 582.4, and 582.5 respectively. In a like manner the second phototransistor 584 is coupled to the second reading station 534, 544, 554, 564, and 574 of each of the light emitting diodes 520, 522, 524, 526, and 528 respectively; with the third phototransistor 586 being coupled to the third reading station 536, 546, 556, 566 and 532 (strobe B) associated with each light emitting diode; the fourth phototransistor 588 being coupled to the fourth reading station 538, 548, 558 and 568 of the first four light emitting diodes and the fifth phototransistor 590 being coupled to the fifth reading station 540, 550, 560, 570 associated with the first four light emitting diodes. Since light emitting diode 528 has only three reading stations associated therewith, phototransistors 588 and 590 are not coupled thereto. For purposes of clarity in the drawing, the coupling of the light pipes to the appropriate reading stations for the second, third and fourth phototransistors 584, 586 and 588 is not illustrated.
As will now be apparent, enabling one of the phototransistors 582, 584, 586, 588 or 590 and enabling one of the light emitting diodes 520, 522, 524, 526 and 528 will result in only one of the reading stations 530 - 574 being read out. For example, enabling phototransistor 590 and light emitting diode 522 will cause a read out from reading station 550 while enabling phototransistor 590 and light emitting diode 526 will cause a read out from reading station 570. In accordance with the present invention, the strobe channels B and A on the program card will be sequentially sampled under control of the computer 26 by sequentially enabling phototransistor 582 -- light emitting diode 520 and phototransistor 586 -- light emitting diode 528. When design information is read out, the information reading stations 534 - 574 will be enabled in sequence under control of the computer 26 during the time that strobe A is white. As will now be apparent, operation of the reader causes a serial data train to appear on the output lead 594.
Before describing the computer 26 controlled card reader 30 in more detail, the digital adapter shown in FIG. 13 will be considered. The adapter includes a comparator 596 the output of which is coupled to the computer 26 by way of a lead 612. One input to the comparator 596 appears on the lead 598 as the output of a non-linear digital to analog conversion unit 600. The other input to the comparator 596 is the serial output from the phototransistors 582, 584, 586, 588 and 590 of FIG. 12A appearing on lead 594. The input to the digital to analog conversion unit 600 is a five bit binary number supplied by the computer 26 on leads 602, 604, 606, 608 and 610. In one embodiment of the present invention the digital to analog conversion unit 600 used a first digital to analog converter 603, the output of which was fed to the multiplying or scaling input 609 of a second analog converter 605 to produce a quadratic output input dependence. Furthermore, the original linear output of the first converter 603, the quadratic output of the second converter 605, and a constant voltage 611 were then summed in a suitable device 607 to give a parabolic approximation to the desired exponential dependence of the analog output to the digital input. In accordance with one embodiment of the present invention which was constructed, the digital to analog converters 603 and 605 were Motorola MC 1408 digital to analog converters.
The operation of the comparator 596 is such that a voltage level on lead 594 which is greater than that appearing on lead 598 causes the output on lead 612 to be low. However, as the voltage level appearing on lead 598 increases, such as by increasing the value of the binary number applied to the digital to analog conversion unit 600, the output on output lead 612 will go high when the voltage level on the lead 598 exceeds that appearing on lead 594. When this occurs, the computer 26 will store the current binary number. Any potential level thereafter appearing on lead 594 can be compared to this digitized value by applying this stored binary number produced by the previous level to the digital to analog conversion unit 600 and monitoring the output level on lead 612 which will indicate whether the current voltage level on lead 594 is greater or less than the previous level. The function of the digital adapter shown in FIG. 13 will become apparent from the description of the program card reader hereinbelow.
As is known to those skilled in the art, the input-output function of a digital to analog converter is linear. In one embodiment of the present invention, as described above, the input-output function was caused to be parabolic as a simple approximation to a preferable exponential function.
Briefly described, the opposite strobe channels A and B of the program card 28 are utilized by the card reader 30, under control of the computer 26, to determine the position of the program card within the card reader. Initially, however, when the program card is first entered into the card reader 30, two of the information channel reading stations are used to detect the presence of the program card edge. Two spaced apart reading stations are utilized to insure that the program card is properly located within the card reader before the card is adapted. Once the card edge is sensed, the computer 26, by means of the digital adapter of FIG. 13, will measure and record the signal level at the strobe A reading station 532, which is over the white border of the program card due to the strobe A reading station 532 being located to the right of the information reading stations 534 - 574 (FIG. 12A), i.e., located closer to the card entry location of the card reader than the information reading stations. The program card is printed such that when the extended length black portion (FIG. 12D) of strobe channel A is detected, the information channel reading stations 534 - 574 and strobe channel B reading station 530 are located over the white border of the program card (FIG. 3). The computer 26 by means of the digital adapter of FIG. 13, will measure and record the signal level for each information channel 534 - 574 and strobe B at the white border of the program card. Before being stored, each digital value is appropriately decreased to prevent smudges and erasures from being read as black marks. As the program card advances into the card reader 30, the computer 26 keeps track of the number of columns on the program card passing the information reading stations 534 - 574. Each time strobe A changes from black to white (FIG. 12D) the column count is incremented by the computer 26 and the information in each information row is read out in sequence and applied to the digital adapter of FIG. 13. If the reading from an information channel is sufficiently lower than the border reading previously recorded, the reading is recorded within the computer 26 as black; if not, it is recorded as white. Light smudges are thus read as white. The program card 28 is considered to have been read without error if all columns of information are read and stored in the computer 26 before the program card 28 is withdrawn from the card reader.
More specifically, when the subject knitting apparatus is placed into the PROGRAM MODE, a computer 26 selected reading station 574 (FIG. 12A) corresponding to row zero on the program card is enabled to read the "black" platen of the card reader 30. The platen is fabricated with depressions and/or coated to minimize the signals produced. The computer 26 will vary the binary number applied to the digital to analog conversion unit 600 (FIG. 13) until the voltage level on lead 598 to the comparator 596 equals that appearing on lead 594 supplied by information reading station 574. To insure that false background noise does not provide an erroneous indication, this binary number is increased by 2. For example, if a binary number of 20 is equivalent to the voltage level appearing on lead 594, the binary 20 is increased to binary 22 by the computer 26 to decrease the threshold sensitivity and binary twenty-two is stored within the computer 26. This process is repeated at information reading station 534 corresponding to row 20 on the program card 28. The computer 26 will then maintain reading station 574 enabled and the input to the digital to analog conversion unit 600 at the digitized value, i.e. a binary 22. Referring now to FIG. 12A, a program card 28 placed into the card reader will approach the reading stations 530-574 moving from right to left. When the edge of the card reaches the reading station 574 corresponding to information row zero on the program card, the voltage level appearing on lead 594 to the comparator will greatly increase, due to the white background of the program card 28, thereby changing the output level appearing on the lead 612 to the computer 26. This level change is recognized by the computer 26 as the program card 28 edge at the information reading station 574. The computer 26 then enables reading station 534 and applies its adapted digitized number to the digital to analog conversion unit 600. Detection of the edge of the program card 28 at reading station 534 is interpreted by the computer 26 as meaning that the program card 28 is properly located within the card reader 30 and the next step in reading of the program card can commence.
Since the strobe A and B reading stations 532 and 530, respectively, are offset to the right, as shown in FIG. 12A, they are now well over the white border portion of the program card. The computer 26 will now enable the strobe A reading station 532 by enabling light emitting diode 528 and phototransistor 586. The white background of the program card 28 adjacent to strobe A produces a corresponding voltage level on lead 594. The digital equivalent of this analog voltage level is determined as described above. The resulting digital number is decreased by two to make it slightly more difficult to see black; i.e., decreasing the threshold sensitivity of strobe channel A. The resulting binary number is stored in the computer 26. Strobe channel A has now been adapted. When monitoring strobe channel A, the stored binary number is recalled and applied to the comparator 596 lead 598 after conversion by the digital to analog conversion unit 600. A voltage level on lead 594 to the comparator 596 from strobe A reading station 532 produces a level output on lead 612 recognized by the computer 26 as "white" if the voltage level on lead 594 is greater than the level appearing on lead 598 and is recognized by the computer 26 as "black" if it is less due to the resulting different level output on lead 612 (FIG. 13). The Strobe A reading station 532 remains active under control of the computer 26 until strobe A becomes black and this is sensed as described above. This corresponds to the left portion of the extended length black portion of strobe A (FIG. 12D) appearing at the reading station 532. At this time the computer 26 will check reading station 574 corresponding to row zero of the program card. If the reading is black, the program card 28 has been pulled out of the card reader 30 and the whole process will begin again. However, if the reading is white, the card is moving into the card reader and all the remaining reading stations 532 - 574 are well over the white border portion of the program card. The computer 26 will now sequentially adapt each information row on the program card, and strobe channel B in a manner as described above. Once this has been completed, the computer 26 will have stored therein the threshold adjusted adapted binary numbers for each strobe and information channel on the program card 28 which were obtained as discussed above. As described, these stored numbers are recalled by the computer 26 and applied to the adapter apparatus shown in FIG. 13 to read a particular row information as black or white.
The computer 26 will now monitor strobe channels A and B by sequentially enabling strobe reading stations 532 and 530 and determining whether they are black or white. When strobe A goes white (see FIG. 12D) the computer 26 will check if strobe B is also white. If it is, the computer 502 will recognize that the program card 28 is being pulled out of the card reader 30. If strobe B is black, however, the program card 28 is continuing through the card reader 30 and the computer 26 will increment the column count therein by one and begin to read the rows of information contained in the first column. This is done by the computer sequentially enabling the information reading stations 534 - 574 by enabling the appropriate light emitting diodes 520 - 528 and phototransistors 582 - 590. The stored adapted binary number for each channel is sequentially recalled to the ditital to analog conversion unit 600 and compared with the voltage level on lead 594 to determine whether the information is white or black. The data from each row in each column is stored in a memory (not shown) contained within the computer 26. The location of each row being read in the column is controlled by the computer 26 maintaining a row count therein.
After all the rows in the first column have been read and stored in the computer 26, the computer 26 will check strobe A; if it is white the column read is considered valid. If column A is black, however, the card 28 may have been traveling too fast through the card reader 30 (see FIG. 12D) and a flag is set by the computer 26 to abort the column read. This results in an error indication appearing on the display 66 at the conclusion of the card read operation as described above when appropriate switches are depressed. If the column read is successful, the computer 26 will continue to monitor strobe channels A and B. When strobe A goes white while strobe B is black, the column count will be incremented and the rows of information read and stored as described above. This process will continue until all of the columns of the program card 28 have been read. This will be recognized by the computer 26 by the column count therein being equal to the number of columns on the program card 28. During the reading of the last column on the program card 28, the computer 26 will check for any ambiguities that may be present in the design options selected. For example, only one of the horizontal magnification options can be selected at one time. Additionally, should an operator attempt to place the subject knitting apparatus into the knitting mode while a program card is being read, the computer 26 will recognize this error and cause an error indication to appear on the display 66 as well as turning off the left and right actuators 22 and 24.
A typical circuit for the light emitting diodes 520, 522, 524, 526 and 528 of FIG. 12A is shown in FIG. 12C wherein light emitting diode 526 is illustrated as being coupled between ground potential and the collector of a PNP transistor T1. Transistor T1 has its emitter coupled to a positive source of potential and its base coupled to the computer 26 controlled input lead 526.6 by means of a diode D1. In the absence of a negative potential on lead 526.6 from the computer 26, transistor T1 is nonconducting and light emitting diode 526 is disabled. The presence of a negative potential on lead 526.6 from the computer 26, however, causes transistor T1 to conduct which in turn enables the light emitting diode 526.
A typical circuit for the photo transistors 582, 584, 586, 588 and 590 of FIG. 12A is shown in FIG. 12B wherein phototransistor 586 is illustrated as having its collector coupled to a source of positive potential and its emitter coupled to ground potential by way of the collector-emitter of NPN transistor T3. The output of phototransistor 586 is coupled to the output lead 586.7 by means of a diode D2. The base of transistor T3 is coupled to ground by means of a resistor R1 and to the collector of a PNP transistor T2 which has its emitter coupled to a source of positive potential by way of a resistor R2 and its base coupled to the computer 26 controlled input lead 586.6 by way of a diode D3. In the presence of a negative potential on lead 586.6 from the computer 26, transistor T2 is conducting, which causes transistor T3 to be conducting, thereby back biasing diode D2 and passing any output from phototransistor 586 to ground. Accordingly, no signal will appear on output lead 586.7. In the absence of a negative potential on input lead 586.6 from the computer 26, however, transistor T2 will not conduct thereby rendering transistor T3 nonconducting such that diode D2 is no longer back biased and any output from the phototransistor 586 now appears on output lead 586.7 by way of the diode D2.
As described hereinabove, the location of each edge of a garment in the subject knitting apparatus is detected by means of butt detectors 118 and 120 (FIGS. 2,5,6, and 7). Electric circuitry located in the I/O box 34 and associated with the butt detector 120 is illustrated in FIG. 14A as including a first flip-flop FF1 which is coupled to the butt switch contacts by means of a lead 624. The input of a second flip-flop FF2 is coupled to the output of the first flip-flop FF1 by way of a lead 622 and the output of the second flip-flop FF2 is coupled to the programmed computer 26 by way of a lead 626. A clock signal is applied to each of the flip-flops FF1 and FF2 by means of a lead 620. Each of the flip-flops FF1 and FF2 may be a well known D type flip-flop. The clock signal on lead 620 is illustrated in FIG. 14B as the waveshape 628 and is obtained by AND gating the PIP B signal and an inverted PIP A signal when going from left to right. The time occurence of signals resulting from actuation of the butt switch 120 is illustrated in FIG. 14B by the vertical dashed lines 630. As shown the clock signal becomes high sometime after the but switch 120 actuation position is passed and will become low before a needle 20 can again contact the butt switch 120 at the next position.
Referring now to FIGS. 14A and 14B and assuming that the carriage 12 is moving from left to right, prior to detecting the edge of a garment in the knitting apparatus no signals appear on lead 624 so that both flip-flops FF1 and FF2 are reset by the first positive occurring clock signal 628. The resulting low output on lead 626 from the second flip-flop FF2 is recognized by the computer 26 as indicating that the edge of the garment has not yet been reached. When the edge of the garment is reached, a needle 20 butt will actuate the butt switch 120 causing a signal to appear on lead 624 that sets flip-flop FF1. The next positive occurring clock signal 628 will reset flip-flop FF1 which results in flip-flop FF2 being set thereby changing the output level on lead 626 from low to high. The computer 26 recognizes this level change as the edge of the garment being reached. A needle 20 in the next position will again cause the flip-flop FF1 to be set. The next positive clock signal 628 will again reset flip-flop FF1 and keep flip-flop FF2 set. The occurrence of a vacant needle position will result in flip-flop FF1 being reset when the next positive clock signal occurs which results in flip-flop FF2 being reset thereby changing the level on output lead 626 from high to low. The computer 26, however, will recognize the other edge of the garment as having been reached only upon three consecutive vacant needle positions being passed.
The circuitry for the other butt switch 118 for carriage travel from right to left is identical to that shown in FIGS. 14A and 14B with the exception that the reset signal is obtained by AND gating the PIP A and PIP B signals.
In order to give an indication to the computer 26 that electrical power is low or that electrical power is about to fail so that the computer 26 can take the necessary shut down steps or procedure, voltage level detecting circuits are located within the I/O box 34. One such circuit is illustrated in FIG. 18 as including a comparator 634 the output of which is coupled to the computer 26 by way of a lead 636. One input to the comparator on lead 642 is provided by a voltage reference 638, which may comprise a battery. The other input to the comparator 634 on lead 640 comprises an operating D.C. voltage the level of which is to be monitored by the comparator 634. As long as the potential on lead 640 is greater than the reference source 638, the potential on the output lead 636 is high which the computer 26 interprets as meaning that the operating potential on lead 640 is satisfactory. If the potential on lead 640 falls below that of the reference 638, output lead 636 goes low which is interpreted by the computer 26 as meaning that the monitored operating potential is unsatisfactory. For example, in one circuit the reference 638 magnitude is such that a lesser magnitude on lead 640 is interpreted by the computer 26 as meaning the monitored voltage level is low; in another circuit, however, the reference magnitude is even less such that a lesser magnitude on lead 640 is interpreted by the computer 26 as meaning that the monitored voltage source is about to fail. As will now be apparent, a separate comparator circuit is utilized for each operating voltage that is to be monitored, and the magnitude of the reference source 638 with respect to the desired magnitude of the monitored source is such as to indicate a low voltage condition or an impending power failure condition.
In accordance with one embodiment of the present invention which was constructed, the display 66 described hereinabove utilized liquid crystal elements. When a particular character or segment is to be displayed, the computer 26 will provide an enabling D.C. potential on an appropriate lead to the selected character or segment. As is apparent to those skilled in the art, a D.C. operating potential will ruin a liquid crystal display device in a relatively short time. In order to overcome this shortcoming, each liquid crystal display enabling signal provided by the computer 26 is converted into an AC signal. This is accomplished by the Exclusive OR circuit shown in FIG. 15A. There is an equivalent Exclusive OR circuit for each segment or character of the display and the circuits are located in the I/O box 34. One input to the Exclusive OR gate 646 appearing on input lead 652 is the liquid crystal enable signal supplied by the computer 26. This signal is shown in FIG. 15C by waveshape 654. The other input to the Exclusive OR gate 646 on lead 650 is the oscillator (not shown) signal supplied to the computer 26 as a real time clock. This signal is shown in FIG. 15C by waveshape 656 and is also supplied to one side of each liquid crystal character, or segment. This is shown in FIG. 15B wherein the oscillator signal 656 is applied to one side of a liquid crystal device 662 by way of lead 660. The output of the Exclusive OR gate 646 appears on lead 648 and is applied to the other side of the selected character or segment of the display 66 as shown in FIG. 15B. The output of the Exclusive OR gate 646 is shown as waveshape 658 in FIG. 15C. Referring now to FIGS. 15A, 15C and 15B, when the output 654 on lead 652 from the computer 26 is low, the oscillator signal 656 provides the only high input to the Exclusive OR gate 646. The output signal 658 on lead 648 for this condition is identical to the input signal 656 on lead 650 so that the signals on each input lead 660 and 648 to the liquid crystal device 662 are the same and the liquid crystal 662 is not turned on. When the computer 26 supplied signal 654 goes high, however, the Exclusive OR gate output 658 will go high only when the oscillator signal 656 is low. Accordingly, for this condition, the output signal 658 is 180° out of phase with the oscillator signal 656 such that an AC signal now appears across the liquid crystal device 662 for the duration of time that signal 654 is high thereby turning the liquid crystal device on for this time period.
When appropriate, the computer 26 will supply an arm signal for the actuator 22 or 24. Such an arm signal is illustrated as waveshape 666 in FIG. 16B. This signal 666 normally has a time duration equal to the time the carriage takes to traverse a needle position shown as time t0 through t4 FIG. 16B. In accordance with the present invention, however, the signal applied to the actuator 22 or 24 has a duty cycle of about 75 percent and will turn off if the carriage 12 is left in the same needle position greater than a predetermined time, such as 10 seconds, to prevent damage to the actuators. The circuit for accomplishing this for the right actuator 24 is shown in FIG. 16A as including an OR gate 678, three AND gates 690, 692 and 694 and two retrigerable one shot multivibrators 682 and 684 and is located in the I/O box 34. The output from the OR gate 678 is applied to the right actuator 24 by way of lead 680 and is illustrated in FIG. 16B as waveshape 676. The inputs to the OR gate 678 comprise the outputs of the three AND gates 690, 692 and 694. Each of the AND gates has four inputs. One input applied to each AND gate 690, 692 and 694 is the arm signal 666 supplied by the computer 26. Another input applied to each of the AND gates is the output of the second one shot 684 which is illustrated in FIG. 16B as waveshape 674. The input to the second one shot 684 is the output form the first one shot 682 which is illustrated in FIG. 16B as waveshape 672. PIP A signal, shown in FIG. 16B as waveshape 668, is applied to the input of the first one shot 682 and to the AND gate 690. The PIP A signal after being inverted by the inverter 698 is applied to AND gates 692 and 694. The PIP B signal, shown in FIG. 16B as waveshape 670, is applied to AND gate 694 and after inversion by the inverter 696 to AND gates 692 and 690.
Referring now to FIGS. 16A and 16B, the operation of the circuit of FIG. 16A is such that at time t0, the arm signal 666 occurs as PIP A 668 goes low, causing the output 672 of the first one shot 682 to go high for a short period of time. This in turn causes the output 674 of the second one shot 684 to go high. Since the second one shot 684 has a time out period of about 10 seconds, the output 674 of the second one shot 684 remains high. During the time period t0 to t1, PIP A 668 is low and PIP B 670 is high which results in only AND gate 694 being enabled for this time period and producing an input to the OR gate 678. During the time period t1 to t2, PIP A 668 remains low and PIP B 670 is also low, which results in only AND gate 692 being enabled for this time period and producing an input to the OR gate 678. During the time period t2 to t3, PIP A 668 is high and PIP B 670 is low, which results in only AND gate 690 being enabled for this time period and producing an input to the OR gate 678. During time period t3 to t4 both PIP A 668 and PIP B 670 are high. However, this will not enable any of the AND gates 690, 692 or 694. Accordingly, there is no input to the OR gate during this time period. As will now be apparent, the signal to the right actuator 24 will be present on lead 680 from the OR gate 678 only during the time period t0 through t3 or for three fourths of a needle position. The analysis set forth above assumes that the carriage 12 did not remain in the needle position for more than 10 seconds. If this were the case, the second one shot 684 would have timed out causing its output 674 on lead 686 to become low, thereby disabling each of the AND gates 690, 692 and 694 which in turn would prevent any output 676 from the OR gate 678 to the right actuator 24.
A circuit virtually identical to that shown in FIG. 16A is provided for the left actuator 22 and is also located within the I/O box 34. The left actuator circuit, however, replaces AND gate 694 which is enabled by PIP A 668 being low and PIP B 670 being high by an AND gate (not shown) which is enabled by PIP A being high and PIP B being high corresponding to time period t3 to t4. A person skilled in the art can readily arrange such a circuit in view of the description of the right actuator circuit described above.
The programmed computer 26 and the signal connections thereto are clearly illustrated in FIG. 17A. In accordance with the present invention, the computer 26 utilized was Texas Instruments Inc. Model 960A (Part # 226881-2) modified by having the following Texas Instruments Inc. Printed circuit boards added thereto: Internal CRU Expander (Texas Instruments Inc. Part # 226722-1), Data Input Module (Texas Instruments Inc. part # 217382-1) and data Output Module (Texas Instruments Inc. part No. 217380-1). The inputs to the computer 26 are shown on the left side of FIG. 17A while the outputs from the computer 26 are shown on the right side. The input and output pin numbers of the computer 26 are shown on the outside of the rectangle which represents the computer 26 while the communications registers which these pin numbers address are shown within the rectangle and adjacent their corresponding pin numbers. For example, input pin number 19 is coupled to communications register E10 while output pin number 19 is coupled to communications register E20.
As shown in FIG. 17A, the output of the 80 Hertz clock oscillator (not shown) within the I/O box 34 is applied to input pin 18. The circuit, such as that described in conjunction with FIG. 18, that will provide an indication that a monitored voltage level is low is coupled to input pin 17 while a similar circuit that provides an indication that a monitored voltage source is about to fail is coupled to input pin 16. The output from the card reader 30 appearing on the output lead 612 of the comparator 596 (FIG. 13) is coupled to input lead 15. The various operating switches associated with the knitting apparatus are coupled to input leads 3 through 14, 19 and 23 as shown. With the exception of the left 22 and right 24 butt switches, these operating switches are directly coupled to the input pins by way of the I/O box 34. The output from the butt switches 118 and 120 as described above, however, are applied to a butt detection circuit, such as that shown in FIGS. 14A and 14B, with the output from such a circuit for each butt switch 118 and 120 being coupled to input pins fourteen and thirteen. Although the OPK switch 50 described above has three positions, it comprises only two switch contacts 706 and 708 which are coupled to input pins 3 and 19 respectively. A truth table shown in FIG. 17B shows that when both switches 706 and 708 are closed, the knitting apparatus is off. When switch 706 is closed and switch 708 is open, the knitting apparatus is in the PROGRAM MODE and when both switches 706 and 708 are open the knitting apparatus is in the KNIT MODE. When closed, the switches 706 and 708 will provide ground potential on their input pins three and nineteen, respectively; while when open a five volt positive potential will appear on their associated input pins. This potential is generated by a "pull up" circuit (not shown) associated with each pin and located within the computer 26. The PIP A signal is coupled to input pin 20 and the PIP B signal is coupled to the input pin 21. Naturally, the computer 26 is also coupled to system ground through pins C-Z.
Referring now to the output signals of the computer 26, the left and right actuator arm signals are provided on output pins twenty four and twenty three, respectively. As discussed above, these signals are not applied directly to left and right actuators 22 and 24, respectively, but are first coupled to a circuit, such as that shown in FIGS. 16A and 16B. Output pin numbers nine through twenty two provide the various output signals needed to drive the display 66. The signals for actuating the four rectangles on the display appear on output pins 20, 21 and 22. The signal for actuating the up arrow on the display 66 appears on output pin 19 while the signal for actuating the down arrow appears on output pin 18. The number 2 on the display 66 is actuated by a signal on output pin 17 while the number "one" on the display 66 is actuated by a signal on the output pin 16. The various segments of the seven segment portion of the display 66 are actuated by signals appearing on output pins 9, 10, 11, 12, 13, 14 and 15 respectively. As discussed above, these signals are not directly coupled to the display devices. Rather, each signal output is coupled to a circuit such as that shown in FIGS. 15A, 15C and 15B to convert the DC signal from the computer 26 into an AC signal. The 5 bit binary number supplied to the digital to analog converter 600 of FIG. 13 from the computer 26 appears on output pins 13, 14, 15, 16 and 17. The computer 26 supplied signals for enabling a selected one of the five light emitting diodes 520, 522, 524, 526 and 528 of the card reader 30 (FIG. 12A) appear on output pins 8, 9, 10, 11, and 12 while the computer 26 supplied signals for enabling a selected one of the five photo transistors 582, 584, 586, 588 and 590 appear on output pins 3, 4, 5, 6 and 7. As will now be apparent, output pins 9 through 17 are time shared by the display 66 and the card reader.
As will now be apparent, the objects, features and advantages of the present invention are obtained by the combination of the mechanical knitting apparatus described, the programmed computer 26 and the electrical interface coupled between the programmed computer 26 and the mechanical knitting apparatus. Attached hereto as an appendix is the detailed program listing used in the computer 26 to implement the present invention. As listed, the left most column shows program card numbers, the next column lists addresses located within the computer 26 followed in the next column by the contents of the addresses listed. Following columns list the operator neumonic followed by the operand neumonic. For a detailed explanation of the items of the program listing appended hereto, together with a system description of the internal organization of the computer 26, the programming system used, machine instructions and the like, reference is made to "Model 960 A Computer Programmer's Reference Manual" revised June 1, 1973, Manual No. 958360-9701 by Texas Instruments, Inc. the contents of which are incorporated herein by reference.
As an aid in understanding the appended program listing, FIGS. 19 through 49 relate to a detailed flow chart of the appended program listing. As shown by FIG. 19, the appended program listing includes three sub programs; i.e., Initialization, PROGRAM MODE and KNIT MODE; and at least eight sub-routines that are used in one or more of the three sub programs. The eight sub-routines include Program Pip Check, Knit Pip Check, Row Advance Forward, Row Advance Reverse, Read, Column Increment, Column Decrement and Adapt. As an aid in understanding and interpreting the various flow charts, FIGS. 48 and 49 contain a glossary of terms used in the flow charts.
It is to be well understood that the program flow charts shown in FIGS. 20 through 47, and much of the operational description contained hereinabove in conjunction with FIGS. 1 through 18, has been culled from the program as defined by the appended detailed program listing. Any deviation in the drawings or description contained herein from the system defined by the appended detailed program listing is inadvertent. Any such deviation or ambiguity is to be resolved by reference to the appended detailed program listing which is controlling as regards the operation of the knitting apparatus of this invention.
the Initialization sub program shown in the top left portion of FIG. 20 clears the various components of the system when the system is first turned on. For example, this sub program is used to initialize the computer 26 registers, reset the input-output lines, clear all flags, counters and the like.
As previously noted herein, in the Program Mode sub program (FIGS. 20 through 25), a program card 28 can be read, the needle one position selected, a motifing sequence entered by the motifing switch 53 and reversal of the design to be knitted from that shown on the program card. The first two operations are mandatory in that knitting will not occur unless they are accomplished, whereas the latter two operations are optional. Briefly described, the Program Mode subroutine begins by setting ClPOS to 200 to prevent a needle one position from being achieved by default after which the two channels (zero and 20) of the card reader 30 used to detect the edge of the program card 28 are adapted to the black background of the card reader 30 platen as described above. If auto design is selected, a preprogrammed design is automatically transferred to the active design memory region of the computer 26 after which checksum is operated and the various design options are decoded and checks made for knit design ambiguities (FIG. 3). If auto design is not selected, various carriage switch positions interrogated to determine whether there have been any changes from their initial positions. The detecting of the program card 28 and reading in of the design information therefrom will then occur as described hereinabove.
An integral part of the Program Mode sub program is the Program Pip Check (FIGS. 32 through 37) subroutine. While in the Program Mode sub program all service requirements present are carried out. However, throughout the Program Mode sub program, whenever conditions permit, a complete Program Pip Check sub routine will be carried out the general purpose of which is to monitor the various carriage 12 switch positions and the position of the carriage 12 on the needle bed 10, even while a program card is being read. The Program Pip Check sub routine will determine whether the carriage 12 position on the needle bed has changed, increase or decrease the absolute position count of the carriage 12 on the needle bed, check the current status of the motifing switches 53, the left-right reverse switch 62, the previous needle one position and whether a new needle one position is being selected. The current status of the OPK switch 50 and the row advance and row descent switches 56 and 58 are checked and the appropriate display enabled re design multiplication factor. The check digit switch 63 is monitored and the display 66 enabled, if necessary, and the status of the program card read in is checked.
Also an integral part of the Program Mode sub program is the Read sub routine (FIG. 43) wherein the data from each block of information on the program card is read and stored. Also an integral part of the Program Mode sub program is the Adapt sub routine (FIGS. 46 and 47) wherein the binary numbers are applied to the digital adapter of FIG. 13, to digitize the voltage levels from the card reader 30 information row reading stations as described above. In the main PROGRAM MODE a number is added or subtracted from the digitized number to compensate for background noise and the like. The strobe channels A and B are similarly digitally adapted.
In the Knit Mode sub programs (FIGS. 26 through 31), the design is knitted by controlling the actuators 22 and 24, the display 66 is operated and the various switches on the knitting apparatus are checked. Briefly described, the Knit Mode sub program first checks for errors. For example, if the program card 28 has not been read properly, the E on the display 66 will be illuminated, if conflicting design options have been selected 2E will be illuminated and if needle one has not been selected 1E will be illuminated. If there are no errors the machine will prepare to knit by noting the carriage 12 position on the needle bed 10, configure the display 66 to show the present status and begin to look for the garment edge. The location of the actuators 22 and 24 with respect to the center of the carriage 12 is determined, salvage is calculated, checks are made for jams, the knit algorithums are computed and the actuator 22 or 24 fired, and the salvage zone is checked upon leaving the garment. After leaving the garment, the row advance 56 and row descent 58 switches are checked and the row display 66 is increased or decreased.
Where possible throughout the Knit Mode sub program, a complete Knit Pip check sub routine (FIGS. 38 through 40) is carried out. Briefly described, this sub routine checks the present status of the OPK switch 50, the PIP A and PIP B signals to determine the location of the carriage 12 on the needle bed 10 and correspondingly increases or decreases the position count. The power low or power fail voltage indicating levels are checked and the display operated, if appropriate. The left right reverse switch 62 re selvedge is monitored and the selvedge count is displayed. The check digit is displayed if the check digit switch 63 is depressed and 1C on the display 66 is illuminated if the carriage is at the needle one position.
Before beginning a new knitting sequence when the new needle position is located to the right or to the left of the old needle position, it must be determined which column of program card 28 information is to be used. Factors which influence the result include the various design options such as multiplication factor, mirroring, inverse and the like. The correct column is determined by the Column Increment, and Column Decrement sub routines shown in FIGS. 44 and 45.
In a like manner, which row of program card 28 information is to be used for the next knitting sequence must also be determined. This is accomplished by the Row Advance Forward sub routine (FIG. 41) when a course is completed and the carriage reverses or when row advance is manually selected, and by Row Advance Reverse subroutine when row reverse is manually selected.
Although the invention has been described in its presently preferred form, it is to be understood that the present disclosure is by way of example only and that numerous changes in construction and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. In particular it should be noted that the Texas Instrument computer 26 shown and described herein is but one example of various general purpose computers that might be used for control purposes in the machine of the invention. It should also be noted that electronic control means in a form different from that of the computer 26 may be utilized to perform the control functions of the computer. If desired, one or more silicon chips adapted to perform all of the control functions of both the computer 26 and the I/O box 34 may be utilized in the machine. | A home knitting machine is provided with electronic control means which function pursuant to patterning instructions on a program card and in response to the operation of control devices by an operator causing needle actuators on the carriage of the machine to be selectively operated and fabric knitted in a prescribed manner on the machine.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to automatic knitting machinery and has particular application to home knitting machines which can be programmed to produce prescribed patterns on a fabric.
2. Description of the Prior Art
Automated home knitting machines are now well known and are exemplified by the machines of the following Patents and applications:
U.s. pat. No. 3,885,405 -- issued May 27, 1975
French Pat. No. 2,212,830 -- Reg. July 23, 1972
Japanese Application No. 85853, laid open Nov. 13, 1973
Although such machines can be programmed to produce various patterns in knitted fabric, there are a variety of desirable control functions pertaining to the formation of patterned fabric which the existing machines can not be programmed to perform automatically. Furthermore, existing machines do not permit the operator to exercise a large measure of control over the knitting of the fabric after the initial programming.
SUMMARY OF THE INVENTION
In order to remedy the deficiencies of the prior art machines, electronic control means are provided in a home knitting machine enabling the machine to perform automatically a variety of control functions which an operator may prescribe by suitably marking a program card to be read by the machine and/or by operating various control instrumentalities, preferably located on the carriage of the machine, and enabling the operator after the machine has been programmed to exercise easily close control over the knitting of fabric on the machine.
More particularly, the machine of the invention is rendered capable of reading and executing instructions which an operator may prescribe by marking the card, including instructions defining a design configuration for fabric to be knit on the machine, size delineating instructions for a unit design area to be formed repetitively in the fabric, instructions specifying that each unit design area be expanded an integral number of times, either horizontally or vertically or in both directions in the fabric, instructions directing that in conjunction with the unit design areas, mirror images thereof also be formed in courses or wales or in both courses and wales of the fabric, and an instruction directing a particular number of wales to be knit as selvedge without the design configuration at opposite side edges of the fabric. The machine is also provided with switches which offer an operator an alternative to the use of certain instructions on the program card. With such switches he can cause the machine to expand the unit design areas, produce mirror images, knit a selected number of wales of selvedge, invert the design configuration and background specified on the card, reverse the left-right orientation of a design configuration as prescribed on the program card and repeat a design row in fabric being knit. In addition, the machine is adapted to execute supplementary and/or modifying instructions in response to the actuation of switch means by an operator including instructions specifying the placement of a pattern between the side edges of a fabric to be knit on the machine, and an instruction directing the formation of selvedge in punch lace fabric with both the yarn and thread used in knitting the punch lace construction.
The machine includes a liquid crystal display which provides an operator with meaningful information enabling him to better control the knitting of designs and to prevent defects due to operating error. The display informs an operator of the row of the program card being knit, of the number of times a given row has been selected for vertical multiplication, of the fact that the machine has been readied for automatic knitting before a card has been read properly where such is the case, of a failure by the operator to select a particular needle for a wale corresponding to an end column of a designated unit design area on the program card, and of the condition of the power supply. | 3 |
RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of co-pending U.S. Provisional Application Ser. No. 61/016,209, filed Dec. 21, 2007, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND
[0002] 1. Field of Invention
[0003] This disclosure relates to earth boring reamer bits, and particularly to reamer bits having stabilizers disposed on the bit body.
[0004] 2. Description of Prior Art
[0005] Drill bits used in drilling of subterranean well bores typically comprise drag bits and roller cone bits. Roller cone bits typically comprise a body having legs extending downward and a head bearing extending from the leg towards the axis of the bit body. Frusto-conically shaped roller cones are rotatably mounted on each of these journals and are included with cutting teeth on the outer surface of these cones. As the bit rotates, the cones rotate to cause the cutting elements to disintegrate the earth formation.
[0006] In some situations a pilot reamer drilling system is employed where two or more bits are combined on a single drill string at different vertical positions. The lower bit of the pilot reamer drilling system, which is commonly referred to as a pilot bit, creates a pilot hole. The upper bit, which follows the lower bit in the drilling process, enlarges the hole diameter over that created by the pilot bit. The bit enlarging the hole diameter is referred to as a reamer bit. Typically the pilot bit comprises a conventional earth boring bit, i.e. either a roller cone bit or a drag bit. The reamer bit usually employs roller cone bits as cutting members modified for attachment to the reamer bit body. Pilot reamer drilling systems are used for drilling large diameter wellbores or surface holes which require enhanced stabilization.
SUMMARY OF INVENTION
[0007] The disclosure herein includes a reamer bit for downhole earth boring operations comprising, a reamer body having an axis, rolling cutters mounted on the body, and stabilizers disposed between adjacent cutters. Pockets may be provided on the body outer diameter formed to receive the stabilizers and cutter mounts therein. A pilot bit is affixed to the drill shaft extending from the body's lower end. The pilot bit can be a roller cone bit or a drag bit. An updrill surface may be included formed on the upper portion of the cutter mounts and the stabilizer pads. The combined radial profile of the bit legs and the stabilizer pads can approximate a circular shape.
[0008] In an alternative embodiment, the present disclosure includes a pilot reamer apparatus for earth boring use comprising a reamer body having an upper end and a lower end, an axis extending through the upper and lower ends, an outer periphery circumscribing the axis, and pockets formed in the outer periphery, a drill string attachment on the body upper end, a drill pipe segment on the body lower end, a pilot bit affixed to the drill pipe terminal end, cutter mounts on the body outer periphery extending downwardly, rolling cutters rotatingly affixed to the mounts, and stabilizer pads affixed to the reamer body outer periphery disposed between adjacent bit legs.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0010] FIG. 1 is a side view of a reamer bit body with rolling cutters and stabilizer pads.
[0011] FIG. 2 is a perspective view of a reamer bit with attached pilot bit.
[0012] FIG. 3 is an upward looking view of a reamer bit in accordance with the present disclosure having stabilizers.
[0013] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0014] The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which 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 illustrated 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.
[0015] It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
[0016] FIG. 1 provides in a side view an example of a reamer 20 comprising a generally cylindrical body 22 having cutter mounts 24 and stabilizer pads 28 affixed on its outer lateral periphery. The stabilizer pads 28 are disposed between adjacently located cutter mounts 24 . In the embodiment shown, the cutter mounts 24 and the stabilizer pads 28 are elongate members wherein their lengthwise axes are substantially aligned with the axis A of the bit body 22 . Each cutter mount 24 comprises a bearing shaft (not shown) extending from the outer end of the mount 24 in a generally downward direction in towards the axis A. Cutters 26 are rotatably mounted on each shaft and have rows of inserts or teeth 27 formed in a generally circumferential arrangement on the cutters outer surface. The inserts 27 also referred to as cutting elements may be secured to the cutter shell in apertures of selected dimensions, integrally formed, such as by machining (teeth), or later attached after forming the cutter 26 and affixed by welding and/or brazing.
[0017] The reamer 20 further includes a connector 34 on its upper end, wherein the connector is generally concentrically placed around the axis A of the cylindrical body 22 . The connector 34 includes threads (not shown) for connection to an associated drill string. A shaft 36 is shown at the bottom end of cylindrical body 22 and extends downward for attachment of a pilot drill bit. Pockets 30 may be formed on the lateral periphery of the body 22 configured to receive cutter mounts 24 and stabilizer pads 28 . The bit legs and stabilizer pads 28 may be welded or brazed to the body 22 . Furthermore, hard facing 32 may be included on the outer surface of the stabilizer pads 28 . Additionally, the upper portion of the stabilizer pads 28 and cutter mounts 24 may be included with ridges inserts, or other raised elements for providing an updrilling function when drawing the reamer 20 upward within the well bore.
[0018] FIG. 2 provides a perspective view of the reamer 20 combined with the shaft 36 and a pilot bit 38 fixed to the lower terminal end of the shaft 36 thereby forming a pilot reamer assembly 18 . The assembly 18 may be attachable to the lower end of a drill string (not shown) and attached thereto by the connector 34 . While the pilot bit 38 is illustrated as a drag bit, it may also comprise a roller cone bit. The pilot reamer system 18 of FIG. 2 may be used to drill large diameter boreholes in which conventional drill bits are less stable due to the radial distance between adjacent cutters.
[0019] FIG. 3 is an upward-looking view of a bottom of a reamer 20 embodiment. In this view the stabilizer pads 28 extend downward between adjacently positioned cutters 26 of corresponding mounts 24 . The stabilizer pads 28 enhance reamer 20 outer circumference surface continuity by providing additional borehole diameter contact points on the reamer outer surface. Enhancing the reamer 20 outer circumference surface continuity aligns the bit in the wellbore and limits the lateral displacements and distributes the side loads more evenly when a cutter 26 tangentially strikes the wellbore wall. Thus better alignment promotes rotation about the center of the reamer and prevents dynamic dysfunctions such as bit whirl.
[0020] To help maintain a continuity of surface, the stabilizer pads in one embodiment may have an outer profile or curvature substantially the same as the outer profile of the cutter mounts. The result of this can be seen in FIGS. 2 and 3 wherein the reamer 20 has a generally circular configuration due to the presence of the stabilizers 28 . The circular configuration is also attributed to the pad outer surface having large diameter curvature and the stabilizer pads 28 having an outer radial profile similar to the cutter mounts 24 outer radial profile. This similarity in outer radial approximates a full circle, thus limiting open spaces that may produce lateral displacements and high side forces during reaming operations.
[0021] The stabilizer pads 28 can have any shape or configuration suitable for smoothing bit operations and total contact area. This includes an elongate member where the elongate axis is parallel to the body axis, perpendicular to the body axis, or oblique to the body axis. Moreover, the reamer 20 profile having stabilizer pads 28 is not limited to a substantially circular shape, but can be any shape, such as one having multiple sides where a side is defined as the area between each adjacent stabilizer pad 28 and cutter mount 24 . | A reamer bit for use in earth boring operations comprising a body, cutter mounts having rolling cutters on the bit body, and stabilizers pads on the body placed between adjacent cutter mounts. The reamer may further include a pilot bit on a drill pipe extending downward from the reamer body. The reamer bit outer periphery with its stabilizers and bit body has a radial profile approximating a circle thereby reducing dynamic perturbations during drilling operations. | 4 |
STATEMENT OF GOVERNMENT INTEREST
This invention was made with government support under Contract No. HL34035 and HL29307 awarded by the National Institutes of Health, National Heart, Lung and Blood Institute. The government has certain rights in the invention.
This is a continuation-in-part of copending applications Ser. Nos. 215,994 filed on July 7, 1988 now abandoned 374,980 filed on July 3, 1989 now U.S. Pat. No. 4,954,519 issued 9/4/90.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel class of heterocyclic compounds useful for selectively inhibiting chymotrypsin-like enzymes, selectively inhibiting elastase or for generally inhibiting serine proteases of all classes. This invention also relates to a method of treating inflammation in patients using the novel compounds of the present invention. We have found that isocoumarins substituted with hydrophobic groups are potent inhibitors of chymases and elastase, therefore they are useful as anti-inflammatory agents.
2. Description of the Related Art
Serine proteases play critical roles in several physiological processes such as digestion, blood coagulation, complement activation, fibrinolysis, viral infection, fertilization, and reproduction. Serine proteases are not only a physiological necessity, but also a potential hazard if they are not controlled. Uncontrolled proteolysis by elastases may cause pancreatitis, emphysema, rheumatoid arthritis, bronchial inflammation and adult respiratory distress syndrome. Human polymorphonuclear leukocyte elastase may also be involved in blistering. Accordingly, specific and selective inhibitors of these proteases should be potent anti-inflammatory agents useful in the treatment of protease-related diseases (Powers and Harper, in Proteinase Inhibitors, Barrett and Salvesen, eds., Elsevier, 1986, pp 55-152, incorporated herein by reference). In vitro proteolysis by chymotrypsin or the elastase family is a serious problem in the production, purification, isolation, transport or storage of peptides and proteins.
Anti-inflammatory agents were used to treat elastases-associated inflammation including rheumatoid arthritis and emphysema. Although the naturally occurring protease inhibitor, α1-protease inhibitor (α1-PI) has been used to treat patients with emphysema, this inhibitor is not widely used clinically due to the high dosage needed for the treatment and difficulty of producing large quantities. Therefore small molecular weight elastase inhibitors are needed for therapy.
SUMMARY OF THE INVENTION
It is an object of this invention to find a novel group of specific inhibitors for elastase, chymotrypsin and other serine proteases of similar substrate specificity and for serine proteases in general. Inhibitors are compounds that reduce or eliminate the catalytic activity of the enzyme. Trypsin and trypsin-like enzymes normally cleave peptide bonds in proteins and peptides where the amino acid residue on the carbonyl side of the split bond (P 1 residue) is Lys or Arg. Elastase and elastase-like enzymes, on the other hand, cleave peptide bonds where the P 1 amino acid is Ala, Val, Ser, Leu and other similar amino acids. Chymotrypsin and chymotrypsin-like enzymes hydrolyze peptide bonds where P 1 amino acid is Trp, Tyr, Phe, Met, Leu or other amino acid residues which contain aromatic or large alkyl side chains. All of the above enzymes have extensive secondary specificity and recognize amino acid residues removed from the P 1 residue.
It is an object of this invention to discover new protease inhibitors, especially elastase inhibitors, and chymase inhibitors. These inhibitors are useful for controlling tissue damage and various inflammatory conditions mediated by proteases particularly elastases. The inhibitors of this invention would also be useful for controlling hormone processing by serine proteases and for treating diseases related to tryptases and chymases such as inflammation and skin blistering.
It is a further object of this invention to find a novel group of specific inhibitors useful in vitro for inhibiting trypsin, elastase, chymotrypsin and other serine proteases of similar specificity and for inhibiting serine proteases in general. Such inhibitors could be used to identify new proteolytic enzymes encountered in research. They could also be used in research and industrially to prevent undesired proteolysis that occurs during the production, isolation, purification, transport and storage of valuable peptides and proteins. Such proteolysis often destroys or alters the activity and/or function of the peptides and proteins. Uses would include the addition of the inhibitors to antibodies, enzymes, plasma proteins, tissue extracts or other proteins and peptides which are widely sold for use in clinical analyses, biomedical research, and for many other reasons. For some uses a specific inhibitor would be desirable, while in other cases, an inhibitor with general specificity would be preferred.
DETAILED DESCRIPTION OF THE INVENTION
Isocoumarins substituted with hydrophobic groups have been found to be excellent inhibitors of several serine proteases including human leukocyte elastase, porcine pancreatic elastase, bovine chymotrypsin and human leukocyte cathepsin G. These compounds inhibit the serine proteases by reaction with the active site serine to form an acyl enzyme, which in some cases may further react with another active site nucleophile to form an additional covalent bond. These structures may be used in vivo to treat diseases such as emphysema, adult respiratory distress syndrome, rheumatoid arthritis and pancreatitis which result from uncontrolled proteolysis by elastase, chymotrypsin, trypsin and related serine proteases. These inhibitors may be used in vitro to prevent proteolysis which occurs in the process of production, isolation, purification, storage or transport of peptides and proteins. The novel substituted isocoumarin and related heterocyclic compounds have the following structural formula: ##STR1## or a pharmaceutically acceptable salt, wherein
Z is methoxy,
R is selected from the group consisting of O═C═N--, S═C═N--, M--NH--, M--AA--NH--, M--AA--AA--NH--, M--O--, M--AA--O, M--AA--AA--O--,
wherein M represents NH 2 --CO--, NH 2 --CS--, NH 2 --SO 2 --, X--NH--CO--, X--NH--CS--, X--NH--SO 2 --, X--CS--, X--SO 2 --, X--O--CO--, X--O--CS--, or D--CO--,
wherein X represents C 1-6 alkyl, C 1-6 fluoroalkyl, C 1-6 alkyl substituted with K, C 1-6 fluoroalkyl substituted with K, 9-fluoroenylmethyl, phenyl, phenyl substituted with J, phenyl disubstituted with J, phenyl trisubstituted with J, naphthyl, naphthyl substituted with J, naphthyl disubstituted with J, naphthyl trisubstituted with J, C 1-6 alkyl with an attached phenyl group, C 1-6 alkyl with two attached phenyl groups, C 1-6 alkyl with an attached phenyl group substituted with J, or C 1-6 alkyl with two attached phenyl groups substituted with J,
wherein D represents C 1-6 fluoroalkyl, C 1-6 alkyl substituted with K, C 1-6 fluoroalkyl substituted with K, 9-fluorenylmethyl, phenyl, phenyl substituted with J, phenyl disubstituted with J, phenyl trisubstituted with J, naphthyl, naphthyl substituted with J, naphthyl disubstituted with J, naphthyl trisubstituted with J, C 1-6 alkyl with an attached phenyl group substituted with J, or C 1-6 alkyl with two attached phenyl groups substituted with J,
wherein J represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, C 1-6 alkyl--O--CO--NH--, or C 1-6 alkyl--S--,
wherein K represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, or C 1-6 alkyl--O--CO--NH, C 1-6 alkyl--S--, or tosylamino,
wherein AA represents alanine, valine, leucine, isoleucine, proline, methionine, phenylalanine, tryptophan, glycine, serine, threonine, cysteine, tyrosine, asparagine, glutamine, aspartic acid, glutamic acid, lysine, arginine, histidine, beta-alanine, norleucine, norvaline, phenylglycine, alpha-aminobutyric acid, epsilon-aminocaproic acid, citrulline, hydroxyproline, ornithine or sarcosine, and
Y is selected from the group consisting of H, halogen, trifluoromethyl, methyl, OH and methoxy.
Alternately the novel isocoumarin and related heterocyclic compound are represented by structure (I) where,
Z is ethoxy,
wherein R is selected from the group consisting of O═C═N--, S═C═N--, M--NH--, M--AA--NH--, M--AA--AA--NH--, M--O--, M--AA--O, M--AA--AA--O--,
wherein M represents NH 2 --CS--, NH 2 --SO 2 --, L--NH--CO--, X--NH--CS--, X--NH--SO 2 --, X--CO--, X--CS--, X--SO 2 --, X--O--CO--, or X--O--CS--,
wherein L represents C 1-6 fluoroalkyl, C 1-6 alkyl substituted with K, C 1-6 fluoroalkyl substituted with K, 9-fluorenylmethyl, phenyl substituted with J, phenyl disubstituted with J, phenyl trisubstituted with J, naphthyl, naphthyl substituted with J, naphthyl disubstituted with J, naphthyl trisubstituted with J, C 1-6 alkyl with an attached phenyl group, C 1-6 alkyl with two attached phenyl groups, C 1-6 alkyl with an attached phenyl group substituted with J, or C 1-6 alkyl with two attached phenyl groups substituted with J,
wherein X represents C 1-6 alkyl, C 1-6 fluoroalkyl, C 1-6 alkyl substituted with K, C 1-6 fluoroalkyl substituted with K, 9-fluorenyl, phenyl, phenyl substituted with J, phenyl disubstituted with J, phenyl trisubstituted with J, naphthyl, naphthyl substituted with J, naphthyl disubstituted with J, naphthyl trisubstituted with J, C 1-6 alkyl with an attached phenyl group, C 1-6 alkyl with two attached phenyl groups, C 1-6 alkyl with an attached phenyl group substituted with J, or C 1-6 alkyl with two attached phenyl groups substituted with J,
wherein J represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, C 1-6 alkyl--O--CO--NH--, or C 1-6 alkyl--S--,
wherein K represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, or C 1-6 alkyl--O--CO--NH, C 1-6 alkyl--S--, or tosylamino,
wherein AA represents alanine, valine, leucine, isoleucine, proline, methionine, phenylalanine, tryptophan, glycine, serine, threonine, cysteine, tyrosine, asparagine, glutamine, aspartic acid, glutamic acid, lysine, arginine, histidine, beta-alanine, norleucine, norvaline, phenylglycine, alpha-aminobutyric acid, epsilon-aminocaproic acid, citrulline, hydroxyproline, ornithine or sarcosine, and
Y is selected from the group consisting of H, halogen, trifluoromethyl, methyl, OH and methoxy.
Alternately the novel isocoumarin and related heterocyclic compound are represented by structure (I) where,
Z is selected from the group consisting of propoxy, C 1-6 alkoxy with a phenyl group attached to the C 1-6 alkoxy group, C 1-6 alkyl with a phenyl group attached to the C 1-6 alkyl, C 1-6 alkoxy with an attached phenyl group substituted with J, C 1-6 alkyl with an attached phenyl group substituted with J,
wherein R is selected from the group consisting of O═C═N--, S═C═N--, M--NH--, M--AA--NH--, M--AA--AA--NH--, M--O--, M--AA--O, M--AA--AA--O--,
wherein M represents NH 2 --CO--, NH 2 --CS--, NH 2 --SO 2 --, X--NH--CO--, X--NH--CS--, X--NH--SO 2 --, X--CO--, X--CS--, X--SO 2 --, X--O--CO--, or X--O--CS--,
wherein X represents C 1-6 alkyl, C 1-6 fluoroalkyl, C 1-6 alkyl substituted with K, C 1-6 fluoroalkyl substituted with K, 9-fluorenylmethyl, phenyl, phenyl substituted with J, phenyl disubstituted with J, phenyl trisubstituted with J, naphthyl, naphthyl substituted with J, naphthyl disubstituted with J, naphthyl trisubstituted with J, C 1-6 alkyl with an attached phenyl group, C 1-6 alkyl with two attached phenyl groups, C 1-6 alkyl with an attached phenyl group substituted with J, or C 1-6 alkyl with two attached phenyl groups substituted with J,
wherein J represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, C 1-6 alkyl--O--CO--NH--, or C 1-6 alkyl--S--,
wherein K represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, or C 1-6 alkyl--O--CO--NH, C 1-6 alkyl--S--, or tosylamino,
wherein AA represents alanine, valine, leucine, isoleucine, proline, methionine, phenylalanine, tryptophan, glycine, serine, threonine, cysteine, tyrosine, asparagine, glutamine, aspartic acid, glutamic acid, lysine, arginine, histidine, beta-alanine, norleucine, norvaline, phenylglycine, alpha-aminobutyric acid, epsilon-aminocaproic acid, citrulline, hydroxyproline, ornithine or sarcosine, and
Y is selected from the group consisting of H, halogen, trifluoromethyl, methyl, OH and methoxy.
Alternately the novel isocoumarin and related heterocyclic compound are represented by structure (I) where,
wherein Z is selected from the group consisting of C 1-6 alkoxy with a halogen attached to the alkoxy group, C 1-6 alkyl with a halogen attached to the alkyl group, C 1-6 alkoxy with an attached C 1-6 alkoxy group substituted with Q,
wherein Q represents H, or C 1-6 alkoxy,
R is selected from the group consisting of OH, NH 2 , NO 2 , O═C═N--, S═C═N--, AA--NH--, AA--AA--NH, AA--O--, AA--AA--O--, M--NH--, M--AA--NH--, M--AA--AA--NH--, M--O--, M--AA--O, M--AA--AA--O--,
wherein AA represents alanine, valine, leucine, isoleucine, proline, methionine, phenylalanine, tryptophan, glycine, serine, threonine, cysteine, tyrosine, asparagine, glutamine, aspartic acid, glutamic acid, lysine, arginine, histidine, beta-alanine, norleucine, norvaline, phenylglycine, alpha-aminobutyric acid, epsilon-aminocaproic acid, citrulline, hydroxyproline, ornithine or sarcosine,
wherein M represents NH 2 --CO--, NH 2 --CS--, NH 2 --CS--, NH 2 --SO 2 --, X--NH--CO--, X--NH--CS--, X--NH--SO 2 --, X--CO--, X--CS--, X--SO 2 --, X--O--CO--, or X--O--CS--,
wherein X represents C 1-6 alkyl, C 1-6 fluoroalkyl, C 1-6 alkyl substituted with K, C 1-6 fluoroalkyl substituted with K, phenyl, phenyl substituted with J, phenyl disubstituted with J, phenyl trisubstituted with J, naphthyl, naphthyl substituted with J, naphthyl disubstituted with J, naphthyl trisubstituted with J, C 1-6 alkyl with an attached phenyl group, C 1-6 alkyl with two attached phenyl groups, C 1-6 alkyl with an attached phenyl group substituted with J, or C 1-6 alkyl with two attached phenyl groups substituted with J,
wherein J represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, C 1-6 alkyl--O--CO--NH--, or C 1-6 alkyl--S--,
wherein K represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, or C 1-6 alkyl--O--CO--NH--, C 1-6 alkyl--S--, or tosylamino, and
Y is selected from the group consisting of H, halogen, trifluoromethyl, methyl, OH and methoxy.
Alternately the novel isocoumarin and related heterocyclic compounds are represented by structure (I) where,
Z is selected from the group consisting of H, halogen, C 1-6 alkyl, C 1-6 fluorinated alkyl, C 1-6 alkyl substituted with K, C 1-6 fluorinated alkyl substituted with K, C 1-6 alkoxy, C 1-6 fluorinated alkoxy, C 1-6 alkoxy substituted with K, C 1-6 fluorinated alkoxy substituted with K, C 1-6 alkyl with a phenyl group attached to the alkyl group, C 1-6 alkoxy with a phenyl group attached to the alkoxy group, C 1-6 alkyl with an attached phenyl group substituted with J, C 1-6 alkyl with an attached phenyl group disubstituted with J, C 1-6 alkoxy with an attached phenyl group substituted with J, C 1-6 alkoxy with an attached phenyl group disubstituted with J,
wherein J represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkyl, C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, C 1-6 alkyl--O--CO--NH--, or C 1-6 alkyl--S--,
wherein K represents halogen, COOH, OH, CN, NO 2 , NH 2 , C 1-6 alkoxy, C 1-6 alkylamine, C 1-6 dialkylamine, C 1-6 alkyl--O--CO--, or C 1-6 alkyl--O--CO--NH--, C 1-6 alkyl--S--, or tosylamino,
R is biotin-spacer-T,
wherein T represents --NH--, --O--, or --S--,
wherein spacer represents --[NH--(CH 2 ) n --CO] n --, --[NH--(CH 2 ) n --NH--CO] n --, --[NH--C 6 H 4 --CO] n --, --[NH--C 6 H 4 --NH--CO] n --, --NH--(CH 2 ) n --CO--NH--(CH 2 ) n --NH--CO--, --NH--(CH 2 ) n --CO--NH--(CH 2 ) 3 --NH--(CH 2 ) 3 --NH--CO--CH 2 CH 2 --CO--, or --(AA) n --, where n=1-6.
wherein AA represents alanine, valine, leucine, isoleucine, proline, methionine, phenylalanine, tryptophan, glycine, serine, threonine, cysteine, tyrosine, asparagine, glutamine, aspartic acid, glutamic acid, lysine, arginine, histidine, beta-alanine, norleucine, norvaline, phenylglycine, alpha-aminobutyric acid, epsilon-aminocaproic acid, citrulline, hydroxyproline, ornithine or sarcosine,
Y is selected from the group consisting of H, halogen, trifluoromethyl, methyl, OH and methoxy.
The compounds of Formula (I) can also contain one or more substituents at position B as shown in the following structure: ##STR2## wherein electronegative substituents such as NO 2 , CN, Cl, COOR, and COOH will increase the reactivity of the isocoumarin, and electropositive substituents such as NH 2 , OH, alkoxy, thioalkyl, alkyl, alkylamino, and dialkylamino will increase its stability. Neutral substituents could also increase the stability of acyl enzyme and improve the effectiveness of the inhibitors.
Other substituted isocoumarins have been prepared earlier for other purposes (illustrative examples: 3-chloroisocoumarin, Davies and Poole, J. Chem. Soc., pp 1616-1629 (1928); 3-chloro and 3,4-dichloroisocoumarin, Milevskaya, Belinskaya, and Yagupol'skii, Zhur. Org. Khim. 9, pp 2145-2149 (1973); 3-methyl and 4-carboxy-3-methylisocoumarin, Tirodkar and Usgaonkar, Ind. J. Chem. 7, pp 1114-1116 (1969); 7-nitro and 7-aminoisocoumarin, Choksey and Usgaonkar, Ind. J. Chem. 14B, pp 596-598 (1976), the preceding articles are incorporated herein by reference).
A number of other substituted isocoumarins have been prepared recently for inhibition of serine proteases (3-chloroisocoumarin, Harper, Hemmi, and Powers, J. Am. Chem. Soc. 105, pp 6518-6520 (1983); 3,4-dichloroisocoumarin, Harper, Hemmi, and Powers, Biochemistry 24, pp 1831-1841 (1985); 3-alkoxy-7-amino-4-chloroisocoumarin, Harper and Powers, J. Am. Chem. Soc. 106, pp 7618-7619 (1984), Harper and Powers, Biochemistry 24, 7200-7213 (1983); substituted isocoumarins with basic groups (aminoalkoxy, guanidino or isothiureidoalkoxy), Kam, Fujikawa and Powers, Biochemistry 27, pp 2547-2557 (1988); 7-substituted 3-alkoxy-4-chloroisocoumarins, Powers, Kam, Narasimhan, Oleksyszyn, Hernandez and Ueda, J. Cell Biochem. 39, pp 33-46 (1989), Powers, Oleksyszyn, Narasimhan, Kam, Radhakrishnan and Meyer, Jr. Biochemistry 29, 3108-3118 (1990), the preceding articles are incorporated herein by reference; Powers and Harper, U.S. Pat. No. 4,596,822; Powers and Kam, U.S. Pat. No. 4,845,242 which are also incorporated by reference).
The following compounds are representative of the invention:
7-isocyanato-4-chloro-3-methoxyisocoumarin
7-ethoxycarbonylamino-4-chloro-3-methoxyisocoumarin
7-phenoxycarbonylamino-4-chloro-3-methoxyisocoumarin
7-benzyloxycarbonylamino-4-chloro-3-methoxyisocoumarin
7-carbamoylamino-4-chloro-3-methoxyisocoumarin
7-methylcarbamoylamino-4-chloro-3-methoxyisocoumarin
7-ethylcarbamoylamino-4-chloro-3-methoxyisocoumarin
7-isopropylcarbamoylamino-4-chloro-3-methoxyisocoumarin
7-t-butylcarbamoylamino-4-chloro-3-methoxyisocoumarin
7-phenylcarbamoylamino-4-chloro-3-methoxyisocoumarin
7-(N-benzyl-N-phenylethylcarbamoyl)amino-4-chloro-3-methoxyisocoumarin
7-heptafluorobutyroylamino-4-chloro-3-methoxyisocoumarin
7-(9-fluorenylmethoxycarbonyl)amino-4-chloro-3-methoxyisocoumarin
7-(N-tosyl-α-phenylglycyl)amino-4-chloro-3-methoxyisocoumarin
7-(o-phthalyl)amino-4-chloro-3-methoxyisocoumarin
7-(o-methoxyphthalyl)amino-4-chloro-3-methoxyisocoumarin
7-methoxysuccinylamino-4-chloro-3-methoxyisocoumarin
7-methoxyglutarylamino-4-chloro-3-methoxyisocoumarin
7-(3-phenylglutaryl)amino-4-chloro-3-methoxyisocoumarin
7-(m-methoxycarbonylaminobenzoyl)amino-4-chloro-3-methoxyisocoumarin
7-ethoxycarbonylamino-4-chloro-3-ethoxyisocoumarin
7-ethylthiocarbamoylamino-4-chloro-3-ethoxyisocoumarin
7-phenylthiocarbamoylamino-4-chloro-3-ethoxyisocoumarin
7-dihydrocinnamoylamino-4-chloro-3-propyloxyisocoumarin
7-ethoxycarbonylamino-4-chloro-3-propyloxyisocoumarin
7-ethylcarbamoylamino-4-chloro-3-propyloxyisocoumarin
7-phenylcarbamoylamino-4-chloro-3-propyloxyisocoumarin
7-phenylthiocarbamoylamino-4-chloro-3-propyloxyisocoumarin
7-benzylthiocarbamoylamino-4-chloro-3-propyloxyisocoumarin
7-(m-nitrobenzoyl)amino-4-chloro-3-propyloxyisocoumarin
7-[(2-thiomethyl)acetyl]amino-4-chloro-3-propyloxyisocoumarin
7-(N-t-butyloxycarbonyl-valyl)amino-4-chloro-3-propyloxyisocoumarin
7-biotinylamino-4-chloro-3-propyloxyisocoumarin
7-biotinylamino-4-chloro-3-(2-phenylethoxy)isocoumarin
7-(6-biotinylaminocaproyl)amino-4-chloro-3-ethoxyisocoumarin
7-(6-biotinylaminocaproyl)amino-4-chloro-3-propyloxyisocoumarin
7-(6-biotinylaminocaproyl)amino-4-chloro-3-(2-phenylethoxy)isocoumarin
7-nitro-4-chloro-3-(2-bromoethoxy)isocoumarin
7-amino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-t-butylcarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-isopropylcarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-phenylcarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-benzylcarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(R-α-methylbenzyl)carbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(S-α-methylbenzyl)carbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-naphthylcarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-t-butylacetylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-phenylacetylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(N-t-butyloxycarbonyl-D-phenylalanyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(N-t-butyloxycarbonyl-L-phenylalanyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(N-t-butyloxycarbonyl-L-alanylalanyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-dansylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-phenylthiocarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(m-carboxyphenyl)thiocarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-(p-carboxyphenyl)thiocarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
7-nitro-4-chloro-3-(3-bromopropoxy)isocoumarin
7-amino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-phenylcarbamoylamino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-benzylcarbamoylamino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-acetylamino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-phenylacetylamino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-dihydrocinnamoylamino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-(N-t-butyloxycarbonyl-D-phenylalanyl)amino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-(N-t-butyloxycarbonyl-L-phenylalanyl)amino-4-chloro-3-(3-bromopropoxy)isocoumarin
7-nitro-4-chloro-3-(2-bromoisopropoxy)isocoumarin
7-amino-4-chloro-3-(2-bromoisopropoxy)isocoumarin
7-amino-4-chloro-3-(2-methoxy)ethoxyisocoumarin
7-amino-4-chloro-3-[2-(2-methoxyethoxy)ethoxy]isocoumarin
It has been found that compounds of Formula (I) have anti-inflammatory activity and can be used to treat and control emphysema, adult respiratory distress syndrome and rheumatoid arthritis as shown in Table I, III, IV and VII by effective inhibition of the proteolytic function of human leukocyte elastase and human cathepsin G. Compounds of Formula (I) are effective in the theraputic use for pancreatitis by inhibiting the proteolytic function of chymotrypsin and pancreatic elastase as shown in Table I, II, III, IV and VII. Compounds of Formula (I) are also effective in the prevention of unnecessary proteolysis caused by chymotrypsin and elastase in the process of purification, transport and storage of peptides and proteins as shown in Table I, II, III, IV and VII by effective inhibition of chymotrypsin and elastase.
Compounds of Formula (I) with a R group consisting of biotinylamino or an alkanoylamino with biotinylamino group attached to alkanoylamino, Y group of Cl, and Z group of phenylethoxy group are effective in the inhibition of rat granule chymase as shown in Table V. The reactivation of inhibited rat granule chymase by these biotin isocoumarins in the presence of hydroxylamine as shown in Table VI is useful in the purification of these enzymes from rat granules by applying the inhibited granules to the avidin beads, where the biotinylated enzymes form tight complex with avidin and retain on the column. Finally the enzyme can be reactivated and eluated out with hydroxylamine solution. The tight complex of biotin-avidin has been used as a powerful tool for purifying proteins. One such an example was shown by Williams et al., J. Biol. Chem. 264, pp 7536-7545 (1989). The biotinylated-ε-aminocaproyl-peptide chloromethylketone was used to react with an active protease to form the biotinylated inactivated enzyme which retained on the avidin beads. This procedure allows removal of the protease from enzyme and zymogen mixture.
Although little information is available on the structure of biotin binding site of avidin, the spacer between the biotin and the ligand molecule such as isocoumarin, chloromethyl ketone or insulin is crucial for the binding of biotinylated ligand to avidin. Green et al. (Biochem. J. 125, pp 781-791 (1971)) attempted to determine the depth of the biotin binding site on avidin by studying the effect of chain length of ω-bis(biotinyldiamines) on avidin polymer formation. He concluded that since stable polymers were formed when the chain linking the carboxyl groups of the biotins was 18 Å long, the carboxyl group must lie about 8-9 Å beneath the surface of the avidin molecule. Finn et al. (Biochemistry 23, pp 2554-2558 (1984)) also calculated that the distance between the carboxyl group of dethiobiotin and the N-terminal amino group of the insulin B-chain would be 9.77 Å for dethiobiotinyl-A1-insulin, 18.36 Å for dethiobiotinyl-A2-insulin, and 25.52 Å for dethiobiotinyl-A1-DPA-insulin (A1, A2, and A 1-DPA were different chain length of spacer). Thus, any of these ligands should have sufficient space between the dethiobiotinyl and insulin portions to bind normally to avidin. However, only the longest of the three ligands showed the same rate of dissociation from Suc-avidin as dethiobiotin itself. Therefore, spacer arms are required for optimizing the interaction between the biotinylated ligand and the avidin complex.
The biotin-avidin interaction is very useful in many areas such as immunoassays, receptor studies, immunocytochemical staining and protein isolation. In the enzyme immunoassay system, the biotinylated antibody is bound to the immobilized antigen or primary antibody, and avidin can be conjugated with enzymes, fluorochromes, ferritin or colloidal markers. The biotin-avidin interaction can also be used in blotting techniques for detecting proteins. It is very useful in the staining of cellular antigenic determinants. A wide variety of biotinylated primary probes such as monoclonal antibodies, lectins, vitamins, sugars, hormones and lipoproteins have been used. This specific interaction has also been used successfully in the selective retrieval of labelled plasma membrane components (Orr, J. Biol. Chem. 256, pp 761-766 (1981)). Biotinylated protein can be used as probes of protein structure and protein-protein interaction (Billingsley et al. Biotechniques 5, pp 22-31 (1987)).
Inactivation rates of serine proteases by substituted isocoumarins were measured by the incubation method. An aliquot of inhibitor (25 or 50 μl) in Me 2 SO was added to a buffered enzyme solution (0.01-2.3 μM) to initiate the inactivation. Aliquots (50 μl) were withdrawn at various intervals and the residual enzymatic activity was measured. Me 2 SO concentration in the reaction mixture was 8-12% (v/v). 0.1M Hepes, 0.5M NaCl, pH 7.5 buffer was utilized for the assays of all serine proteases. The inhibitor concentrations are shown in the Tables I, II, III, IV, V, VI and VII. Peptide nitroanilides with appropriate sequence were used as substrates for various serine proteases. All peptide 4-nitroanilide hydrolysis was measured at 410 nm (ε 410 =8800M -1 cm -1 ; Erlanger et al., Arch. Biochem. Biophys. 95, pp 271-278 (1961)). First order inactivation rate constant (k obs ) were obtained from plots of 1n (v t /v o ) vs time, and the correlation coefficients were greater than 0.98.
Table I shows the inactivation rate constants of porcine pancreatic elastase (PPE), human leukocyte elastase (HLE) inhibited by substituted isocoumarins. The inactivation by these inhibitors was less efficient toward PPE than HLE. The structures with R group of o-methoxyphthalylamino or phenylcarbamoylamino, Y group of Cl, and Z group of methoxy are best inhibitors for PPE. The structures with R group of Tosphenylglycylamino or m-methoxycarbonylaminobenzoylamino, Y group of Cl, and Z-group of methoxy are best at inhibiting HLE.
Table II shows the inhibition of PPE by substituted isocoumarins, the structure with R group of phenylthiocarbamylamino, Y group of Cl, and Z-group of ethoxy is the best inhibitor of PPE. Table III shows the inhibition of PPE, HLE, chymotrypsin and cathepsin G by substituted isocoumarins. It is unexpected that all the compounds with Y group of Cl and Z group of propoxy are very potent inhibitors of HLE. The structure with R group of phenylcarbamoylamino, or dihydrocinnamoylamino, Y group of Cl, and Z group of propoxy are the best inhibitors of HLE. However they are poor inhibitors of cathepsin G. The structure with R group of ethoxycarbonylamino, Y group of Cl and Z group of propoxy is a good inhibitor for chymotrypsin.
Table IV shows the inhibition of PPE, HLE, chymotrypsin and cathepsin G by biotin isocoumarin derivatives. The compound with R group of 6-biotinylaminocaproylamino, Y group of Cl and Z group of phenylethoxy is a good inhibitor for chymotrysin. The structure with R group of 6-biotinylaminocaproylamino, Y group of Cl and Z group of propoxy or ethoxy are the best inhibitors for HLE.
Table V shows the inhibition of rat granule chymase and tryptase by biotin isocoumarin derivatives. The structure with a R group of 6-biotinylaminocaproylamino, Y group of Cl and Z group of phenylethoxy inactivated chymase instantly with 50% inhibition, and also inhibited tryptase very slowly. Table VI shows the reactivation of inhibited chymotrypsin and rat granule chymase by biotin isocoumarins in buffer and in the presence of hydroxylamine. Inhibited chymotrypsin regained 40-85% of activity and inhibited rat granule chymase regained 30-100% of activity in the presence of hydroxylamine.
Table VII shows the inhibition of PPE, HLE, chymotrypsin and cathepsin G by isocoumarins substituted with bromoalkoxy groups. The structure with R group of R-methylbenzylcarbamylamino, Y group of Cl and Z group of bromoethoxy is the best inhibitor for PPE. It is unexpected that all the compounds with Y group of Cl, Z-group of bromoethoxy are potent inhibitors of HLE, especially the structure with R group of phenylcarbamoylamino is the most potent inhibitor of HLE. The structures with R group of NO 2 , Y group of Cl, Z group of 2-bromoisopropoxy and R group of phenylacetyl, Y group of Cl, Z-group of bromopropoxy are the best at inhibiting chymotrypsin.
Table VIII shows the half-life for the deacylation of inactivated elastase by substituted isocoumarins. Only the enzyme inactivated by compound with R group of phenylcarbamyl, Y group of Cl, and Z group of methoxy is stable with the half-life more than 48 hrs.
Pulmonary emphysema is a disease characterized by progressive loss of lung elasticity due to the destruction of lung elastin and alveoli. The destructive changes of lung parentchyma associated with pulmonary emphysema are caused by uncontrolled proteolysis in lung tissues (Janoff, Chest 83 pp 54-58 (1983)). A number of proteases has been shown to induce emphysema in animals (Marco et al., Am. Rev. Respir. Dis. 104, pp 595-598 (1971); Kaplan, J. Lab. Clin. Med. 82, pp 349-356 (1973)), particularly human leukocyte elastase (Janoff, ibid 115, pp 461-478 (1977)). Leukocyte elastase and other mediators of inflammation also appear to play a role in diseases such as mucocutaneous lymph node syndrome (Reiger et al., Eur. J. Pediatr. 140, pp 92-97 (1983) and adult respiratory distress syndrome (Stockley, Clinical Science 64, pp 119-126 (1983); Lee et al., N. Eng. J. Med. 304, pp 192-196 (1981); Rinaldo, ibid 301, 900-909 (1982 )).
It is known that in vitro activity of elastase inhibitors correlates with in vivo activity in animal models of emphysema and inflammation (Otterness et al., editor, Advances in Inflammation Research, Vol. 11, Raven Press 1986, and this article is incorporated herein by reference). Prophylactic administration of an inhibitor of elastase significantly diminishes the extent of elastase-induced emphysema (Kleinerman et al., Am. Rev. Resir. Dis. 121, pp 381-387 (1980); Lucey et al., Eur. Respir. J. 2, pp 421-427 (1989)). Thus the novel inhibitors described here should be useful for the treatment of emphysema and inflammation. Elastase inhibitors have been used orally, by injection or by instillation in the lungs in animal studies (Powers, Am. Rev. Respir. Dis., 127, s54-s58 (1983); Powers and Bengali, Am. Rev. Respir. Dis. 134, pp 1097-1100 (1986) and these two articles are incorporated herein by reference). The inhibitors described above can be used by any of these routes.
For treatment of inflammation, the compounds of Formula (I) may be administered orally, topically or parenterally. The term parenteral as used includes subcutaneous injection, intravenous, intramuscular, intrasternal injection or infusion techniques. The dosage depends primarily on the specific formulation and on the object of the therapy or prophylaxis. The amount of the individual doses as well as the administration is best determined by individually assessing the particular case.
The pharmaceutical compositions containing the active ingredient may be in a form suitable for oral use, for example as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules or syrups or elixirs. Dosage levels of the order to 0.2 mg to 140 mg per kilogram of body weight per day are useful in the treatment of above-indicated conditions (10 mg to 7 gms per patient per day). The amount of active ingredient that may be combined with carrier materials to produce a single dosage form will vary depending upon the host treated and the particular mode of administration.
For injection, the therapeutic amount of the compounds of Formula (I) or their pharmaceutically acceptable salts will normally be in the dosage range from 0.2 to 140 mg/kg of body weight. Administration is made by intravenous, intramuscular or subscutaneous injection. Accordingly, pharmaceutical compositions for parenteral administration will contain in a single dosage form about 10 mg to 7 gms of compounds of Formula (I) per dose. In addition to the active ingredient, these pharmaceutical compositions will usually contain a buffer, e.g. a phosphate buffer which keeps the pH in the range from 3.5 to 7 and also sodium chloride, mannitol or sorbitol for adjusting the isotonic pressure.
A composition for topical application can be formulated as an aqueous solution, lotion, jelly or an oily solution or suspention. A composition in the form of an aqueous solution is obtained by dissolving the compounds of Formula (I) in aqueous buffer solution of pH 4 to 6.5 and if desired, adding a polymeric binder. An oily formulation for topical application is obtained by suspending the compounds of Formula (I) in an oil, optionally with the addition of a swelling agent such as aluminium stearate and/or a surfactant.
To use the above inhibitors in vitro, they are dissolved in an organic solvent such as dimethylsulfoxide or ethanol, and are added to an aqueous solution containing serine proteases. The final concentration of the organic solvent should be less than 25%. The inhibitors may also be added as solids or in suspension. The serine protease inhibitors of this invention would be useful in a variety of experimental procedures where proteolysis is a significant problem. Inclusion of these inhibitors in a radioimmunoassay experiments would result in higher sensitivity. The use of these inhibitors in plasma fractionation procedures would result in higher yields of valuable plasma proteins and would make purification of the proteins easier. The inhibitors disclosed here could be used in cloning experiments utilizing bacterial cultures, yeast and purified cloned product in higher yield.
The following examples are given to illustrate the invention and are not intended to limit it in any manner.
EXAMPLE 1
Preparation of 7-heptafluorobutyroylamino-4-chloro-3-methoxyisocoumarin
7-Amino-4-chloro-3-methoxyisocoumarin (1 eq.) and heptafluorobutyryl chloride (1.5 eq.) were dissolved in THF and then Et 3 N (1.5 eq.) was added dropwise to the stirred mixture over a period of 4 h. After addition of Et 3 N was completed, the reaction mixture was stirred for 20 h at r.t., then the solvent was removed in vacuo and the residue dissolved in ethyl acetate. This solution was washed with water, 10% citric acid, 4% NaHCO 3 and finally again with water, dried over MgSO 4 and evaporated. The residue was crystallized from THF-hexane to give yellow solid; yield 62%; mp 189°-190° C.; MS, m/e 421 (M + ). Anal. Calc. for C 14 H 7 F 7 ClNO 4 : C, 39.84; H, 1.66; N, 3.32. Found: C, 40.24; H, 1.70; N, 3.33.
7-(3-fluorobenzoyl)amino-4-chloro-3-propoxyisocoumarin, 7-(4-methoxybenzoyl)amino-4-chloro-3-propoxyisocoumarin, 7-heptafluorobutyroylamino-4-chloro-3-ethoxyisocoumarin, 7-heptafluorobutyroylamino-4-chloro-3-(2-bromoethoxy)isocoumarin, 7-heptafluorobutyroylamino-4-chloro-3-(2-phenylethoxy)isocoumarin, 7-(3-fluorobenzoyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin, 7-(3-nitrobenzoyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin, 7-(α-toluenesulfonyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 2
Preparation of 7-[(3-phenylglutaryl)amino]-4-chloro-3-methoxyisocoumarin
One gram of 7-amino-4-chloro-3-methoxyisocoumarin dissolved in 15 ml of pyridine was treated with 4 equivalents of 3-phenylglutaric anhydride. After 5 hrs, 3 ml of water were added to the reaction mixture. Partial evaporation of the solvents left a semisolid residue, which was diluted with a mixture of acetone and water (3:1), and filtered. The crude crystals were then recrystallized from acetone/water to give yellow crystals, yield 62%.; mp 105°-106° C.; MS (FAB + ) m/e 416 (M + +1). Anal. Calc. for C 21 H 18 ClNO 6 .1.2H 2 O: C, 57.66; H, 4.42; Cl, 3.20. Found: C, 57.60; H, 4.77; N, 3.17.
7-(o-phthalyl)amino-4-chloro-3-ethoxyisocoumarin and 7-(o-phthalyl)amino-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 3
Preparation of 7-[(methoxyglutaryl)amino]-4-chloro-3-methoxyisocoumarin
7-Glutarylamino-4-chloro-3-methoxyisocoumarin was prepared by the same procedure described in example 2, mp 194° C. (dec.); MS m/e 339 (M + ). Anal. Calc. for C 15 H 14 ClNO 6 .1.2 H 2 O: C, 57.66; H, 4.42; N, 3.20. Found: C, 57.60; H, 4.77; N, 3.17. An etheral solution containing 2.5 mmoles of diazomethane was added to a solution of 0.6 mmoles of 7-glutarylamino-4-chloro-3-methoxyisocoumarin in a mixture of DMF and ethyl acetate. After 30 min, the reaction mixture was evaporated to dryness and the crude ester crystallized from acetone, giving a yellow solid, mp 147°-151° C. (dec.); MS m/e 353 (M + ). Anal. Calc. for C 16 H 16 ClNO 6 : C, 54.30; H, 4.56; N, 3.96; Cl, 10.03. Found: C, 54.39; H, 4.58; N, 3.39; Cl, 10.13.
7-(methoxysuccinyl)amino-4-chloro-3-ethoxyisocoumarin and 7-(methoxysuccinyl)amino-4-chloro-3-(2-phenylethoxy)isocoumarin was prepared by the same procedure.
EXAMPLE 4
Preparation of 7-[(N-tosyl-α-phenylglycyl)amino]-4-chloro-3-methoxyisocoumarin
N-Tosyl phenylglycine (1.8 mmole) was dissolved in 2 ml of SOCl 2 and stirred at reflux temperature for 40 min. The reaction mixture was concentrated to dryness in vacuo and the residue triturated with EtOAc/Hexane (3:1) to yield the acid chloride (94%) which is used in the next step without further purification. Tos-phenylglycine acid chloride (155 mg) and 7-amino-4-chloro-3-methoxyisocoumarin (72 mg) were dissolved in a mixture of methylene chloride (1 ml) and THF (1 ml). A solution of triethylamine (0.06 ml in 2 ml of CH 2 Cl 2 ) was added dropwise and the reaction mixture was stirred at room temperature for 2 h. The solvent was removed in vacuo and the residue was triturated with ethyl acetate (1.5 ml). The resulting yellow solid was recrystallized from THF/H 2 O to yield 108 mg (66%); mp 150°-151° C. (dec.); MS, m/e 512 (M + ). Anal. Calc. for C 25 H 21 ClN.sub. 2 O 6 S: C, 58.53; H, 4.13; N, 5.46. Found: C, 58.43; H, 4.15; N, 5.40.
EXAMPLE 5
Preparation of 7-(N-phenylcarbamoylamino)-4-chloro-3-methoxyisocoumarin
This compound was prepared by reaction of 110 mg (0.5 mmol) of 7-amino-4-chloro-3-methoxyisocoumarin with 60 mg (0.5 mmol) of phenyl isocyanate at room temperature in CH 2 Cl 2 for 24 h. After standard work-up, this isocoumarin was obtained as yellow crystals; mp 203°-204° C.; MS, m/e 344 (M + ). Anal. Calc. for C 17 H 13 ClN 2 O 4 : C, 59.23; H, 3.08; N, 8.13; Cl, 10.28. Found: C, 59.28; H, 3.82; N, 8.11; Cl, 10.35.
7-benzylamino-4-chloro-3-ethoxyisocoumarin and 7-benzylamino-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 6
Preparation of 4-chloro-7-phenylthiocarbamoylamino-3-ethoxyisocoumarin
This compound was preparation by reaction of 7-amino-4-chloro-3-ethoxyisocoumarin with phenyl isothiocyanate at r.t. in THF for 24 hrs. The product was obtained as yellow solid: yield 55%, m.p. 176°-177° C. (dec.); TLC, R f =0.76 (CH 3 Cl:MeOH=9:1), MS m/e=374 (M + ). Anal. Calcd. for C 18 H 15 N 2 O 3 ClS: C, 57.62; H, 4.00. Found: C, 57.77; H, 4.04.
EXAMPLE 7
Preparation of 7-dihydrocinnamoylamino-4-chloro-3-propyloxyisocoumarin
This compound was synthesized by reaction of equimolar of 7-amino-4-chloro-3-propoxyisocoumarin, dihydrocinnamic acid chloride and triethylamine in dry THF. The reaction mixture was stirred overnight, and the solution was washed with water, 4% NaHCO 3 , water and dried over MgSO 4 . After filtration and evaporation, a yellow residue was crystallized from THF-pentane, yield 81%; mp 182°-184° C.; TLC, R f =0.74 (CH 3 Cl:MeOH=9:1); MS, m/e 385 (M + ). Anal. Calc for C 21 H 20 O 4 NCl.0.5H 2 O: C, 63.81; H, 5.32. Found: C, 63.47; H, 5.30.
7-phenoxycarbonylamino-4-chloro-3-ethoxyisocoumarin and 7-phenoxycarbonylamino-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 8
Preparation of 7-(Boc-valyl)amino-4-chloro-3-propyloxyisocoumarin
This compound was synthesized by reaction of an equimolar amount of 7-amino-4-chloro-3-propoxyisocoumarin and Boc-Val anhydride in THF. The reaction mixture was stirred overnight. The work-up as described above gives a yellow solid which was recrystallized from THF-pentane, yield 48%: mp 171°-173° C.; TLC, R f =0.8 (CH 3 Cl:MeOH=9:1); MS, m/e 452 (M + ). Anal. Calc. for C 22 H 29 O 6 N 2 Cl: C, 58.35; H, 6.41; N, 6.19; Cl, 7.83. Found: C, 58.40; H, 6.47; N, 6.20; Cl, 7.79.
7-(Boc-phenylalanyl)amino-4-chloro-3-propyloxyisocoumarin, 7-(benzoylalanylalanyl)amino-4-chloro-3-propyloxyisocoumarin, 7-(Boc-valyl)amino-4-chloro-3-ethoxyisocoumarin, 7-(Boc-alanyl)amino-4-chloro-3-ethoxyisocoumarin and 7-(Boc-alanyl)amino-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 9
Preparation of 7-ethylcarbamoylamino-4-chloro-3-propyloxyisocoumarin
This compound was synthesized by the reaction of an equimolar amount of 7-amino-4-chloro-3-propoxyisocoumarin and ethyl isocyanate in small amount of dry THF. The reaction mixture was stirred at r.t. for a few days. During this time the yellow crystals slowly crystallized out. After filtration, the compounds were recrystallized once more from THF-pentane, yield 45%; mp 189°-191° C.; TLC, R f =0.43 (CH 3 Cl:MeOH=9:1); MS, m/e 324 (M + ). Anal. Calc. for C 15 H 17 O 4 N 2 Cl: C, 55.42; H, 5.23. Found: C, 55.31; H, 5.28.
EXAMPLE 10
Preparation of 7-amino-4-chloro-3-(2-bromoethoxy)isocoumarin
This compound was prepared by cyclization of 1 equivalent of bromoethyl nitrohomophthalate with 2.5 equivalent of PCl 5 , followed by catalytic reduction of the nitro group. The product was yellow solid, mp 134°-137° C.; MS, m/e 317 (M + ). Anal. Calc. for C 11 H 9 NO 3 ClBr: C, 41.44; H, 2.83, N, 4.40. Found: C, 42.11; H, 2.87; N, 4.46.
EXAMPLE 11
Preparation of 7-(phenylcarbamoylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin
7-Amino-3-(2-bromoethoxy)-4-chloroisocoumarin was synthesized as described above. This compound (0.32 g, 1 mmole) was mixed with phenylisocyanate (0.12 g, 1 mmole) in 5 ml of THF and the reaction mixture was stirred at r.t. overnight. The product 7-(phenylcarbamoylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin precipitated out, yield 40%, mp. 215°-217° C.; MS, m/e 437.9 (M + ). Anal. Calc. for C 18 H 14 N 2 O 4 ClBr: C, 49.40; H, 3.22; N, 6.40; Cl, 8.10. Found: C, 49.48; H, 3.25; N, 6.34; Cl, 8.12.
7-(4-Fluorobenzyl)thiocarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin, and 7-(2,4-dimethylbenzyl)thiocarbamoylamino-4-chloro-3-(2-bromoethoxy)isocoumarin and 7-(4-fluorobenzyl)thiocarbamoylamino-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 12
Preparation of 7-(acetylamino)-4-chloro-3-(3-bromopropoxy)isocoumarin
7-Amino-3-(3-bromopropoxy)-4-chloroisocoumarin was synthesized similarly as described in Example 10. This compound (0.33 g, 1 mmole) was heated with 0.15 g of acetic anhydride (1.5 mmole) in 20 ml of dry THF. After a few minutes, yellow solid was precipitated out. After 3 hrs, the solution was concentrated to 5 ml, and the solid was filtered to give 0.37 g of 7-(acetylamino)-4-chloro-3-(3-bromopropoxy)isocoumarin, mp. 170°-172° C.; MS, m/e 375 (M + ). Anal. Calc. for C 14 H 13 NO 4 ClBr: C, 44.89; H, 3.50. Found: C, 44.95; H, 3.54.
EXAMPLE 13
Preparation of 7-(R-α-methylbenzylcarbamoylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin
This compound was synthesized by the reaction of 7-amino-4-chloro-3-(2-bromoethoxy)isocoumarin with R-α-methylbenzyl isocyanate as described above, mp. 183°-185° C.; MS m/e 464 (M + ). Anal. Calc. for C 20 H 18 N 2 O 4 ClBr: C, 51.58; H, 3.90. Found: C,51.66; H, 3.90.
EXAMPLE 14
Preparation of 7-(Boc-D-phenylalanylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin
Boc-D-Phe (0.33 g, 1.2 mmole) reacted with 1,3-dicyclohexylcarbodiimide (0.13 g, 0.6 mmole) in 10 ml THF at 0° C. for 1 hr to form the symmetric anhydride, and then 7-amino-4-chloro-3-(2-bromoethoxy)isocoumarin (0.2 g, 0.6 mmole) was added. The reaction was stirred at r.t. overnight and 7-(Boc-D-phenylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin was precipitated out (0.29 g, 71%), mp. 180°-182° C.; TLC, R f =0.95 (CH 3 Cl:MeOH=9:1); MS m/e=566 (M + ). Anal. Calc. for C 25 H 26 N 2 O 6 ClBr: C, 53.07; H, 4.63; N, 4.95; Cl 6.27. Found: C,53.25; H, 4.66; N, 4.87; Cl, 6.24.
7-(Benzoyl-L-alanylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin and 7-(benzoyl-L-alanylamino)-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
7-(D-Phenylalanylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin and 7-(alanylalanylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin can be prepared by deblocking the Boc group of 7-(Boc-D-phenylalanylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin and 7-(Boc-D-alanylalanylamino)-4-chloro-3-(2-bromoethoxy)isocoumarin with trifluoroacetic acid.
EXAMPLE 15
Preparation of 7-dansylamino-4-chloro-3-(2-bromoethoxy)isocoumarin
Dansyl chloride (0.17 g, 0.63 mmole) was mixed with 7-amino-4-chloro-3-(2-bromoethoxy)isocoumarin (0.2 g, 0.63 mmole) in 5 ml of THF, and Et 3 N (0.065 g) was then added. The reaction mixture was stirred at r.t. for a few days, and a yellow solid precipitated out. The final product was crystallized from THF/hexane, yield 41%, mp 114°-117° C.; MS, m/e 552 (M + +1). Anal. Calc. for C 23 H 21 N 2 O 5 ClBrS.1.5H 2 O: C, 47.63; H, 4.14. Found: C, 47.41; H, 4.27.
7-(p-Toluenesulfonyl)amino-4-chloro-3-(2-bromoethoxy)isocoumarin and 7-(p-toluenesulfonyl)amino-4-chloro-3-(2-phenylethoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 16
Preparation of 7-(biotinylamino)-4-chloro-3-(2-phenylethoxy)isocoumarin
Biotin acid chloride was prepared by incubating 0.4 g of biotin in 6 ml of thionyl chloride at 25°-35° C. for 1 hr, and excess thionyl chloride was removed under vacuum. The acid chloride was used for the next step without further purification. Biotin acid chloride and 7-amino-4-chloro-3-(2-phenylethoxy)isocoumarin (0.26 g) was dissolved in small amount of DMF, and then Et 3 N (0.08 g) were added. The reaction mixture was stirred at r.t. overnight. The product was purified by column chromatography, yield 0.1 g, mp 182°-185° C.; TLC, R f =0.25 (CH 2 Cl 2 :MeOH=15:1). Anal. Calc. for C 27 H 28 N 3 O 5 ClS.0.25 H 2 O: C, 59.39; H, 5.22, N, 7.70. Found: C, 59.08; H, 5.37; N, 7.94.
7-(Biotinylamino)-4-chloro-3-(pentafluoropropoxy)isocoumarin can be prepared by the same procedure.
EXAMPLE 17
Preparation of 7-[(6-biotinylamino)caproyl]amino-4-chloro-3-(2-phenylethoxy)isocoumarin
6-(Biotinylamino)caproic acid was prepared from N-hydroxysuccinimido biotinate (Jasiewicz et al., Exp. Cell Res. 100, pp 213-217 (1976)) and methyl 6-aminocaproic acid hydrochloride by a previously described method (Hofmann et al., Biochemistry 23, pp 2547-2553 (1984)). 6-(Biotinylamino)caproic acid chloride was synthesized and reacted with 7-amino-4-chloro-3-(2-phenylethoxy)isocoumarin as described above. The product was purified by column chromatography, mp 163°-167° C. Anal. Calc. for C 33 H 39 N 4 O 6 ClS.H 2 O: C, 58.72; H, 6.22; N, 8.96; Cl, 5.59. Found: C, 58.87; H, 6.14; N, 8.32; Cl, 5.27.
TABLE I__________________________________________________________________________Inhibition Constants for Inactivation of Elastases by 7-substituted-4-chloro-3-methoxyisocoumarins.sup.a. HLE PPECompounds [I] k.sub.obs /[I] [I] k.sub.obs /[I]7-Substituent (μM) (M.sup.-1 s.sup.-1) (μM) (M.sup.-1 s.sup.-1)__________________________________________________________________________NCO 1.8 9,200 8.3 650EtOCONH 2.3 47,000 8.3 2,000PhOCONH 1.8 13,000 8.8 850PhCH.sub.2 OCONH 1.6 71,000 136.0 260H.sub.2 NCONH 8.2 2,100CH.sub.3 NHCONH 3.3 9,460 13 1,300EtNHCONH 6.3 1,700i-PrNHCONH 3.0 9,000 12 2,300t-BuNHCONH 6.6 20,000 13 3,200PhNHCONH 2.0 49,000 8.3 7,300PhCH.sub.2 (PhCH.sub.2 CH.sub.2)NCONH 2.2 12,000 490.0 17C.sub.3 F.sub.7 CONH 2.7 47,000 17.0 1,100Fmoc-NH 2.5 10,000 600.0 20Tos-Phenylglycyl-NH 1.6 84,000 8.3 1,500o-HOOCC.sub.6 H.sub.4 CONH 1.8 52,000 17.0 2,700o-CH.sub.3 OOCC.sub.6 H.sub.4 CONH -- -- 8.3 7,100CH.sub.3 OOCCH.sub.2 CH.sub.2 CONH 2.3 43,000 17.0 2,200CH.sub.3 OOCCH.sub.2 CH.sub.2 CH.sub.2 CONH 2.3 54,000 8.3 2,800HOOCCH.sub.2 CH(Ph)CH.sub.2 CONH 1.6 66,000 8.3 3,100m-CH.sub.3 OOCNHC.sub.6 H.sub.4 CONH 1.4 100,000 17.0 2,500__________________________________________________________________________ .sup.a Inhibition constants were in 0.1 M Hepes, 0.5 M NaCl, pH 7.5 buffer, 8-9% Me.sub.2 SO and at 25° C.
TABLE II______________________________________Inhibition Rates of Inactivation of PorcinePancreatic Elastase by 7-Substituted-4-chloro-3-ethoxyisocoumarin.sup.a.Compounds [I] k.sub.obs /[I]7-Substituent (μM) (M.sup.-1 s.sup.-1)______________________________________EtO-CO-NH 9.6 3,500Et-NH-CS-NH 20-50 4,200Ph-NH-CS-NH 9-31 12,000______________________________________ .sup.a Inhibition rates were measured in 0.1 M Hepes, 0.5 M NaCl, 8.3% Me.sub.2 SO, pH 7.5 and at 25° C.
TABLE III__________________________________________________________________________Inhibition Rates of Inactivation of Serine Proteases by Derivativesof 7-Subsitituted-4-chloro-3-propyloxyisocoumarins.sup.a.Compounds k.sub.obs /[I] (M.sup.-1 s.sup.-1)7-Substituted PPE.sup.b HLE.sup.c Chymotrypsin.sup.d Cathepsin G.sup.e__________________________________________________________________________PhCH.sub.2 CH.sub.2 CONH >250,000 20CH.sub.3 CH.sub.2 OCONH 220 >181,000 12,000 138CH.sub.3 CH.sub.2 NHCONH 1,600 >276,000 5,200 166PhNHCONH 80 143,000 120 NIPHNHCSNH 520 >166,000 6,100PhCH.sub.2 NHCSNH >131,0003-NO.sub.2 --C.sub.6 H.sub.4 CONH >210,000 4CH.sub.3 SCH.sub.2 CONH >152,000 28Boc-Val-NH 64,000 17__________________________________________________________________________ .sup.a Inhibition rates were measured in 0.1 M Hepes, 0.5 M NaCl, 2.5% Me.sub.2 SO, pH 7.5 and at 25° C. .sup.b Inhibitor concentrations were 34-56 μM. .sup.c Inhibitor concentrations were 0.7-1.9 μM. .sup.d Inhibitor concentrations were 3.4-70 μM. .sup.e Inhibitor concentrations were 8.7-87 μM.
TABLE IV__________________________________________________________________________Inhibition of Serine Proteases by Biotin-Isocoumarin Derivatives.sup.a. k.sub.obs /[I] (M.sup.-1 s.sup.-1)Compounds Chymotrypsin.sup.b Cat. G.sup.c HLE.sup.d PPE.sup.e__________________________________________________________________________7-biotinylamino-4-chloro- 330 NI 740 NI3-(2-phenylethoxy)isocoumarin 1657-biotinylamino-4-chloro- 65 6.7 19,900 4703-propoxyisocoumarin7-(6-biotinylaminocaproyl)amino-4-chloro- 1,080 13% 670 NI.sup.f3-(2-phenylethoxy)isocoumarin 1907-(6-biotinylaminocaproyl)amino- 260 3.3 76,700 3504-chloro-3-propoxyisocoumarin7-(6-biotinylaminocaproyl)amino- 260 59 96,000 5204-chloro-3-ethoxyisocoumarin__________________________________________________________________________ .sup.a Inhibition was measured in 0.1 M Hepes, 0.5 M NaCl, pH 7.5 buffer, 5-10% Me.sub.2 SO and at 25° C. SucVal-Pro-Phe-NA (0.48 mM) was used as the substrate for chymotrypsin and cat G. MeOSuc-Ala-Ala-Pro-Val-NA (0.24-0.47 mM) and SucAla-Ala-Ala-NA (0.29-0.48 mM) were used as the substrate for HLE and PPE respectively. .sup.b Inhibitor concentrations were 20-400 μM. .sup.c Inhibitor concentrations were 75-400 μM. .sup.d Inhibitor concentrations were 2.0-78 μM. .sup.e Inhibitor concentrations were 38-78 μM. .sup.f No inhibition.
TABLE V__________________________________________________________________________Inhibition of Rat granule Serine Proteases by Biotin-IsocoumarinDerivatives.sup.a. [I] Rat Granule Chymase Rat Granule TryptaseCompounds (mM) % of inhibition.sup.b k.sub.obs /[I] (M.sup.-1 s.sup.-1)__________________________________________________________________________7-(6-Biotinylaminocaproyl)amino-4-chloro- 0.078 30-50 6-123-(2-phenylethoxy)isocoumarin7-Biotinylamino-4-chloro- 0.2 10-20 2-33-(2-phenylethoxy)isocoumarin__________________________________________________________________________ .sup.a Inhibition was measured at 0.1 M Hepes, 0.5 M NaCl, pH 7.5 buffer, 10% Me.sub.2 SO and 25° C. SucPhe-Leu-Phe-SBzl (0.14 mM) and ZGly-Arg-SBzl (0.06 mM) were used to measure chymase and tryptase activit respectively. .sup.b Inhibition was not time dependent.
TABLE VI__________________________________________________________________________Reactiviation of Inhibited Chymotrypsin and Rat Granule Chymase byBiotin-IsocoumarinDerivatives in Buffer and in the Presence of NH.sub.2 OH.sup.a. % of Enzyme Activity Reactivated [I] Chymotrypsin Rat granule chymaseInhibitor (μM) in buffer.sup.b +NH.sub.2 OH +NH.sub.2 OH__________________________________________________________________________7-(6-Biotinylaminocaproyl)amino-4-chloro- 39 6 503-(2-phenylethoxy)isocoumarin 78 0 40 30-507-Biotinylamino-4-chloro- 39 51 853-(2-phenylethoxy)isocoumarin 78 7 79 100__________________________________________________________________________ .sup.a Inhibition was performed at 0.1 M Hepes, 0.5 M NaCl, pH 7.5 buffer 10% Me.sub.2 SO and 25° C. Reactivation was carried out in the presence of 0.36 M of NH.sub.2 OH, and occurred immediately after the addition of NH.sub.2 OH. .sup.b Enzyme activity was measured after two days.
TABLE VII__________________________________________________________________________Inhibition Rates of Serine Proteases by 7-substituted-4-chloro-3-bromoalkoxyisocoumarinsand 7-amino-4-chloro-3-alkoxyisocoumarins.sup.a. k.sub.obs /[I] (M.sup.-1 s.sup.-1)Compounds PPE.sup.b HLE.sup.c Chymotrypsin.sup.d Cathepsin G.sup.e__________________________________________________________________________(I) 7-substituted-4-chloro-3-(2-bromoethoxy)isocoumarin7-NH.sub.2 1,000 200,000.sup.f 1,160 4107-NO.sub.2 6,330 65,600 98,000.sup.g 7107-(t-Bu-NH-CO-NH) 6,600 320 567-(isopropyl-NH-CO-NH) 4,470 646,000.sup.g 1340.sup.H 777-(Ph-NH-CO-NH) 36 1,200,000.sup.g 12 NI.sup.i7-(Ph-CH.sub.2 -NH-CO-NH) 3,010 480,000.sup.g 890 23%.sup.j7-(R-(C.sub.6 H.sub.5)(CH.sub.3)CH-NH-CO-NH) 9,900 >440,000.sup.g 180.sup.h 777-(S-(C.sub.6 H.sub.5)(CH.sub.3)CH-NH-CO-NH) 2,660 >570,000.sup.g 440 21%.sup.j7-(Naphthyl-NH-CO-NH) 76 390,000.sup.g 80 22%.sup.j7-((CH.sub.3).sub.3 C-CH.sub.2 CO-NH) 3,650 1,070 2407-(Ph-CH.sub.2 -CO-NH) 4,950 480,000.sup.g 82,000.sup.g 707-(Boc-D-Phe-NH) 30 150 19%.sup.j7-(Boc-L-Phe-NH) 50 400 19%.sup.j7-(Boc-Ala-Ala-NH) 1,670 230,000.sup.g 2,750.sup.h 46 810.sup.h7-(PhNHCSNH) 1,250 >480,000.sup.g 39,000.sup.g 2007-(m-COOH-PhNHCSNH) >240,000.sup.g 1,960 3207-(p-COOH-PhNHCSNH) >390,000.sup.g 1,720 450(II). 7-substituted-4-chloro-3-(3-bromopropoxy)isocoumarin7-NH.sub.2 10 4,000 790 2107-NO.sub.27-(Ph-NH-CO-NH) 4 13,750.sup.h 180 17%.sup.j 2,890.sup.h7-(Ph-CH.sub.2 -NH-CO-NH) 13 15,650 440 21%.sup.j7-(CH.sub.3 -CO-NH) 24 24,400 3,980 1707-(Ph-CH.sub.2 -CO-NH) 28 32,350 140,000.sup.g 28%.sup.j7-(Ph-CH.sub.2 CH.sub.2 CO-NH) 35,650.sup.h 600 NI 9,870.sup.h7-(Boc-D-Phe-NH) 1,480 70 NI7-(Boc-L-Phe-NH) 1,320 490 NI(III). 7-substituted-4-chloro-3-(2-bromoisopropoxy)isocoumarin7-NO.sub.2 1,060 200,000.sup.g 1,6607-NH.sub.2 62 24,000 320 150(IV). 7-amino-4-chloro-3-alkoxyisocoumarin3-CH.sub.3 CH.sub.2 CH.sub.2 O 4.3 390 375 613-CH.sub.3 CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 O 0.5 33 140 2.6__________________________________________________________________________ .sup.a Inhibition rates were measured in 0.1 M Hepes, 0.5 M NaCl, pH 7.5 buffer, 8-9% Me.sub.2 SO and at 25° C. Substrates were SucAla-Ala-Ala-NA (0.48 mM) for PPE; MeOSuc-Ala-Ala-Pro-Val-NA (0.24 mM) for HLE; SucVal-Pro-Phe-NA (0.48 mM) for chymotrypsin and cathepsin G. .sup.b Inhibitor concentrations were 0.04-2.0 mM. .sup.c Inhibitor concentrations were 0.07-710 mM. .sup.d Inhibitor concentrations were 1.7-58 mM. .sup.e Inhibitor concentrations were 35 -710 mM. .sup.f Progress curve method was used according to Tian & Tsou (1982) Biochemistry 21, 1028-1032. .sup.g Second order rate constant was obtained using equimolar concentration of inhibitor and enzyme. .sup.h Biphasic plot was obtained, and two inhibition rates were shown. .sup.i NI = No inhibition. .sup.j Percentage of inhibition was obtained after 5 min incubation of inhibitor with enzyme.
TABLE VIII______________________________________Half-Lives for Deacylation of Elastases Inactivated by7-Substituted-4-chloro-3-methoxyisocoumarins.sup.a.Compounds t.sub.1/2 (h)7-Substituted HLE PPE______________________________________HOOCCH.sub.2 CH.sub.2 CONH 1.5 1.3HOOCCH.sub.2 CH.sub.2 CH.sub.2 CONH 1.7 1.5o-HOOCC.sub.6 H.sub.4 CONH 5.0 17CH.sub.3 OOCCH.sub.2 CH.sub.2 CH.sub.2 CONH 1.0 1.0PhNHCONH >48 >48______________________________________ .sup.a Enzyme activity was followed after removal of excess inhibitors by centrifugation using Amicon centricon10 microconcentrator. | Substituted isocoumarins, their use in inhibiting serine proteases with chymotrypsin-like and elastase-like specificity and their roles as anti-inflammatory agents. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a heat-dissipating device and a housing thereof, and more particularly to an axial fan having an increased intake airflow rate without modifying the assembling conditions with other elements so as to greatly enhance the heat-dissipating performance of the fan, and a housing for the fan.
2. Description of the Related Art
A typical electrical product usually includes electrical elements positioned in a closed housing in order to prevent the electrical elements from being contaminated with particles in the air. However, since the electrical element (such as a central processing unit (CPU) or circuit board) raises its temperature during operation, the element tends to be consumed and the lifetime thereof tends to be shortened if the element is continuously kept at the high-temperature condition. Thus, a fan is typically disposed in the housing to dissipate heat to the outside in order to prevent the electrical element from failing.
As shown in FIG. 1 , a conventional fan 1 is mainly composed of a fan housing 11 and an impeller 12 . When the fan is operating, a motor may be used to drive the impeller 12 to rotate and to produce air streams flowing toward the electrical element in order to dissipate the heat generated from the electrical element. The fan housing includes an air inlet and an air outlet in communication with the air inlet via a central, cylindrical air passage 11 a . The air streams caused by the impeller 12 may freely flow into and out of the fan housing via the air passage. Furthermore, a plurality of tapered portions 13 , through which the air streams may smoothly flow into the air inlet side, are provided at the corners on the air inlet side of the air passage. In addition, a plurality of screw holes 14 is formed at four corners of the fan housing such that the fan may be mounted to a frame of an electrical apparatus (i.e., a computer) via the screw holes 14 .
However, due to the restriction in the dimension of the rectangular fan housing of the conventional fan, the air passage at the lateral side has to be reduced. The optimized design in the shape of the blade based on the curve of the air passage is also restricted, and the space and material of the fan housing are also wasted. Besides, due to the restriction in the construction of the fan housing, air may be taken into the fan only in the axial direction. However, it only can achieve very limited improvement effect in the increased intake airflow rate by doing so.
SUMMARY OF THE INVENTION
An object of the invention is to provide a heat-dissipating fan and a housing thereof, wherein an sidewall of the housing extends outwards to enlarge the intake airflow area thereof without modifying the assembling conditions between the existing fan and other heat dissipation elements, and the shape of the housing at the air outlet side is kept unchanged in order to enhance the heat-dissipating efficiency of the fan. The fan may be mounted to a system or other heat dissipation elements without changing the assembling conditions with the system and the heat dissipation elements.
Another object of the invention is to provide a heat-dissipating device and a housing thereof, wherein an sidewall of the housing extends outwards to enlarge its intake airflow area so that the impeller of the heat-dissipating device may increase its dimension with the outward extension of the housing. Thus, the airflow rate may be increased and the heat-dissipating efficiency may be enhanced.
Still another object of the invention is to provide a heat-dissipating fan and a housing thereof, wherein the air passage formed by the sidewall of the passage of the housing reduces gradually and evenly in its cross-sectional area. Thus, the air streams produced by the rotation of blades of the impeller of the heat-dissipating device can be effectively concentrated to the center and then blow to the center portion of the heat sink having the highest temperature when the heat sink is assembled with the heat-dissipating device so as to enhance its heat-dissipating efficiency.
According to the first aspect of the invention, the housing includes an outer frame having a passage for guiding air streams to flow from an opening to another opening, wherein an sidewall of the passage of one of the opening sides extends radially outwards so as to enlarge intake or discharge area for the air streams.
The sidewall of the passage extends radially outwardly with respect to a central axis of the passage in a symmetrical manner. In addition, the sidewall of the passage extends radially outwardly with respect to a longitudinal axis of the passage and beyond the peripheral edge of the outer frame. Alternatively, the sidewall of the passage extends radially outwardly with respect to a longitudinal axis of the passage in a frustum-conical or a frustum-elliptically conical manner.
Preferably, the sidewall of the passage is formed with an inclined portion or a beveled edge there around.
According to the second aspect of the invention, the housing includes an outer frame including an air inlet, an air outlet, and a passage for guiding air streams from the air inlet to the air outlet, wherein an sidewall of the passage at the air inlet side extends radially outwardly so as to enlarge an intake area of the air streams.
Preferably, the sidewall of the passage at the air inlet side extends radially outwardly with respect to a central axis of the passage in a symmetrical manner. Alternatively, the sidewall of the passage at the air inlet side extends radially outwardly with respect to a longitudinal axis of the passage and beyond the peripheral edge of the outer frame. Furthermore, the sidewall of the passage at the air inlet side extends radially outwardly with respect to a longitudinal axis of the passage in a frustum-conical or a frustum-elliptically conical manner.
Preferably, the sidewall of the passage is formed with an inclined portion extending from the air inlet to the air outlet.
Preferably, the radially outward extension of the sidewall of the passage at the air inlet side is partially cut off to form a notch in order to enlarge an intake area for lateral side air streams.
According to the third aspect of the invention, the heat-dissipating device includes an impeller and a housing for receiving the impeller, wherein the housing includes a passage for guiding air streams to flow from an opening to another opening, an sidewall of the passage at least one of the opening sides extends radially outwards so as to enlarge an intake/discharge area for the air streams. A dimension of a blade of the impeller increases along with the radially outwardly extending direction of the sidewall of the passage.
According to the fourth aspect of the invention, the heat-dissipating device includes an impeller and a housing for receiving the impeller, wherein the housing includes an air inlet, an air outlet, and a passage for guiding air streams from the air inlet to the air outlet, and an sidewall of the passage at the air inlet side extends radially outwards so as to enlarge an intake area of the air streams.
According to the fifth aspect of the invention, the heat-dissipating system includes a casing, at least one electrical element mounted within the casing, and a heat-dissipating device mounted on the casing for dissipating heat generated from the at least one electrical element when it operates, wherein the heat-dissipating device includes an impeller and a housing for receiving the impeller. Further, the housing includes a passage for guiding air streams to flow from an opening of the housing to another opening, and an sidewall of the passage at one of the openings extends radially outwardly with respect to a rotational axis of the heat-dissipating device so as to enlarge an intake/discharge area for the air streams.
Preferably, the heat-dissipating device is an axial fan.
Further, the heat-dissipating device includes a heat sink assembled with the housing.
According to the sixth aspect of the invention, the heat-dissipating system includes a casing, at least one electrical element mounted within the casing, and a heat-dissipating device mounted on the casing for dissipating heat generated from the at least one electrical element when it operates, wherein the heat-dissipating device includes an impeller and a housing for receiving the impeller. Further, the housing includes an air inlet, an air outlet, and a passage for guiding air streams to flow from the air inlet to the air outlet, wherein the sidewall of the passage at the air inlet side extends radially outwardly with respect to a rotational axis of the heat-dissipating device so as to enlarge an intake area for the air streams.
Other objects, features, and advantages of the invention will become apparent from the following detailed description of the preferred but non-limiting embodiments. The following description is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view showing a conventional fan.
FIG. 2A is a perspective view showing a heat-dissipating device according to a first preferred embodiment of the invention.
FIG. 2B is a top view showing the heat-dissipating device of FIG. 2A .
FIG. 2C is a cross-sectional view showing the heat-dissipating device taken along a line A-A′ of FIG. 2B .
FIG. 2D is a cross-sectional view showing the heat-dissipating device taken along a line B-B′ of FIG. 2B .
FIGS. 3A and 3B are cross-sectional views showing several modified structures of the housing for the heat-dissipating device of the invention, wherein FIG. 3A also shows the direction of the flow field.
FIG. 4A is a top view showing the housing for the heat-dissipating device according to another preferred embodiment of the invention.
FIG. 4B is a cross-sectional view showing the heat-dissipating device taken along a line C-C′ of FIG. 4A .
FIG. 5 is a top view showing a housing for the heat-dissipating device according to still another preferred embodiment of the invention.
FIG. 6 is a perspective view showing the heat-dissipating device according to another preferred embodiment of the invention.
FIG. 7 is a schematic illustration showing the heat-dissipating device of the invention mounted in a system frame having with electrical elements disposed therein.
FIG. 8A is an exploded, cross-sectional view showing the assembly of the heat-dissipating device of the invention and the heat sink.
FIG. 8B is a cross-sectional view showing the combination of the heat-dissipating device and the heat sink of FIG. 8A .
FIG. 8C is a perspective view showing the combination of the heat-dissipating device and the heat sink of FIG. 8A .
FIG. 9 is a schematic illustration showing the assembly of the heat-dissipating device of the invention and the heat sink, which is disposed in the framework with electrical elements.
FIG. 10 is another schematic illustration showing the assembly of the heat-dissipating device of the invention and the heat sink, which is mounted on the casing.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 2A to 2D , which show a heat-dissipating device according to a first preferred embodiment of the invention. The heat-dissipating device 2 is mainly composed of a housing and an impeller 22 . The housing includes a rectangular outer frame 21 having an air inlet, an air outlet, and a passage 23 connecting the air inlet to the air outlet. An sidewall 23 a of the passage extends radially outwards with respect to a rotational axis of the fan motor of the heat-dissipating device or an axis of passage, or even protrudes over the rectangular outer frame 21 . Since the air inlet side of the housing has a circular shape extending outwards, the bottom part of the housing is still kept as a rectangular shape, and screw holes 24 and their positions are kept unchanged, the way of assembling the housing with other elements is also kept unchanged. The dimension of the blade of the impeller can be enlarged along with the outward extension of the sidewall of the housing, and an inclined portion 231 can be formed at the sidewall of the housing, as shown in FIG. 2C . The inclined portion 231 can greatly enlarge the intake airflow area and reduce noises of the turbulent flow produced owing to uneven intake airflow area of the conventional fan. In addition, an inclined portion 232 can also be designed at the sidewall of the air outlet side of the housing, as shown in FIG. 2D , wherein the inclined portion 232 can significantly increase the heat-dissipating area of the air outlet side.
In addition to the designs of inclined portions towards different directions at the sidewall from the air inlet side to the air outlet side, the sidewall may be formed with an inwardly inclined portion from the air inlet side to the air outlet side of the housing, as shown in FIGS. 3A and 3B . In this case, the air streams can be concentrated toward the center to provide better heat-dissipating performance for the heat-dissipating device that requires concentrated air streams. In addition, the fan housing assembly housing may be formed with a beveled edge at the air inlet side around the screw holes so that the intake airflow area can also be enlarged.
Furthermore, in addition to the sidewall of the passage at the air inlet side extending radially outwards and protruding over the rectangular outer frame 21 , the same designs may be configured at the air outlet side. In other words, the sidewall of the passage at the air outlet side also extends radially outwards and protrudes over the rectangular outer frame 21 , as shown in FIGS. 4A and 4B , such that the sidewalls at the air inlet side and the air outlet side have a symmetrical structure with respect to a longitudinal axis L of the air passage including the same axis or a horizontal median plane H of the heat-dissipating device.
In addition that the sidewall of the passage at the air inlet side of the housing as shown in FIG. 2A evenly radially extends outwards in a circular manner, it can also be designed into an elliptic shape extending outwards in a symmetrical manner, as shown in FIG. 5 . In other words, the sidewall of the passage at the air inlet side of the housing can extend radially outwards in a symmetrical manner with respect to the longitudinal axis L of the air passage, that is, in a right-and-left or upper-and-lower symmetry from the top view of the housing.
In addition to the outward extension of the sidewall of the housing, when the lateral side of the housing cannot be extended owing to the dimensional limitation, a part of the side wall of the housing may be cut off to form a notch or notches, as shown in FIG. 6 . In this case, the intake airflow area at the lateral side can be enlarged, the air can be smoothly introduced, and the noise can also be reduced.
In practice, the heat-dissipating device 2 may be disposed within a system casing 3 in which electrical elements are mounted, as shown in FIG. 7 . Several heat sources or electrical elements, which will generate a lot of heat during operation, are mounted on a circuit board 4 . The heat-dissipating device 2 of the invention is mounted to a proper position (close to the heat sources) to discharge air streams toward the heat sources or electrical elements. Thus, the heat-dissipating efficiency can be enhanced, and it is possible to prevent the electrical elements from being damaged owing to high-temperature conditions.
In addition, the heat-dissipating device 2 of the invention may also be used with a heat sink 31 , which may be mounted to the heat-dissipating device 2 by screws 32 , as shown in FIGS. 8A to 8C . The assembly may be mounted to a central processing unit (CPU) 5 , as shown in FIG. 9 and FIG. 10 . That is, the bottom surface of the heat sink 31 is in close contact with the surface of the CPU 5 , and the heat generated by the CPU 5 during operation may be quickly conducted to the heat sink 31 . Then, the heat-dissipating device 2 produces cooling air streams to dissipate the generated heat. Moreover, the design of the inclined portion of the sidewall of the passage of the heat-dissipating device 2 of the invention may further be utilized to guide air streams toward the central portion of the heat sink having the highest temperature, and the heat-dissipating effects may be effectively achieved accordingly.
In summary, according to the aspect of the invention, the outward extension of the sidewall of the housing can greatly enlarge the air inlet area or air outlet area so as to enhance the heat-dissipating efficiency of the fan. In addition, the dimensions of the blades of the heat-dissipating fan can be enlarged along with the outward extension of the housing so that the airflow can be greatly increased and the heat-dissipating efficiency can be enhanced. Furthermore, the passage formed by the sidewall of the housing of the invention has a gradually reduced inner diameter formed from the inlet side to the outlet side (i.e., the formed passage has the inclined portion), and the air streams produced when the impeller rotates may be effectively concentrated to the central portion. Then, the air streams can directly flow toward the central portion of the heat sink having the highest temperature, and the heat-dissipating effects of the fan may be further enhanced.
While the invention has been described by way of examples and in terms of preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications. | A heat-dissipating device and a housing thereof. The housing includes a passage for guiding an air stream flowing from an opening to another opening, wherein an sidewall of the passage at least one of the opening sides extends radially outwards with a rotational axis of the heat-dissipating device or the passage so as to enlarge intake or discharge area for the air streams. Accordingly, the intake airflow rate may be greatly increased and the heat-dissipating efficiency of the heat-dissipating device may be greatly enhanced without changing assembling conditions with other elements. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This patent application is a continuation-in-part of U.S. patent application Ser. No. 10/224,168 (Attorney Docket No. CRD1061), filed on Aug. 20, 2002, entitled, “Guidewire With Deflectable Tip,” which is a nonprovisional patent application of U.S. patent application Ser. No. 60/366,739 (Attorney Docket No. CRD1035), filed on Mar. 22, 2002, entitled, “Deflection Wire Concept.”
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a steerable guidewire having improved torque characteristics, and more particularly to a bi-directional steerable guidewire having a tip which may be very precisely “steered,” and deflected. The guidewire is particularly suitable for use in conjunction with the insertion of a catheter into a vessel of the body, or alternatively, the guidewire may be used by itself to open obstructions within a vessel or to carry a therapeutic device for removing obstructions within a vessel.
[0004] 2. Description of the Prior Art
[0005] For many years guidewires have included a core wire with the distal end being tapered and with a coil spring mounted on the tapered distal nd. These guidewires have been used to facilitate the insertion of a catheter into a vessel of the body. Generally, the guidewire is inserted into a vessel, a catheter is inserted over the guidewire and the catheter is then moved through the vessel until the distal end of the catheter is positioned at a desired location. The guidewire is then retracted from the catheter and the catheter is left in the vessel. Alternatively, the guidewire may be first inserted into the catheter with the distal portion of the guidewire extending beyond the distal end of the catheter. This assembly is then inserted into a vessel with the distal tip of the guidewire being used to facilitate movement of the guidewire and catheter through the vessel. Again, when the distal tip of the catheter has been placed in a desired location, the guidewire may be retracted thereby leaving the catheter in place within the vessel.
[0006] Another common application for guidewires is that of using the distal tip of the guidewire for removing an obstruction within a vessel. Often times this procedure is accomplished by inserting the guidewire within a vessel, moving the distal tip of the guidewire into contact with the obstruction and then very gently tapping the distal tip of the guidewire against the obstruction until the guidewire passes through the obstruction. Alternatively, various types of devices may be placed on the distal end of a guidewire for actively opening an obstruction within the vessel. Examples of such devices which may be placed on the end of the guidewires in order to open an obstruction are disclosed in the following Robert C. Stevens U.S. Pat. Nos. 5,116,350; 5,078,722; 4,936,845; 4,923,462; and, 4,854,325.
[0007] While most guidewires used today do not include a mechanism for deflecting or steering the tip of the guidewire, it is very desirable to provide tip steering in order to facilitate movement of the guidewire through the tortuous vessels of the body. There are many patents directed toward different mechanisms for deflecting the distal tip of a guidewire in order to steer the guidewire. Examples of such guidewires are disclosed in the following patents: U.S. Pat. No. 4,815,478 to Maurice Buchbinder, et al., U.S. Pat. No. 4,813,434 to Maurice Buchbinder, et al., U.S. Pat. No. 5,037,391 to Julius G. Hammerslag, et al., U.S. Pat. No. 5,203,772 to Gary R. Hammerslag, et al., U.S. Pat. No. 6,146,338 to Kenneth C. Gardeski, et al., U.S. Pat. No. 6,126,649 to Robert A. VanTassel, et al., U.S. Pat. No. 6,059,739 to James C. Baumann and U.S. Pat. No. 5,372,587 to Julius G. Hammerslag, et al. U.S. Pat. No. 4,940,062 to Hilary J. Hampton, et al., discloses a balloon catheter having a steerable tip section. All of the above-identified patents are incorporated herein by reference.
[0008] While each of the latter group of patents disclose guidewires having some degree of steerability, there is a need to have a guidewire with very precise steering in a guidewire of a very small diameter which is suitable for the purposes described above. More particularly, there is an important need for a very small diameter guidewire having improved torque characteristics which includes a distal tip which may be deflected very precisely in either of two directions to enhance steerability.
SUMMARY OF THE INVENTION
[0009] In accordance with one aspect of the present invention, there is provided a very small diameter steerable guidewire having a deflectable tip which includes an elongated flexible tubing, a flexible helical coil attached to the distal portion of the flexible tubing, an elongated deflection member which is slidably disposed within the tubing and within the helical coil. The flexible helical coil is formed from an elongated member having a rectangular, or square cross section, and having continuous undulations wherein the undulations of adjacent turns interlock with each other, i.e., peak undulation of one turn interlocking with valley undulation of adjacent turn, to thereby enhance the rotational rigidity, referred to as torque characteristic, of the coil. The proximal portion of the deflection member is of a cylindrical configuration and the distal portion is tapered to form a deflection ribbon. Alternatively, the deflection member may take the form of a proximal cylindrical wire which is attached at its distal end to a deflection ribbon. In addition, a retaining ribbon is attached to the distal end of the flexible tubing and is oriented to extend in a plane which is generally parallel to the plane of the ribbon portion of the deflection member. An attachment member which may take the form of a rounded bead, preferably formed from epoxy, is bonded to the distal end of the helical coil, the distal end of the deflection ribbon and the distal end of the retaining ribbon so that longitudinal movement of the deflection member causes the distal end of the helical coil to be deflected. With the enhanced rotational rigidity of the coil portion or the guidewire, the entire guidewire has enhanced rotational rigidity.
[0010] In accordance with another aspect of the present invention, the continuous undulations take the form of a sinusoidal wave, or alternatively a square sinusoidal wave, having positive and negative peaks and in which the positive peaks of adjacent turns of coils engage negative peaks, or valleys, of adjacent turns.
[0011] In accordance with another aspect of the present invention, the retaining ribbon and the deflection ribbon are preferably pre-shaped into a curved configuration to thereby cause the flexible helical coil to be biased into a normally curved shape.
[0012] In accordance with a further aspect of the present invention, the distal portion of the deflection ribbon engages the attachment member, or rounded bead, at a location offset from the center of the attachment member, and the distal portion of the retaining ribbon engages the attachment member at a location offset from the center of the attachment member. Preferably, the retaining ribbon engages the attachment member at a location offset from the center portion of the attachment member in the opposite direction from the offset location of the deflection ribbon.
[0013] In accordance with still another aspect of the present invention, the deflection ribbon and the retaining ribbon are connected to each other within the attachment member. Preferably these two elements are formed as a single unitary element. In a preferred embodiment of the invention the cylindrical deflection member is flattened to form the deflection ribbon and is further flattened at its distal end to form the retaining ribbon. The retaining ribbon is bent 180 degrees with respect to the deflection ribbon to form a generally U-shaped bend to thereby establish a predetermined spacing between the ribbons and to also cause these ribbons to remain parallel to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is an enlarged elevational view of a balloon on a guidewire having a deflectable tip and control handle in accordance with the one aspect of the present invention;
[0015] [0015]FIGS. 2 and 2A are enlarged elevational sectional views showing the distal end of the balloon on a guidewire in its normal pre-shaped position;
[0016] [0016]FIG. 3 is an enlarged sectional view showing the distal end of the steerable guidewire of FIG. 2 rotated 180 degrees; and,
[0017] [0017]FIGS. 4 and 5 are sectional views showing the steerable guidewire deflected from its normal position to opposite extremes of deflection.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] [0018]FIG. 1 generally illustrates a steerable guidewire system 10 which embodies the present invention and comprises a steerable guidewire 12 coupled to a control handle 14 . More particularly, the steerable guidewire comprises an elongated hypotube 16 , a helical coil 18 attached to and extending from the distal end of the hypotube 16 . The helical coil 18 is of a rectangular or square cross-sectional configuration and is preferably formed from platinum tungsten with the proximal turns being wound such that adjacent turns of the proximal portion are in contact, or loosely interlocked with each other.
[0019] While the preferred embodiment of the present invention includes the helical coil 18 , this element may take the form of any flexible rectangular or square cross-sectional member, such as for example a thin square metallic tube with or without portions of the tube removed, for example laser cutting, so as to form a very flexible cylindrical or square member. An elongated deflection member 20 extends from the proximal end of the control handle through the hypotube 16 and through the helical coil 18 , and is connected into an attachment member, or rounded bead 22 , which is disposed at the distal tip of the helical coil 18 . In addition, a retaining ribbon 24 is connected to the distal end of the hypotube 16 and is also connected to the rounded bead 22 .
[0020] The control handle 14 generally comprises a slidable control knob 26 which may be moved longitudinally with respect to the control handle. The control handle 14 is coupled to the deflection member 20 . As will be discussed in more detail, the longitudinal movement of the slidable control knob 26 causes deflection of the distal tip of the guidewire in either an upward or downward direction.
[0021] [0021]FIGS. 2, 2A and 3 illustrate in more detail the distal portion of the steerable guidewire 12 . As may be appreciated, FIG. 3 is a view of the guidewire 12 shown in FIG. 2 with the guidewire being rotated 90 degrees about its longitudinal axis. More particularly, the proximal end of the helical coil 18 is bonded, preferably by use of an epoxy, to the outer surface near the distal end of the hypotube 16 . The elongated deflection member 20 takes the form of a small diameter cylindrical deflection member 20 having an intermediate portion which is flattened to form a thin deflection ribbon 34 having a thickness of approximately 0.002 inches. The distal end of the cylindrical deflection member 20 is further flattened to a thickness of approximately 0.0015 inches and is bent back 180 degrees to form a U-shaped bend 26 a between the deflection ribbon 34 and the retaining ribbon 24 . The proximal end of the retaining ribbon 24 is bonded, preferably by use of epoxy, to the outer surface of the distal end of the hypotube 16 . The retaining ribbon 24 is aligned in a plane parallel to the plane of the deflection ribbon 34 and the U-shaped portion between the ribbons is encapsulated by the attachment member which preferably takes the form of a rounded epoxy bead 22 bonded to the distal tip of the helical coil 18 .
[0022] As may be appreciated, with this unitary construction of the ribbon members, these members remain aligned so that both lie in planes parallel to each other. In addition, the U-shaped bend portion when encapsulated into the rounded bead 22 causes the retaining ribbon and deflection ribbon to be properly spaced with respect to each other.
[0023] As illustrated in FIG. 2, the retaining ribbon 24 is preferably attached to the rounded bead 22 at a position offset from the center of the bead in the same direction that the retaining ribbon 24 is offset from the longitudinal axis of the steerable guidewire 12 . In addition, the deflection ribbon 34 is attached to the bead at a position offset from the center of the bead in an opposite direction from the offset of the retaining ribbon 24 .
[0024] Also, as may be seen in FIG. 2, the deflection ribbon 34 and the retaining ribbon 24 are pre-shaped into an arcuate, or curved, configuration to thereby maintain the helical coil 18 in a normally curved configuration. The ribbons 24 , 34 are pre-shaped such that the distal tip of the guidewire curves away from the longitudinal axis of the guidewire in a direction toward that side of the guidewire containing the retaining ribbon 24 .
[0025] The helical coil 18 is formed as an elongated member having a rectangular, or square, cross-sectional configuration and wound in a helical configuration. In addition as illustrated in FIG. 2A, the elongated member is formed with re-occurring steps, or step undulations, which when wound into a helical configuration so that adjacent turns to loosely interlock thereby preventing movement between adjacent turns. Such interlocking turns enhance the rotational rigidity or “torqueability” of the coil such that when the proximal end of the coil is rotated 180 degrees, the distal end of the coil will rotate approximately 180 degrees. Accordingly, the distal end of the coil more nearly tracks, rotationally, the proximal end of the coil thereby significantly improving the “tortional” characteristics of the coil. By improving the “tortional” characteristics of the coil, the overall “tortional” characteristics of the guidewire are significantly improved.
[0026] As opposed to winding an elongated member to form the helical coil 18 , a preferred method of forming the helical coil is by laser cutting the coil from a single thin-walled tube of an alloy in the undulations locking, stepped configuration as illustrated in FIG. 2A. Such laser cutting provides a coil with precise mating surfaces to assure proper interlocking between adjacent turns of the helical coil.
[0027] In operation, as previously described, the distal tip of the steerable guidewire 12 is normally biased into a downwardly curved position as illustrated in FIG. 2 because of the curve of the pre-shaped deflection ribbon 34 and the retaining ribbon 24 . When the slidable control knob 26 is moved distally as shown in FIG. 5, the deflection member 20 will be moved distally thereby causing the deflection ribbon 34 to move in a distal direction. As the deflection ribbon is moved distally, a pushing force is applied to the top portion of the rounded bead 22 . The retaining ribbon 24 is attached to the lower portion of the bead 22 to thereby maintain the bead at a fixed distance from the distal end of the hypotube 16 . As the deflection ribbon 34 is moved to the right, the tip of the guidewire is caused to deflect downwardly to a maximum deflected position.
[0028] Since the deflection ribbon 34 and the retaining ribbon 24 are pre-shaped prior to any activation of the steerable guidewire, the amount of force required to deflect the guidewire in this direction is very small thereby preventing buckling of the deflection ribbon 34 as the deflection ribbon is pushed distally. As the deflection ribbon 34 is moved distally, the upper turns of the helical coil become slightly stretched and the lower turns of the coil become slightly compressed. The deflection member 20 has a diameter of about 0.0065 inches and the deflection ribbon has a thickness of about 0.002 inches to thereby provide sufficient stiffness to prevent the buckling of these elements when the deflection member 20 is pushed distally. This construction also provides sufficient stiffness to transmit the necessary force from the proximal end to the distal end of the guidewire.
[0029] When the slidable control knob 26 is moved in a proximal direction as shown in FIG. 4, the deflection member 20 will be pulled to the left to thereby cause the deflection ribbon 34 to pull on the top portion of the bead 22 . Since again the retaining ribbon 24 causes the lower portion of the bead to remain at a fixed distance from the distal end of the hypotube 16 , the tip of the guidewire 12 is caused to bend in an upward direction to a maximum deflection as shown in FIG. 4. Since the deflection ribbon 34 is in tension when the deflection member 20 is pulled, there is no concern for buckling of the deflection ribbon 34 . As the deflection ribbon 34 is moved proximally, the upper coil turns become slightly compressed and the lower coil turns become somewhat stretched.
[0030] As previously discussed, when the proximal end of the guidewire 12 is rotated by a physician to “steer” the distal end of the guidewire, with the interlocking turns of adjacent coils of the helical coil 18 , the distal tip will rotate on a one-to-one basis with respect to the proximal end of the hypotube 16 . In other words, there is no “play” or “lag” between rotation of the proximal end and the distal end of the guidewire.
[0031] In a preferred mbodiment of the present invention, the elongated deflection member 20 , retaining ribbon 24 and deflection ribbon 34 are constructed of nitinol, but these elements may be formed from other flexible materials including polymers. The helical coil 18 preferably formed by laser cutting as previously discussed, is constructed from an alloy comprised of about 92 percent platinum and 8 percent tungsten, but this element may also be constructed from numerous other materials. It is desirable that the coil exhibit the characteristic of being radiopaque to X-rays to assist in the positioning of the distal tip of the steerable guidewire 12 . The deflection member 20 is formed from a single cylindrical nitinol wire of about 0.0065 inches in diameter having an intermediate portion which is flattened to form the deflection ribbon 34 with a thickness of about 0.002 inches, and a distal portion which is flattened to form the retaining ribbon 24 with a thickness of about 0.0015 inches. The retaining ribbon 24 is bent back 180 degrees to form a generally U-shaped bend, which is subsequently encapsulated within the rounded bead 22 . The rounded bead 22 is preferably formed with epoxy, but may be formed with soldering or by welding.
[0032] It has been found that the addition of graphite between the deflection member 20 and deflection ribbon 34 , and the inner lumen of the hypotube 16 provides lubrication. Other lubricants, such as Teflon or MDX may be used for this purpose. The helical coil 18 is preferably coated with an elastomeric polymer 41 on its distal end to act as a sealant preventing the entry of blood and contrast media into the guidewire and a fluorinated polymer 39 , such as Teflon, on its proximal end for lubrication purposes.
[0033] It may be seen that the guidewire as disclosed may be very easily and very precisely rotated and then deflected in either of two directions for very precise steering of the guidewire through the vessels of the body. As may be apparent, the disclosed guidewire may be used for placement of a catheter within the vasculature of the human body, it may be used by itself to cross an obstruction within the vessels or it may be used to carry a therapeutic device mounted on the distal end of the guidewire for purposes of removing obstructions which may exist within a vessel of the body.
[0034] The preceding specific embodiment is illustrated of the practice of this invention. It is to be understood, however, that other variations may also be employed without departing from the spirit and scope of the invention as hereinafter claimed. | A bi-directional steerable guidewire having a deflectable distal tip which comprises a longitudinal hypotube and an interlocking spring coil attached to the distal end of the hypotube and also includes a longitudinally movable deflection member which is attached to the distal end of the spring coil and a tip retaining member which extends from the distal end of the hypotube to the distal end of the spring coil for providing very precise deflection of the distal tip. | 0 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/564,939, filed 17 Jul. 2006, entitled “Apparatus and Method for Measuring Concentrations of Scale-Forming Ions” which is incorporated herein by reference and which was based on PCT application PCT/GB2004/003040, filed 12 Jul. 2004, entitled “Apparatus and Method for Measuring Concentrations of Scale-Forming Ions”. This application claims priority under 35 U.S.C. 119 from Great Britain Patent No. 2404252, filed 24 Jul. 2003, entitled “Measuring concentrations of ions in downhole water”.
FIELD OF INVENTION
This invention relates to the determination of ion concentrations in downhole water from hydrocarbon wells, aquifers etc. This is useful in a wide range of applications, including predicting the formation of scale and fingerprinting waters from different sources.
BACKGROUND
The prediction of the location and type of mineral scale that may form around or within the production or surface facilities of an oil well is an important factor both in the design of the well and the formulation of strategies to cope with the mineral scale.
Current methods for predicting mineral scale formation involve the retrieval of samples from downhole, which are then either analyzed at the surface or else sent off to laboratories for analysis. Errors and delays can arise from this ex situ analysis.
Electrochemical methods have previously been developed for the measurement of the concentration of a number of different metal ions, and some have been deployed in shallow boreholes, lakes and ocean waters. However, the application of these methods to oilfield operations has been limited, as the high temperatures (up to 175 Celsius) and pressures (up to 1500 bar) common to most reservoirs, make their use impractical. Furthermore, many electrochemical methods are not able to distinguish between the principal metal ions (Ca 2+ , Ba 2+ and Sr 2+ } responsible for scale formation. This problem is compounded by the low concentrations of these ions (about 10 s mg/L) in formation water which is often highly saline.
The ability to rapidly and conveniently distinguish scaling ions may also find application, for example, in fingerprinting waters flowing into a hydrocarbon well from different producing zones. This information, which is indicative of connectivity between different zones of a producing well, may allow the optimization of production strategies for recovering the oil in place.
SUMMARY OF THE INVENTION
An object of the invention is to provide improved methods for the measurement of the scaling ions, which are suitable for use in situ i.e. in a continuous connection to a flow of fluid.
Accordingly, a first aspect of the invention provides an apparatus for determining the concentration of scaling ions in downhole water; the apparatus comprising a ligand which binds scaling ions from a flowing fluid, which could be downhole water, said ligand having an electronic configuration which is altered on binding of a scaling ion, and a detector for determining alterations in said electronic configuration, the amount of said alterations being indicative of the concentration of the scaling ion in the sample.
Preferably the ligand is contained within an electrochemical cell and changes in the electroactivity of the ligand are determined, for example amperometrically or voltammetrically. In other embodiments, the binding of a scaling ion may alter the fluorescent properties of the ligand. Changes in the fluorescence of the ligand upon binding of the ligand may be determined using any of a range of conventional techniques.
The apparatus may comprise a single ligand which binds specifically to a single scaling ion, such that changes in the electronic configuration of the ligand are directly related to the concentration of the scaling ion in the sample water.
More preferably, the apparatus may contain two or more different ligands, for example three, four, or five or more. Alterations in the electronic configuration of each ligand may be determined independently, either simultaneously or sequentially.
In some embodiments, each ligand may bind specifically to a different scaling ion. Changes in the electronic configuration of each ligand are directly related to the concentration of the corresponding scaling ion in the sample water.
In other embodiments, each ligand may bind to two or more different scaling ions. Changes in the properties (i.e. the electronic configuration) of each ligand are directly related to the concentration in the sample water of the two or more scaling ions to which that ligand binds. The different electronic response of the ligand to different ions can be translated into a respective concentration measurements, for example by locating the peaks in a voltagram.
Alternatively, each ligand may bind to a different combination of scaling ions such that the concentration of each individual scaling ion in the sample water may be calculated from the measurements determined for two or more different ligands.
An advantage of the apparatus is that it allows in situ analysis to be performed, thereby avoiding the problems associated with transporting samples to the surface for ex situ analysis. The present invention is partly based on the realisation that electrochemical techniques can be adapted for performance downhole, i.e. in relatively demanding and hostile conditions.
Preferably the detector is operably connected to a processor for determining the concentration of scaling ions from the current or potential in the cell. In some embodiments, the apparatus is adapted for use downhole (i.e. in a hydrocarbon well or aquifer). The processor may also be adapted for use downhole, or alternatively it may be intended for remote installation e.g. at the surface. For example, the processor may be a suitably programmed computer.
A further aspect of the invention provides for the use of apparatus as described herein for in situ measurement of scaling ion concentration.
In another aspect the invention provides a method of monitoring the concentrations of scaling ions in downhole water comprising;
contacting a sample of downhole water with a ligand which selectively binds scaling ions, wherein the binding of scaling ions in said sample to the ligand alters the electronic configuration of the ligand;
measuring changes in the electronic configuration of the ligand; and,
determining the concentration of said scaling ion from said changes in electronic configuration.
BRIEF DESCRIPTION OF THE FIGURES
Specific embodiments of the invention will now be described with reference to the following drawings, in which:
FIGS. 1A and 1B show examples of an apparatus according to the invention.
FIGS. 2 to 5 show examples of ligands suitable for use in accordance with the invention.
FIG. 6 shows a voltagram measured using a ligand of FIG. 5 in an ion-free fluid and a fluid with Ba-ions.
FIG. 7 shows a flow diagram of a method in accordance with an example of the present invention.
FIG. 8 shows an example of a scale sensor in a downhole application.
DETAILED DESCRIPTION OF THE INVENTION
In general terms, the present invention relates to the measurement of concentration of ions in downhole water, in particular ions responsible for scale formation by means of changes in the electronic configuration of a ligand which binds scaling ions. A preferred approach involves the use of an electrochemical cell containing a ligand whose electroactivity changes on binding a scaling ion. Changes in ligand electroactivity upon ion binding alter the electrochemical properties of the cell and may be measured using a detector. Other approaches may comprise the use of a ligand whose fluorescent properties change on binding of a scaling ion.
Downhole water may be comprised within a production fluid from a hydrocarbon well or reservoir, which may comprise hydrocarbons, drilling mud etc. The downhole water may, for example, be connate water.
Scaling ions are ions which are responsible for the formation of scale. The principal scaling ions in downhole water are Ca 2+ , Ba 2+ and Sr 2+ . A suitable ligand may bind selectively to one or more of these scaling ions e.g. a ligand may bind to Ca 2+ , Ba 2+ and Sr 2+ . Preferably, a ligand shows substantially no binding to other ions.
In some embodiments, the ligand may have a different binding affinity for each of the three principal scaling ions (Ca 2+ , Ba 2+ and Sr 2+ ), allowing the levels of each individual ion in the downhole water to be determined. Discrimination between different ligands may be achieved, for example, by determining the characteristic redox properties of each ligand at different potentials.
The ligand may be present in the cell in an aqueous solution at a concentration of 0.1 to 10 mM, preferably 1 to 10 mM, or may be dispersed within a porous polymer membrane.
Ligands suitable for use in accordance with the invention are stable and able to bind scaling ions under downhole conditions, for example at high temperature (e.g. up to 175° C.) and pressure (e.g. up to 1500 bar).
One class of suitable ligands have the formula (I):
where R1 is a C 1-5 alkyl (including, e.g. unsubstituted C 1-5 alkyl and substituted C 1-5 alkyl) or C 1-8 aryl (including, e.g. unsubstituted C 1-8 aryl and substituted C 1-8 aryl); and,
R2 to R9 may independently be H, halogen (F, Cl, Br, I); C 1-5 alkyl group; O—C 1-5 alkyl group; COOH; NH 2 ; —CONH 2 ; CO—C 1-5 alkyl group; or a fluorophore group such as carboxy-X-rhodamine (ROX), tetramethylrhodamine (TAMRA) and fluorescein (FAM).
“C 1-5 alkyl” pertains to a monovalent moiety obtained by removing a hydrogen atom from a C 1-5 hydrocarbon compound having from 1 to 5 carbon atoms, which may be aliphatic or alicyclic, or a combination thereof, and which may be saturated, partially unsaturated, or fully unsaturated.
Examples of suitable ligands according to formula I are shown in FIG. 2 .
In some embodiments, the aromatic rings of suitable ligands may comprise substitutions in the ortho, meta or para positions (i.e. at one or more of positions R2 to R9), in order to shift the redox features of a ligand to allow scanning for the different ions in well-separated spectral windows, in order to prevent interference.
For the purpose of this invention the above class of ligands are referred to as O,O′-Bis(2-aminophenyl)ethyleneglycol-N,N,N′,N′-tetraacetic acid or BAPTA derivatives.
Other suitable ligands may include cryptands (Lehn & Sauvage (1975) J. Am. Chem. Soc. 97 23 6700), for example a ligand shown in FIG. 3 , and thymolphtalein and their derivatives (Qing and Yuying (1987) Talanta 34 6 555), for example ligands shown in FIG. 4 . Other suitable ligands may include neutral ionophores (Simon et al Anal. Chem. 1985, 57, 2756), specific crown ethers (D. J. Cram et al J. Am. Chem. Soc., 1973, 95, 3021) or antibiotics such as valinomycin.
A further ligand of the cryptand family is shown in FIG. 5 . The cryptand is derivatized by a redox-active group or moiety M. The entity M can be selected for example from a group consisting of Fe, Ru, Co, V, Cr, Mo, and W and n and m can range from 1 to 3.
For the purpose of this invention, ligands of the type of FIGS. 3 and 5 are referred to as crypt and derivatives.
The apparatus may further comprise a porous membrane or porous electrode block which allows ions within the downhole water to pass into the cell to contact the ligand. A suitable porous membrane may be made of zeolite or a ceramic material. A block may be made of epoxy material as base material.
The membrane may be contacted with discrete samples or batches of downhole water or the membrane may be contacted with a continuous flow of downhole water.
The apparatus may comprise one or more liquid guidance channels to direct downhole water to the membrane and to remove downhole water after contact with the membrane.
The detector may comprise one or more electrodes which contact the ligand. Various arrangements of electrodes may be used as is conventional in electrochemistry.
Conveniently a three-electrode arrangement consisting of a working electrode, a reference electrode and a counter electrode may be used. Preferably, the working electrode is composed of a material resistant to fouling, such as boron-doped diamond or glassy carbon, the counter electrode is platinum and the reference electrode is Ag/AgCl. Other suitable electrode materials, such as AgI, are known to those skilled in the art.
The electrodes may be used to detect changes in the electroactivity of the one or more ligands. For example, electroactivity changes caused by the presence of scaling ions may alter the current flow or voltage between electrodes. Current or voltage may be detected or measured by the detector. For example, the potential of the electrodes may be varied and the current measured or vice versa. The current or potential difference associated with the electroactivity of each of the one or more ligands may be measured by the detector and correlated with the concentration of scaling ions in the downhole water sample. In the presence of the target ions, the peak current(s) should increase, proportional to the concentration of the target species. A power source may be connected to the electrodes to drive the current between the electrodes. The power source may be an integral part of the apparatus, and, for example, may be comprised within the detector. In other embodiments, the power source may be separate from the apparatus and connectable thereto. The apparatus may comprise appropriate circuitry for connection to the power source.
The ligand may be contained within the apparatus in any of a number of ways. In some embodiments, the ligand may be dispersed in an aqueous solution within a chamber of the apparatus. In other embodiments, the ligand may be dispersed within a porous polymer membrane. Binding of the scaling ions by the ligand occurs within the pores of the membrane and resultant changes in current or potential are detected by circuitry connected directly to the membrane via the working, counter and reference electrodes. The use of a porous membrane is convenient in allowing the miniaturisation of the voltammetric or amperometric sensor, thus leading to faster response times, lower consumption of reagents and lower unit costs.
In other embodiments, the ligands may be attached to conducting solid particles, such as carbon or a metal (e.g., gold), which are incorporated into the surface of one or more of the electrodes, preferably, the working electrode. The accumulation of particles with attached ligand forms a conducting porous electrode with ligand attached to the walls of the pores. Suitable techniques for fixing the particles to the electrode surface include epoxy resin adhesion or abrasive immobilisation. A porous electrode for hydrogen sulfide determination, for example, is described in co-pending published United Kingdom application GB-A-2391314.
For example, the ligand (I) above may be designed such that group R8 is an amine (—NH 2 ), which can be reacted with nitrous acid to form the diazonium ion —N + ≡N and subsequently coupled to carbon particles by reduction of the diazonium group by hypophosphorous acid. The ligand is thus chemically bonded to the carbon particles and these can be incorporated into the working electrode 4 as described above. In other embodiments, the ligand (I) above may be coupled to gold particles with one of the groups R2 to R9 being either an amine (—NH 2 ) or a thiol (—SH).
As described above, the detector may be operably connected to a processor that determines the concentration of scaling ions in the sample from the current or potential difference measured by the detector. The processor may be separate from or part of the detector. The processor may also be adapted for use under downhole conditions (i.e. high temperature, high pressure and high salinity). Alternatively, it may be intended for remote installation e.g. at the surface. For example, the processor may be a suitably programmed computer.
The measurement of scaling ion concentrations as described herein may be useful in downhole sampling, production logging to characterize flow into the well, and thereby aid remediation or production strategies, and in permanent monitoring applications, where the build up of scale or water breakthrough/flooding of the reservoir might be gauged.
FIG. 1A shows a cross-sectional diagram of an apparatus according to one embodiment of the invention. The apparatus is shown separated into an upper and a lower part as in a stage of being assembled. Inlets 11 and outlets 12 for sampling downhole water are indicated by arrows pointing in the direction of the flow. The sample water contacts a membrane 13 A which allows the passage of ions into the cell 14 . The ligand solution in the cell 14 is contacted by a Ag/AgCl reference electrode 15 , a platinum ring counter electrode 16 and a glassy carbon working electrode 17 . The electrodes 15 , 16 and 17 detect changes in the electroactivity of ligand in the cell 14 which are related to scaling ion concentration.
In the variant of FIG. 1B , a scale sensor 20 is shown coupled to a flowline 23 . The body 21 of the sensor is fixed into the end section of an opening 22 . The body carries a microporous epoxy matrix 211 embedding the catalysts 214 and contacts 212 that provide connection points to voltage supply and measurement through a small channel 221 at the bottom of the opening 22 . A sealing ring 213 protects the contact points and electronics from the wellbore fluid that passes under operation conditions through the sample channel 23 .
In an example according to an embodiment of the invention, the four ligands (2A-2D) shown in FIG. 2 may be present in solution in cell 14 or embedded in block 211 .
These ligands have different binding properties; ligand 2A binds Ca 2+ , Sr 2+ and Ba 2+ ; ligand 2B binds Ca 2+ and Sr 2+ , ligand 2C binds Sr 2+ and Ba 2+ and ligand 2D binds Ba 2+ .
The level of Sr 2+ in the sample water may be determined, for example, by measuring the alterations of the electroactivities of ligands 2C and 2D in the cell and then subtracting the value obtained for ligand 2D from value obtained for ligand 2C, to provide a value which represents the concentration of Sr 2+ . (i.e. 2C−2D=[Sr 2+ ]). As above the figure label is taken as a representative of the respective ligand and/or the concentration measurement associated with it.
The level of Ca 2+ in the sample water may be determined by measuring the alterations of the electroactivities of ligands 2B, 2C and 2D in the cell. The values for ligands 2B and 2D are added together and the value obtained for ligand 2C is subtracted from this combined figure, to provide a value which represents the concentration of Ca 2+ . (i.e. 2B+2D−2C=[Ca ++ ]).
The level of Ba 2+ in the sample water is determined by measuring the alterations of the electroactivities of ligands 2A and 2B in the cell and then subtracting the value obtained for ligand 2B from the value obtained for ligand 2A, to provide a value which represents the concentration of Ba 2+ . (i.e. 2A−2B=[Ba 2+ ] or ligand 2D).
The chemical structure of further examples of ligands are shown in FIGS. 3 and 4 . The indices n and m of the ligand in FIG. 3 can be 1 or 2. FIG. 5 shows the example of a crypt and modified with a redox active moiety. The entity M can be selected from a group consisting of Fe, Ru, Co, V, Cr, Mo, and W and n and m can range from 1 to 3.
In FIG. 6 there is shown the response of the ligand of FIG. 5 with M=Fe and n=m=2 to the presence of Ba 2+ . The solid line 51 is the typical electrochemical response of the pure ligand, whereas the dashed line 52 is the same response in the presence of Ba cations. The ligand of FIG. 5 is sensitive to more than one species of scale-forming ions and the presence of different ions can be readily detected from determining the peak locations in the voltagramm. This ligand thus alleviates the need to use multiple ligands. Square wave voltametry may be used instead of the shown full cycle voltametry.
The flowchart of FIG. 7 summarizes steps of a method exemplary of the present invention, including the step 71 of contacting a sample of for example downhole water with a ligand which selectively binds scaling ions, the step 72 of measuring changes in the electronic configuration of the ligand, and the step 73 of determining the concentration of the scaling ions from the change in electronic configuration. The results of the measurement may be fed into a model 74 that predicts the built-up of scaling in tubulars and other flow exposed equipment, for example production tubing or downhole pumps.
An application of the sensor is illustrated in FIG. 8 . It shows a Venturi-type flowmeter 810 , as well known in the industry and described for example in the U.S. Pat. No. 5,736,650. Mounted on production tubing or casing 812 , the flowmeter is installed at a location within the well 811 with a wired connection 813 to the surface following known procedures as disclosed for example in the U.S. Pat. No. 5,829,520.
The flowmeter consists essentially of a constriction or throat 814 and two pressure taps 818 , 819 located conventionally at the entrance and the position of maximum constriction, respectively. Usually the Venturi flowmeter is combined with a densiometer 815 located further up- or downstream.
The novel scale sensor 816 is preferably located downstream from the Venturi to take advantage of the mixing effect the Venturi has on the flow. A recess 817 protected by a metal mesh provides an inlet to the unit.
During production wellbore fluid enters the recess 817 and is subsequently analyzed using sensor unit 816 . The results are transmitted from the data acquisition unit to the surface via wires 813 .
While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention. | This invention relates to methods and apparatus for determination of ion concentrations, particularly in downhole water from hydrocarbon wells, aquifers etc. It is useful in a wide range of applications, including predicting the formation of scale and fingerprinting waters from different sources. More particularly, the invention relates to the use of ligands whose electronic configuration is altered by the binding of the scaling ions within a water sample. These alterations are detected electrochemically by applying varying potential to electrodes and measuring current flow as potential is varied, from which is derived the concentration of scaling ions in the fluid. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority of U.S. Provisional Application No. 61/680,848, filed on Aug. 8, 2012, and the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention generally relates to the operation of a User Equipment (UE) during a signaling procedure with a Public Land Mobile Network (PLMN), and more particularly, to apparatuses and methods for recovering service from a signaling procedure rejected with network failure.
[0004] 2. Description of the Related Art
[0005] With growing demand for ubiquitous computing and networking, various wireless technologies have been developed, such as the Wireless Local Area Network (WLAN) technologies, including the Wireless Fidelity (WiFi) technology, Bluetooth technology, and the Zigbee technology, etc., and also, the cellular technologies, including the Global System for Mobile communications (GSM) technology, General Packet Radio Service (GPRS) technology, Enhanced Data rates for Global Evolution (EDGE) technology, Wideband Code Division Multiple Access (WCDMA) technology, Code Division Multiple Access 2000 (CDMA2000) technology, Time Division-Synchronous Code Division Multiple Access (TD-SCDMA) technology, Worldwide Interoperability for Microwave Access (WiMAX) technology, Long Term Evolution (LTE) technology, Time-Division LTE (TD-LTE) technology, and LTE-Advanced technology, etc.
[0006] For user convenience and flexibility, most User Equipments (UEs) (or may be referred to as Mobile Stations (MSs)) nowadays support more than one wireless technology, and most Public Land Mobile Networks (PLMNs) support multiple wireless technologies for providing wireless services to the UEs. Taking a UE supporting the GSM/GPRS/EDGE technology, the WCDMA technology, and the LTE technology for example, it may camp on a PLMN to obtain wireless services using one of the supported wireless technologies. While the UE is camped on a PLMN, it may perform signaling procedures, such as attach procedures, location update procedures, routing area update procedures, and/or tracking area update procedures, with the PLMN.
[0007] However, there are situations where the network element(s), e.g., Base Station (BS), Node-B, or others, of the PLMN in the area of the UE's location may be under maintenance, e.g., backbone environment fixing or system configuration updates. In such cases, the signaling procedure performed with the PLMN by the UE will be rejected due to network failure, and according to chapter 5 of the 3GPP TS 24.301 specification and chapter 4 of the 3GPP TS 24.008 specification, the UE will keep retrying the signaling procedure for several times with the same PLMN using the same wireless technology as it earlier used for camping on the PLMN. Unfavorably, during this time, the UE cannot obtain wireless services, and even worse, the maintenance of the network element(s) may take a long time. As a result, the user of the UE may unexpectedly experience a long break of services.
BRIEF SUMMARY OF THE INVENTION
[0008] In order to solve the aforementioned problem, the invention proposes apparatuses and methods for a UE to recover service from a signaling procedure rejected with network failure, by performing a PLMN selection procedure with different PLMNs or with the same PLMN using different wireless technologies without retrying the signaling procedure.
[0009] In one aspect of the invention, a mobile communication device is provided. The mobile communication device comprises a wireless module and a controller module. The wireless module performs wireless transmissions and receptions to and from a first Public Land Mobile Network (PLMN) and a second PLMN. The controller module performs a signaling procedure with the first PLMN via the wireless module, and performs a PLMN selection procedure via the wireless module without retrying the signaling procedure with the first PLMN, in response to the signaling procedure being failed with a rejection cause indicating a network failure.
[0010] In another aspect of the invention, a method for a mobile communication device to recover service from a signaling procedure rejected with a network failure is provided. The method comprises the steps of performing the signaling procedure with a first PLMN; and performing a PLMN selection procedure without retrying the signaling procedure with the first PLMN, in response to the signaling procedure being failed with a rejection cause indicating a network failure.
[0011] Other aspects and features of the present invention will become apparent to those with ordinarily skill in the art upon review of the following descriptions of specific embodiments of the mobile communication devices and the methods for recovering service from a signaling procedure rejected with a network failure.
BRIEF DESCRIPTION OF DRAWINGS
[0012] The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0013] FIG. 1 is a block diagram of a wireless communications environment according to an embodiment of the invention;
[0014] FIG. 2 is a block diagram illustrating the mobile communication device 110 according to an embodiment of the invention;
[0015] FIG. 3 is a flow chart illustrating the method for a mobile communication device to recover service from a signaling procedure rejected with network failure according to an embodiment of the invention; and
[0016] FIG. 4 is a flow chart illustrating the method for a mobile communication device to recover service from a signaling procedure rejected with network failure according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. It should be understood that the embodiments may be realized in software, hardware, firmware, or any combination thereof.
[0018] FIG. 1 is a block diagram of a wireless communications environment according to an embodiment of the invention. The wireless communications environment 100 comprises a mobile communication device 110 and two PLMNs 120 and 130 , wherein the mobile communication device 110 may selectively camp on one of the PLMNs 120 and 130 to obtain wireless services. Each of the PLMNs 120 and 130 comprises at least two service networks utilizing different wireless technologies. Specifically, the PLMN 120 comprises the service networks 121 and 122 , and the PLMN 130 comprises the service networks 131 and 132 , wherein each of the service networks 121 , 122 , 131 , and 132 comprises an access network and a core network.
[0019] For example, the PLMN 120 may be deployed by an operator A, and the service network 121 may be a Universal Mobile Telecommunications System (UMTS), wherein the access network 11 may be a Universal Terrestrial Radio Access Network (UTRAN) and the core network 12 may be a General Packet Radio Service (GPRS) core which includes a Home Location Register (HLR), at least one Serving GPRS Support Node (SGSN), and at least one Gateway GPRS Support Node (GGSN), while the service network 122 may be an LTE/LTE-Advanced system, the access network 21 may be an Evolved-UTRAN (E-UTRAN) and the core network 22 may be an Evolved Packet Core (EPC) which includes a Home Subscriber Server (HSS), Mobility Management Entity (MME), Serving Gateway (S-GW), and Packet Data Network Gateway (PDN-GW or P-GW).
[0020] The PLMN 130 may be deployed by an operator B, and the service network 131 may be a GPRS/EDGE system, wherein the access network 31 may be a Base Station Subsystem (BSS) and the core network 32 may be a GPRS core which includes an HLR, at least one SGSN, and at least one GGSN, while the service network 132 may be a UMTS, and the access network 41 may be a UTRAN and the core network 42 may be a GPRS core which includes an HLR, at least one SGSN, and at least one GGSN.
[0021] The mobile communication device 110 may be a smart phone, a panel Personal Computer (PC), a laptop computer, or any computing device supporting at least two of the wireless technologies utilized by the service networks 121 and 122 of the PLMN 120 and the service networks 131 and 132 of the PLMN 130 . FIG. 2 is a block diagram illustrating the mobile communication device 110 according to an embodiment of the invention. The mobile communication device 110 comprises a wireless module 210 and a controller module 220 . The wireless module 210 is responsible for performing the functionality of wireless transmissions and receptions to and from the service networks 121 and 122 of the PLMN 120 and the service networks 131 and 132 of the PLMN 130 . The controller module 220 is responsible for controlling the operations of the wireless module 210 , and other functional components (not shown), such as a display unit and/or keypad serving as the Man-Machine Interface (MMI), a storage unit storing the program codes of applications or communication protocols, or others. Also, the controller module 220 controls the wireless module 210 for performing the method for recovering service from a signaling procedure rejected with network failure.
[0022] To further clarify, the wireless module 210 may be a Radio Frequency (RF) unit (not shown), and the controller module 220 may be a general-purpose processor or a Micro Control Unit (MCU) of a baseband unit (not shown). The baseband unit may contain multiple hardware devices to perform baseband signal processing, including analog to digital conversion (ADC)/digital to analog conversion (DAC), gain adjusting, modulation/demodulation, encoding/decoding, and so on. The RF unit may receive RF wireless signals, convert the received RF wireless signals to baseband signals, which are processed by the baseband unit, or receive baseband signals from the baseband unit and convert the received baseband signals to RF wireless signals, which are later transmitted. The RF unit may also contain multiple hardware devices to perform radio frequency conversion. For example, the RF unit may comprise a mixer to multiply the baseband signals with a carrier oscillated in the radio frequency of the mobile communication system, wherein the radio frequency may be 900 MHz, 1800 MHz, or 1900 MHz utilized in the GPRS/EDGE technology, 900 MHz, 1900 MHz, or 2100 MHz utilized in the WCDMA technology, or 900 MHz, 2100 MHz, or 2.6 GHz utilized in LTE/LTE-Advanced technology, or others depending on the wireless technology in use.
[0023] FIG. 3 is a flow chart illustrating the method for a mobile communication device to recover service from a signaling procedure rejected with network failure according to an embodiment of the invention. In this embodiment, the mobile communication device is initially camped on a PLMN. To begin, the mobile communication device performs a signaling procedure with the PLMN (step S 310 ). Specifically, the signaling procedure may be an attach procedure, a location update procedure, a routing area update procedure, or a tracking area update procedure. Next, the signaling procedure is rejected by the PLMN with a rejection cause indicating a network failure (step S 320 ). Specifically, the rejection cause may be included in an ATTACH REJECT message, a LOCATION UPDATE REJECT message, a ROUTING AREA UPDATE REJECT message, or a TRACKING AREA UPDATE REJECT message, and it is set to a value of 17 which means the signaling procedure is rejected with a network failure.
[0024] In response to the signaling procedure being rejected with a network failure, the mobile communication device performs a PLMN selection procedure for other PLMNs without retrying the signaling procedure with the PLMN (step S 330 ). Note that, the PLMN selection procedure is performed for the PLMNs other than the PLMN which the mobile communication device was camped on initially. That is, the PLMN selection procedure is performed for finding any suitable PLMN other than the one for which the signaling procedure was rejected. Subsequently, it is determined whether the PLMN selection procedure is successful to find another PLMN (step S 340 ). If so, the mobile communication device camps on the found PLMN (step S 350 ). Otherwise, if the PLMN selection procedure fails, the mobile communication device sets the Subscriber Identity Module (SIM) or Universal SIM (USIM), which is coupled to the mobile communication device, as invalid, and enters the “no-service” state (step S 360 ).
[0025] Note that, unlike the conventional operation of UE, the mobile communication device in the embodiment of FIG. 3 does not retry the signaling procedure with the same PLMN and performs the PLMN selection procedure for other PLMNs in response to failure of the signaling procedure with a rejection cause indicating a network failure, so that it may camp on another PLMN to obtain wireless services as soon as possible.
[0026] FIG. 4 is a flow chart illustrating the method for a mobile communication device to recover service from a signaling procedure rejected with network failure according to another embodiment of the invention. Similarly, the mobile communication device is initially camped on a PLMN. To begin, the mobile communication device performs a signaling procedure with the PLMN using one of the supported wireless technologies (step S 401 ), and the signaling procedure is rejected by the PLMN with a rejection cause indicating a network failure (step S 402 ). Specifically, the signaling procedure may be an attach procedure, a location update procedure, a routing area update procedure, or a tracking area update procedure. Next, it is determined whether there is another wireless technology supported by the mobile communication device (step S 403 ). If so, the mobile communication device performs a PLMN selection procedure for the same PLMN using another wireless technology without retrying the signaling procedure using the same wireless technology (step S 404 ).
[0027] After that, it is determined whether the PLMN selection procedure for the same PLMN is successful to detect another Radio Access Technology (RAT) utilized by the PLMN (step S 405 ). If so, the mobile communication device camps on the same PLMN using the detected RAT (step S 406 ). Specifically, the detected RAT is the same as the wireless technology used in the step S 404 . Otherwise, if the PLMN selection procedure for the same PLMN fails, the method proceeds to step S 403 .
[0028] Subsequent to the step S 403 , if there is no other wireless technology supported by the mobile communication device (i.e., all of the supported wireless technologies have been tried), the mobile communication device performs another PLMN selection procedure for other PLMNs (step S 407 ). Note that, the PLMN selection procedure in the step S 407 is performed for the PLMNs other than the PLMN which the mobile communication device was camped on initially. That is, the PLMN selection procedure in the step S 407 is performed for finding any suitable PLMN other than the one for which the signaling procedure was rejected. Next, it is determined whether the PLMN selection procedure is successful to find another PLMN (step S 408 ). If so, the mobile communication device camps on the found PLMN (step S 409 ). Otherwise, if the PLMN selection procedure fails, the mobile communication device sets the SIM/USIM, which is coupled to the mobile communication device, as invalid, and enters the “no-service” state (step S 410 ).
[0029] Note that, unlike the conventional operation of UE, the mobile communication device in the embodiment of FIG. 4 does not retry the signaling procedure using the same wireless technology, and instead, it performs the PLMN selection procedure for the same PLMN using another wireless technology in response to failure of the signaling procedure with a rejection cause indicating a network failure, so that it may camp on the same PLMN with another RAT to obtain wireless services as soon as possible.
[0030] While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. Those who are skilled in this technology can still make various alterations and modifications without departing from the scope and spirit of this invention. Therefore, the scope of the invention shall be defined and protected by the following claims and their equivalents. | A mobile communication device is provided with a wireless module and a controller module. The wireless module performs wireless transmissions and receptions to and from a first Public Land Mobile Network (PLMN) and a second PLMN. The controller module performs a signaling procedure with the first PLMN via the wireless module, and performs a PLMN selection procedure via the wireless module without retrying the signaling procedure with the first PLMN, in response to the signaling procedure being failed with a rejection cause indicating a network failure. | 7 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/923,752, filed on Jun. 21, 2013, which is a continuation of Ser. No. 13/556,379, filed on Jul. 24, 2012, now U.S. Pat. No. 8,490,832, which is a continuation of U.S. application Ser. No. 12/925,972, filed on Nov. 3, 2010, now U.S. Pat. No. 8,225,959, which is a continuation-in-part of U.S. application Ser. No. 12/798,415, filed on Apr. 2, 2010, now U.S. Pat. No. 8,141,746, which is a divisional of U.S. application Ser. No. 11/010,598, filed on Dec. 13, 2004, now U.S. Pat. No. 7,712,637, which claims the benefit of U.S. Provisional Application No. 60/528,565 filed Dec. 11, 2003, the entire teachings of these applications being incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of Invention
This invention relates generally to the dispensing or extracting of fluids from within containers and finds particular utility in the dispensing and preservation of wine.
SUMMARY OF THE INVENTION
The field of the invention includes devices and methods for extracting fluids from within containers.
An object of one or more embodiments of the invention is to allow a user to withdraw a volume of liquid from within a container that is sealed by a cork, plug or elastomeric septum without removing the cork, septum or closure device. It is a further object of one or more embodiments of the invention to allow removal of liquid from such a container repeatedly without causing enough damage to the cork that either gas or fluid exchange through the cork is possible under standard storage conditions. It is a further object of one or more embodiments of the invention to ensure that no gas which is reactive with the liquid passes into the container either during or after extraction of fluid from within the container.
Various embodiments of the invention enables the user to withdraw wine from within a wine bottle without removal of, or damage to the cork that would allow undesired gaseous or liquid egress or ingress during or after extraction of wine.
One embodiment of the invention involves at least one or more needle, valve, and source of pressurized gas. The needle is connected to the valve which is in turn connected to the source of pressurized gas. The needle is passed through the cork or between the cork and an interior wall of the bottle until it makes contact, at a minimum, with the interior of the bottle beyond the cork. Prior to or following insertion of the needle, the bottle is positioned such that the liquid content of the bottle can contact at least a portion of the needle. The valve is then opened such that pressurized gas can pass through the needle into the interior of the bottle. The valve is then switched to a position preventing further ingress of gas while allowing the liquid contents of the bottle to be expelled from the bottle through the needle by the pressurized gas now within the bottle. Once a desired amount of liquid content has been removed from the bottle, the bottle is then repositioned such that the pressurized gas content of the bottle is in contact with at least a portion of the needle so that the gas may be expelled from the bottle until there is no or an acceptably low pressure differential between the bottle and atmosphere. The needle is then removed from the cork.
In a preferred embodiment, the needle is a smooth exterior walled, cylindrical needle with a non-coring tip that can be passed through the cork without removing any material from the cork. The preferred non-coring tip is a pencil-tip that dilates a passageway through the cork, although deflected-tip and stylet needles have also been found to work and could be used in alternative embodiments. The pencil-tip needle preferably has at least one lumen extending along its length from at least one inlet on the end opposite the pencil-tip and at least one outlet proximal to the pencil-tip. The preferred outlet is through the side-wall of the needle.
With the correct needle gauge, it has been found that the passageway that remains following removal of such a needle self-seals against egress or ingress of fluids and gasses under normal storage conditions. While multiple needle gauges can work, preferred needle gauges range from 16 to 22 gauge, with the optimal needle gauge being between 17 and 20 gauge. These needles gauges offer optimal fluid flow with minimal pressures while doing an acceptably low level of damage to the cork even after repeated insertions and extractions.
Multiple needle lengths can be adapted to work within the scope of the present invention, however it has been found that a minimum needle length of 1.5 inches is required to pass through standard corks. Needles as long as 9 inches could be employed, but the optimal range of length has been found to be between 2 and 2.6 inches. The needle may be connected to the valve directly through any standard fitting (e.g. NPT, RPT, Leur, quick-connect or standard thread) or alternatively may be connected to the valve through an additional means such as a flexible or rigid tube. When two or more needles are used their lengths may be the same or different and vary from 0.25 inches to 10 inches. Creating distance between the inlet/outlets of the needles can prevent the formation of bubbles.
While many standard valves could be employed, two are of particular utility for this application. The first is a three-way trumpet or spool valve. Such valves have a piston which slides within a cylinder. The piston is moved downward into the cylinder by the user depressing a button connected to or integral to the piston. The piston is moved upward by a return spring in contact with the piston. When the piston is depressed by the user, a first passageway through the cylinder allows passage of gas from a pressurized gas source connected to the valve at the “gas connection” into the needle connected to the valve at the “needle connection”. Gas is allowed to enter the bottle through the needle until the user decides to release the piston. When the piston is released by the user, the spring pushes the cylinder upward exposing a second passageway through the cylinder which allows passage of the pressurized content in connection with the needle to pass through the cylinder to a “valve exit”. This valve exit may, for example be a simple hole positioned above a glass or may be a tube leading to a secondary container. This process may be repeated until a desired amount of liquid is removed from the bottle. The user then positions the bottle such that pressurized gas within the bottle is in contact with at least one outlet of the needle. With the valve cylinder released, pressurized gas can then vent from the bottle through the needle connection and out of the valve exit until a desired final pressure is reached. The needle is then removed from the cork.
The second advantageous valve is an automatic, pressure regulated valve. The primary function of this valve is to maximize the rate of liquid content egress through the needle by automatically maintaining an optimal pressure range within the bottle. A secondary function of such a valve is to control the final pressure within the bottle just prior to removal of the needle from the cork. Such a valve could be operated by a user through the use of a toggle between two valve positions—extract and vent. In the extract position a passage between the pressurized gas source and the needle would be opened by the valve until a desired maximum pressure limit is achieved within the bottle. The valve would then automatically switch to the vent position wherein a passageway is opened between the needle and a valve exit so that contents of the bottle can be expelled. The valve would then automatically switch back to the extract position when a lower pressure limit was reached. This process continues until a desired amount of the liquid content of the bottle is extracted. The bottle is then positioned such that the gaseous contents of the bottle are in contact with at least a portion of the needle allowing gas to exit in the vent position prior to extraction of the needle. The lower pressure limit could be changed for this gas-venting procedure to allow a final/controlled pressure within the bottle. This changing of the lower pressure limit could be achieved automatically through the use of a switch that is activated by the tilting of the bottle (e.g. when the bottle is standing upward the switch would be activate the lower pressure while when the bottle is on its side the switch would activate the higher pressure.)
Other valves that could be used include, but are not limited to ball, solenoid, pivoted-armature, rotating cylinder, and toggle valves. Additional valves could further be added to the system. For example, a simple two-way check valve placed at the wine exit could be employed to maintain pressure within the bottle without flow of wine. In this way, wine can be released from the bottle at the users discretion after pressurization.
It has been found that the maximum value for the upper pressure limit is between around 40 and 50 PSI but is optimally between around 15 and 30 PSI. These pressures are well tolerated by even the weakest of cork-to-bottle seals. The lower pressure limit during wine extraction could be between 1 and 20 PSI lower than the upper pressure limit. For example, selecting an upper pressure limit of 30 PSI, it has been found that a lower limit of 15-20 PSI maintains an adequate pressure gradient to ensure rapid expulsion of wine through a 17 to 20 gauge needle. The final/controlled pressure (the lower of the lower pressure limits) can be between 0 and 15 PSI, with an optimal range of 0 to 5 PSI.
The source of pressurized gas can be any of a variety of regulated or unregulated pressurized gas containers filled with a variety of non-reactive gasses. In a preferred embodiment, the source consists of a container of gas with the gas at an elevated initial pressure (2000-3000 psi). This container is then regulated to the desired outlet pressure by either a fixed or variable regulator. This regulator can be any of a variety of single or two stage regulators available on the market. This configuration allows the use of conveniently small bottles of compressed gas that contain relatively large quantities of gas capable of emptying many bottles of wine. It further insures that the outlet pressure of the valve is maintained as the pressure within the container of gas changes during use. Multiple gasses have been tested successfully over extended periods of time, but the preferred gasses are nitrogen and argon. Preferably the gas is non-reactive with the fluid within the subject vessel such as wine and can otherwise protect the fluid from the deleterious effect of air infiltration or exposure. Nitrogen has the advantage of being very inexpensive and readily available in a variety of container sizes and initial pressures. Argon has the advantage of being a completely inert, noble gas as well as being heavier-than-air. By being heavier-than-air, argon minimizes the risk of inadvertent ingress of reactive atmospheric gasses during the final venting of the pressurized gas from within the container. Other non or minimally reactive gases or mixtures thereof also work, for example helium and neon. Preferably, the gas used should be equal to or greater in weight than air to prevent ingress of unwanted gasses and should have a low permeability through cork and/or glass, all resulting in helium being less preferred. Mixtures of gas are also possible. For example, a mixture of argon and another lighter gas would blanket the wine in argon while the lighter gas would occupy volume within the bottle and perhaps reduce the overall cost of the gas. Preferred embodiments use disposable membrane cylinders of nitrogen or argon at storage pressures equal to or greater than 2500 psi and a simple regulator set at a fixed outlet pressure between 15 and 30 PSI.
An alternative source of gas that allows greater volumes to be stored in smaller containers is a liquid that changes phase to gas and expands once released from its container.
In one exemplary embodiment a device is provided that has a hollow needle having an inlet at one end and an outlet at a second end and wherein the needle is adapted to penetrate beyond a closure device (such as a cork, plug, or septum) sealing a container; a pressurized source of gas; a pressure regulator capable of reducing the pressure of the gas from the pressurized source to a lower pressure at a regulator outlet, wherein the regulator is connected to the pressurized source at a regulator inlet; a valve secured at a first valve inlet to the regulator outlet, secured at a first valve outlet to the needle inlet, and having a second valve outlet for the passage of gas or fluids from within the container; and wherein the valve controls the flow of gas from the pressurized source into the container through the needle and the flow of gas or fluid from within the container through the needle and out of said valve outlet.
In one exemplary method fluid can be extracted from within a container sealed by a closure device by inserting the outlet of a single lumen, non-coring needle with a smooth exterior wall beyond the closure device and into the container; injecting a pressurized non-reactive gas into the container through the hollow needle thereby causing an increase of pressure within the container to a level higher than the surrounding atmospheric pressure; allowing the fluid within the container to be forced out of the container by this pressure through the needle until a desired amount of fluid is extracted; and then removing the needle from the closure device thereby allowing the closure device to reseal.
Other components can be added to the system to increase its functionality or durability. Of particular utility include a linear drive mechanism, a container attachment mechanism, a sealing member retention means, and an anti-buckling mechanism.
A linear drive mechanism is any mechanism that forces the needle to be inserted into and through the closure device or between the closure device and container in a linear path. This can help to prevent buckling of the needle due to side loads or bending moments. This system could be as simple as a single keyed rod passing through a matching keyed hole wherein the rod's travel through the hole is along a line co-linear with the desired needle path. This rod can be connected directly to the needle or to an intervening device. Further embodiments could include multiple cylindrical rods that pass through multiple closely matching round holes or tubes that are co-linear with the desired needle path, among others.
A container attachment mechanism is any mechanism capable of securing or stabilizing at least a portion of the device to the container. This can serve the purpose of again reducing the risk of buckling of the needle by ensuring that the needle path stays fixedly relative to the container. It can also aid in preventing inadvertent withdrawal of the needle from the container. It can further be used in concert with a cork or sealing member retention means to prevent expulsion of the sealing member from the container during pressurization. An attachment mechanism can provide an anchoring location that would give such a sealing member retention means the stability necessary to hold the sealing member in place during pressurization. For example, such a retention means could comprise a surface of the device that contacts a surface of a sealing member outside of the container and, when secured to the container by an attachment mechanism, could obstruct the path that the sealing member must travel to be expelled from the container. Suitable attachment mechanisms can include, but are not limited to, two clamping arms that close about a portion of the container. For example, in the case of a wine bottle, these two clamp arms could close about the neck of the bottle. An attachment mechanism could alternatively involve glue, Velcro, threaded attachments that are driven into a wall of the container, suction cups, tape, and the like. The attachment mechanism could additionally have a releasable lock that acts to releaseably secure the device to the container. In the case of the clamp arms, such a lock could include a simple threaded bolt that passes through both arms and has a nut on one end that can be threaded down the bolt to apply varying clamping force to the container and then be unthreaded to release the container.
An anti-buckling mechanism is any mechanism that acts to reduce the risk of the needle buckling during insertion and withdrawal of the needle. Apposing arms that contact the sides of the needle's length are one possible embodiment of such a mechanism. The arms could have a slot running through a surface of the arm. This slot could be as wide and deep as the needle diameter. As the needle is advanced into the sealing device, these slots would act to resist buckling of the needle by restraining bending of the needle due to contact between the needle length and the walls of the slot, giving the needle the opportunity to bend only toward the opening of the slot. Apposing arms could meet at an angle to create unlikely buckling paths offset by this angle. 90 degrees has been found to be a particularly effective angle. Other anti-buckling mechanisms are possible and include, but are not limited to, telescoping cylinders along the needle's length, a collapsible sleeve or bellows that supports the needle at various points along its length, a stiff coiled spring that contacts the needle along its inner diameter, or a single sliding cylinder that contacts the needle at the mid-point of the needle's exposed length outside of the sealing means during insertion and withdrawal.
Various exemplary embodiments of the device are further depicted and described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an embodiment comprising a pencil tip needle connected to a 3-way toggle valve which is in turn connected to a variable regulator connected to a compressed gas cylinder. A wine bottle that has been accessed by the device is also shown in the Figure. Note that the foil 742 covering the corked opening of the bottle is still intact and has not been removed but that small needle hole perforation at an insertion point 740 is shown.
FIG. 2 depicts a cross section of a preferred embodiment of the present invention. The embodiment consists of a cylinder of compressed gas, a fixed pressure regulator, a valve, a needle, and a linear drive mechanism. Details of this embodiment and its use are depicted in FIGS. 2A-E .
FIG. 2A is an exploded view of the three-way spool valve used in this embodiment.
FIG. 2B depicts the valve in its normal position which allows flow between the valve exit and the needle.
FIG. 2C depicts the valve in its activated position which allows flow between the needle and the regulator.
FIG. 2D depicts the linear drive mechanism attached to the needle with the linear drive mechanism at its upward most position.
FIG. 2E depicts the linear drive mechanism attached to the needle with the linear drive mechanism at its downward most position.
FIG. 3A depicts the embodiment positioned on the bottle with the needle positioned over the wine bottle cork and the linear drive mechanism at its upward most position.
FIG. 3B depicts the linear drive mechanism at its downward most position with the needle tip driven through the cork and into the interior of the bottle.
FIG. 3C depicts the system shown in 3 B with the bottle tilted on its side causing the needle tip to come in contact with the liquid contents of the bottle.
FIG. 3D depicts the system of 3 C with the valve activated causing gas at a pressure regulated by the fixed regulator to enter the bottle through the needle, increasing the pressure within the bottle.
FIG. 3E depicts the system of 3 D with the valve returned to its normal position, enabling the increased pressure within the bottle to drive wine through the needle and out of the valve exit.
FIG. 3F depicts the bottle returned to an upright position allowing excess gas from within the bottle to contact the needle tip and vent through the valve exit until the pressure equilibrates with atmospheric pressure.
FIG. 3G depicts the system shown in FIG. 3F with the needle withdrawn from the bottle and the linear drive mechanism at its upward most position.
FIG. 4 is a side view of an alternative embodiment further comprising an anti-buckling mechanism that resists buckling of the needle as it is advanced into the bottle. It further employs a trumpet valve, a linear drive mechanism comprising a linear drive shaft and gear, and a container attachment or bottle clamping mechanism.
FIG. 5A and FIG. 5B depict detail of a preferred embodiment of the anti-buckling mechanism. FIG. 5A shows a front view of a swing arm and indicates a swing arm slot which fits over a section of the needle length to resist buckling. FIG. 5B depicts two swing arms and their relationship to each of two swing arm axes and the needle.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention is shown in FIG. 1 . This system uses a pressurized source of gas 100 regulated by a variable regulator 600 . The cylinder 100 is secured to the pressure regulator 600 by a simple threaded connection. This embodiment employs a 3-way toggle valve 300 allowing both extract and vent positions described above. This system also uses a pencil-tip non-coring needle 200 with a needle outlet along the side of the needle length near the needle tip. The connection between the valve 300 either the regulator 600 or needle is shown to be rigid. Alternatively these connections could be flexible if desired.
Additional components of a preferred embodiment of the present invention may include:
a bottle attachment or clamping mechanism securing the needle to the bottle,
a linear needle drive system to facilitate insertion of the needle into the bottle along a linear path,
a needle guide that allows insertion of the needle through a particular region of the cork,
an anti-buckling means to minimize the risk of the needle buckling during insertion,
a cork retention means that acts to prevent cork expulsion during pressurization,
a bottle stand that facilitates holding and/or tilting of the bottle during the extraction and venting phases,
a pressure meter that allows the user to know the pressure within the bottle and/or the exit pressure of the gas source,
a needle protection means or lock preventing inadvertent injury of the user by the needle once it is withdrawn from the bottle.
Multiples of these components could be combined into single parts or components serving multiple functions. For example, the anti-buckling means could also serve as a needle protection means, the cork retention means and the needle guide could be combined into a single unit secured to the bottle at the exterior of the cork, and this needle guide/cork retainer could further be a part of the bottle clamping means that may be further combined with the linear needle drive.
FIG. 2 depicts a cross section of a preferred embodiment of the present invention. The embodiment consists of a cylinder of gas 100 connected to a regulator 600 which is in turn connected to a valve 300 . This valve 300 is then secured to a needle 200 . The needle 200 and/or the valve 300 are secured to a linear drive mechanism 400 . The pressure within cylinder 100 is preferably considerably higher than the outlet pressure of the regulator 600 . Regulator 600 is shown without detail, but can be any of a variety of commercially available single or two stage pressure regulators capable of regulating gas pressures to a pre-set or variable outlet pressure. The connection of the various components is not depicted in detail, but can be achieved through either rigid (threaded, welded, taper lock etc.) means or flexible (tubing, o-ring seal, gasket seal) means. The length of such a connection can be varied depending upon the specifics of the desired application.
FIGS. 2A-C detail a preferred embodiment of a three-way, spool valve 300 that has been found particularly useful to control the flow of wine and gas. The valve 300 consists of a piston 310 and a valve body 305 . The piston 310 employs three o-rings—an upper 312 , middle 313 , and lower 314 —to control the flow of fluids and gasses through the valve cylinder 301 .
In FIG. 2B , the upper 312 and lower 314 o-rings are sealing against the inner walls of the valve cylinder 301 , allowing flow between the needle attachment site 303 and the wine exit 304 . In this position, flow between the gas entrance 302 and the other two ports is prevented by the lower o-ring 314 . This is the normal state of the valve with the return spring 311 holding the cylinder in this position. This is the “vent” position described above which, for convenience, will be referred to as B-C.
In FIG. 2C , the upper 312 and middle 313 o-rings are sealing against the inner walls of the valve cylinder 301 , allowing flow between the gas entrance 302 and the needle attachment site 303 . Flow between the wine exit 304 and the other two ports is prevented by o-ring 313 in this position. This is the “extract” position described above which, for convenience, will be referred to as A-B. The user achieves this valve position by pushing down on piston 310 compressing the return spring 311 . Once the user stops depressing the valve piston 310 , the return spring 311 causes the piston to return to position B-C depicted in FIG. 2B .
FIGS. 2D and 2E detail an embodiment of a linear drive mechanism 400 . In this embodiment, two cylindrical rods (front rod 410 and back rod 420 ) pass through two closely matching rod holes (front rod hole 460 and back rod hole 470 ). These two rods are securely attached to upper piece 430 which is also secured to needle 200 . The offset of the two rods creates a resistance to angulations of or side loads on needle 200 by providing a resistive moment. This insures that the needle 200 can travel into and out of a cork only along a line co-linear with the rods.
A flat has further been cut onto the front surface of front rod 410 . This flat acts in concert with rod stop 450 to restrict the upward travel of the needle 200 relative to the bottom piece 440 when stop surface 415 on front rod 410 engages rod stop 450 . This method could also be used to limit downward travel of the needle 200 relative to bottom piece 440 . FIG. 2D illustrates the needle 200 at full upward travel while FIG. 2E illustrates the needle 200 at full downward travel relative to bottom piece 440 .
During use, the needle guide 480 and its through hole 485 are positioned above the cork of a wine bottle and are secured to or part of bottom piece 440 . In this embodiment, the needle guide 480 could be used as a cork retainer if a bottle clamping mechanism is incorporated into bottom piece 440 . Such a bottle clamping mechanism has been left out of this embodiment to detail the other components of the system, but could readily be added. Various embodiments of such a clamping mechanism are described below in alternate embodiments.
FIGS. 3A-3G illustrate the use of the embodiment depicted in FIG. 2 and detailed in FIGS. 2A-E . In FIG. 3A , the bottom piece 440 has been placed on top of wine bottle 700 with the upper piece 430 at full upward travel. The valve is in its normal position B-C. The wine 710 and gas 720 within the bottle 700 are in their undisturbed state as bottled by the vintner. FIG. 3B depicts the needle outlet 220 beyond cork 730 and within bottle 700 with the upper piece 430 at full downward travel. This position is achieved by simply pushing downward on valve 300 or upper piece 430 . The valve 300 is still in its normal B-C position.
In FIG. 3C , the bottle has been tilted on its side, causing wine 710 to contact the needle outlet 220 . In FIG. 3D , the valve has been moved by the user into its A-B position, allowing pressurized gas 120 from within cylinder 100 to pass through the regulator 600 at its upper pressure setting, through gas entrance 302 , through needle attachment 303 , out of needle outlet 220 into wine 710 within the bottle 700 . This gas 120 increases the pressure within the bottle until it reaches equilibrium with the gas pressure determined by the regulator 600 . In FIG. 3E , the valve 300 has been allowed to return to its normal state B-C, opening a path between the needle outlet 220 and the wine exit 304 . The wine 710 is now driven by the elevated pressure of the gasses 720 and 120 within the bottle through the needle outlet 220 and out of valve 300 . This flow will continue until pressure within the bottle equilibrates with atmospheric pressure if the user wishes. However, excess pressure can be allowed to vent by simply standing the bottle upright, as depicted in FIG. 3F . Once the bottle is upright, the gasses 720 and 120 within the bottle are in contact with the needle outlet 220 and can vent from valve 300 with the valve in its normal position B-C. Once the pressure has reached a desired level, the needle can be withdrawn from the cork 730 by pulling upward on the upper piece 430 or valve 300 until the upper piece reaches its upward most travel. The bottom piece 440 and the rest of the system can then be removed from bottle 700 .
It has been found that corks accessed by such a system, particularly with a smooth walled exterior, pencil point or Huber point needle of 16 gauge or higher, seal effectively and prevent the ingress or egress of gases or fluids and can be stored in the same way as an un-accessed bottle for years without abnormal alteration of the wines flavor. Other needle profiles and gauges are also usable with the system.
In the above described embodiment, the needle guide through hole 485 is depicted over the center of the cork 730 . Alternatively, the through hole 485 could be offset from the center of cork 730 to decrease the potential that multiple uses of the system will allow the needle to pass through the same site in the cork.
An alternative embodiment is depicted in FIG. 4 . This embodiment employs an alternate linear drive system, a bottle clamping mechanism, a different configuration of 3-way spool or trumpet valve, and an anti-bucking mechanism.
FIG. 4 illustrates a side view of this exemplary embodiment in a multi-component, assembled fashion. On the upper left the figure is a cylinder of compressed gas 100 attached to a regulator 600 . Below the regulator 600 is a trumpet valve 300 . Below valve 300 are the needle 200 , anti-buckling assembly 800 , linear drive mechanism 400 , needle guide and cork retention means 480 , and bottle clamp 500 . The regulator 600 of this embodiment is a variable regulator. It has a simple threaded attachment to the compressed gas cylinder 100 . The trumpet valve 300 is attached to the regulator 600 through a simple Luer connector. The valve 300 is actuated by depressing the piston 310 shown in FIG. 4 . This valve 300 is a simple trumpet or spool valve. With the piston 310 in the un-depressed position, the valve 300 is opened such that fluid can flow from the needle 200 and out of the valve exit 304 (position B-C or vent position). When the piston 310 is depressed, gas can flow from the regulator 600 through the needle 200 (position A-B or extract position).
The linear drive mechanism 400 of this embodiment consists of a steel shaft or front rod 410 and gear 490 toward the bottom of the figure. The front rod 410 passes through a closely matching hole 460 in lower piece 440 . Gear 490 is a rack and pinion system wherein when the circular gear turns, the gear teeth mesh causing the needle to be driven downward into the cork or upward out of the cork depending upon the rotational direction of the circular gear.
The clamp mechanism 500 and the anti-buckling mechanism 800 . The anti-buckling system 800 comprises two steel rods 810 and seven swing arms 820 pivoting about rods 810 . Each swing arm has a proximal end with a through hole for the steel rod 810 and a small slot cut at their opposite end which fits over the needle 200 along its length. Each steel rod 810 acts as an axis about which the arms 820 swing. Each arm's slot opposes the neighboring arm's slot. These opposite facing slots act to entrap the needle 200 and prevent it from buckling along 270° of the circumference of the needle at any one arm 820 . Because the slots oppose each other, it is highly unlikely that the needle 200 can buckle along a length greater than the length of any individual slot. Even along one slot, the needle 200 can only buckle in the direction that the slot is open, eliminating the risk of buckling along 270° of the needle circumference. These axes 810 are spaced from each other such that alternate swing arms meet at an angle. A particularly preferred angle of intersection of the swing arms is 90°, but a range between 45 and 135 is also acceptable. By alternating the swing arms 820 in this fashion the needle slot of each swing arm 820 has an opening that is offset by roughly 90 degrees from its neighboring swing arm 820 . This radically reduces the risk of needle 200 buckling as the ability to buckle in any single plane is eliminated. The needle 200 can only buckle along any one length supported by any one swing arm 820 in the direction that the needle slot is open. As the tendency to buckle is strongly dependent upon the free length available to buckle, the risk of buckling is exponentially lower than an unprotected needle. A particularly useful swing arm slot length has been found to be less than 0.5 inches for needles within the preferred gauge range of 17 to 20 with a particularly useful length being 0.25 inches. The slot width and depth preferably closely matches the diameter of the needle used.
In this embodiment, the needle 200 moves through the anti-buckling mechanism 800 as it is advanced into the bottle's cork. As the needle 200 moves, a small taper on the needle's hub 240 pushes the swing arms 820 outward allowing the needle 200 to pass. There is also an elastic band 830 which acts to return the swing arms 820 to the needle 200 after they have been moved aside by the needle hub 240 or the hub extenders 250 . This elastic band 830 essentially acts as a return spring. The extended needle hubs 250 , depicted here as white cones, guide the swing arms 820 around the needle hub 240 and its larger base at the upper piece 430 without catching any edge due to the force of the elastic band 830 . Alternative embodiments of the anti-buckling mechanism might include a series of telescoping cylinders, a single sliding cylinder, a collapsible bellows that makes contact with the needle at the narrowest diameter of the bellows, or a stiff coiled spring making contact with the needle diameter at the spring's inner surface.
The bottle clamping mechanism 500 consists of two simple clamping arms 510 and a locking mechanism comprised of a screw 520 and nut 530 to secure the arms 510 at a fixed position. Each clamp arm swings about an axis 540 . This clamping mechanism 500 also ensures that the cork is centered beneath the needle 200 and that the needle guide and cork retaining system rests atop the bottle cork or sealing means.
A combined needle guide and cork retaining system 480 is shown as a simple disk with a small hole equal to or greater in diameter than the needle diameter that passes through its center. When the clamping mechanism 500 is secured to the bottle 700 , this component 480 preferably rests against the upper surface of the cork as depicted in FIG. 4E . As this component 480 is fixed in position relative to the clamping arms 510 , it acts to secure the cork in position during pressurization of the bottle.
FIGS. 5A and 5B depict further detail of the anti-buckling mechanism 800 shown in FIG. 4 . FIG. 5A shows a front view of a swing arm 820 with a slot 840 running along one end. FIG. 5B shows how this slot 840 fits over a length of the needle 200 . In this figure, the swing arm 820 on the left constrains the needle 200 within slot 840 . The swing arm 820 on right has swung away from the needle 200 about axis 810 . When both swing arms 820 are engaging the needle 200 , the needle is constrained such that the risk of needle buckling is reduced. By using multiple, alternating swing arms, the needle can be protected against buckling during advancement into and through a cork.
Alternative embodiments of the device might be integral to a bottle stand. In this embodiment there may be no need for a bottle clamp. The bottle could simply be slid along the bottle stand into the needle and anti-buckling mechanism. In this fashion the bottle would be on its side during insertion of the needle better guaranteeing contact between the needle tip and the fluid within the bottle. After use, the stand could be pivoted upward to allow the gas to vent.
In still further embodiments there might be more than one needle. Two needles would allow insertion of gas and extraction of fluid at the same time. One needle would be dedicated to allowing ingress of gas and would be connected to the pressurized gas source, while the other needle would allow the extraction of wine or fluid from within the bottle. In such an embodiment there may be no need for the trumpet valve described above, but simply for an on-off switch for the pressurized gas source. The needles can have the same or different diameters or the same or different length varying from 0.25 to 10 inches. For example, one needle delivering gas could be longer than another that extracts wine from the bottle. This could also be achieved with a two lumen needle wherein gas would travel down one lumen and wine would travel up the other. Each lumen could have a separate entrance and exit. These exits could be spaced from each other within the bottle to prevent circulation of gas.
Still further embodiments may employ a dilator instead of a needle. Such a dilator could be passed between the cork and the bottle wall into the wine, leaving no damage to the cork itself. Such a dilator could be cannulated and arcuately shaped to best match the outer diameter of the cork.
The bottle clamping mechanism employed in the above described embodiments comprises two clamping handles pivoting around axes secured to the bottom piece. These handles are lockable to the wine bottle through the use of a clamp bolt/screw and nut. Many alternative embodiments of a bottle clamp are possible. Alternatives to the bolt and nut lock include, but are not limited to a ratcheting lock, or a simple strap that can be slid down or wrapped around the swing arms, locks located at the axes of the swing arms, etc. The clamp handles could be replaced by a cylinder that fits over the wine bottle neck. Such a cylinder could have a split wall with a conically tapered outer surface. An outer ring could be slid along the conical surface to cause the inner diameter of the cylinder to decrease, clamping the cylinder about the bottle neck. A locking feature between the ring and the cylinder could be used to lock the cylinder to the bottle. This cylinder could be incorporated into the bottom piece.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | Devices and methods are disclosed for extracting fluids from within a container sealed by a cork or septum without removal of the cork or septum or the contamination of the fluid within the container by reactive gases or liquids. Embodiments of the device can include a needle connected to a valve which is in turn connected to a source of pressurized gas for displacing the fluid. Further embodiments of the device can comprise additional components that act to force the needle to be inserted through the cork or septum along a linear path, to aid in preventing buckling of the needle, to clamp the device to the container, to prevent expulsion of the cork or septum from the container, and to guide the needle through a specified region of the cork or septum. This device is particularly suited for the dispensing and preservation of wine. | 1 |
PRIORITY CROSS REFERENCE
This application claims priority to EP/01108480.3, filed Apr. 4, 2001 under the European Patent Convention and which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The invention relates to a method of producing a turbine blade in hollow section.
BACKGROUND OF THE INVENTION
Gas turbines are used in many fields for driving generators or driven machines. In the process, the energy content of a fuel is used for producing a rotational movement of a turbine shaft. To this end, the fuel is burned in a combustion chamber, in the course of which air compressed by a compressor is supplied. In this case, the working medium which is produced in the combustion chamber by the combustion of the fuel and is under high pressure and high temperature is directed via a turbine unit connected downstream of the combustion chambers, where it expands to perform work. In the process, the impulse transfer, required for producing the rotational movement of the turbine shaft, from the working medium is achieved via turbine blades. To this end, a number of profiled moving blades are arranged on the turbine shaft, these moving blades, for directing the flow medium in the turbine unit, being complemented by guide blades connected to the turbine casing. In this arrangement, for suitable guidance of the flow medium, the turbine blades normally have a profiled blade body extended along a blade axis.
To achieve an especially favorable efficiency, such gas turbines, for thermodynamic reasons, are normally designed for especially high outlet temperatures of the working medium flowing out of the combustion chamber and into the turbine unit, these outlet temperatures ranging between about 1200° C. and 1300° C. At such high temperatures, the components of the gas turbine, in particular the turbine blades, are subjected to comparatively high thermal loads. In order to also ensure high reliability and a long service life of the respective components under such operating conditions, the components affected are normally designed to be coolable. In modern gas turbines, therefore, the turbine blades are normally designed as a “hollow section”. To this end, the profiled blade body, in its inner region, has cavities (also designated as blade core) in which a cooling medium can be directed. Cooling-medium passages formed in such a way enable cooling medium to be admitted to the regions of the respective blade body which are especially subjected to thermal stress. In this case, an especially favorable cooling effect and thus especially high operating reliability can be achieved by the cooling-medium passages occupying a comparatively large spatial region in the interior of the respective blade body, and by the cooling medium being directed as close as possible to the respective surface exposed to the hot gas. On the other hand, in order to ensure sufficient mechanical stability and loading capacity in such a design, flow may occur in the turbine blade through a plurality of passages, in which case a plurality of cooling-medium passages to which cooling medium can be admitted and which are separated from one another in each case by comparatively thin dividing walls are provided.
Such turbine blades are normally produced by casting. To this end, a casting mold adapted in its contour to the desired blade profile is filled with blade material. To produce the aforesaid blade cores or flow passages for the cooling medium, “core elements” are arranged in the casting mold during the casting, these core elements being removed from the blade body after the casting operation has been effected, so that the cavities desired for the cooling-medium passages are produced. In this case, during the production of a turbine blade having a plurality of the cooling-medium passages separated from one another by dividing walls, a plurality of core elements adapted to the specific shape in each case are arranged in the casting mold. In order to hold these core elements in the correct position during the casting operation, on the one hand relative to one another and on the other hand relative to the casting mold, the core elements are normally connected to one another and/or to the casting mold via spacers. These spacers leave behind undesirable additional cavities when the core elements are removed, and these additional cavities impair the fluidic isolation, actually intended, of the respective core regions from one another and in particular from the outer region of the turbine blade. The spacers are therefore normally designed to be tapered in order to reliably rule out the formation of unacceptably large openings. In this case, the spacers are designed in such a way that, during the casting of the turbine blade, as far as possible a continuous surface or dividing wall which is not completely penetrated by the respective spacer is obtained at the respective location. Nonetheless, the cast turbine blade normally has weak points at the locations of the spacers, these weak points promoting at least local crack formation in the region in question. The defect or scrap rate during the production of the turbine blades is thus comparatively high.
SUMMARY OF THE INVENTION
The object of the invention is therefore to specify a method of producing a turbine blade in hollow section with which an especially low defect or scrap rate can be achieved.
This object is achieved according to the invention by a first core element being connected via a number of approximately cylindrical spacers to a further core element and/or to a casting mold, the cavities left in the casting mold by the core elements being filled by blade material, and the openings remaining in the turbine blade after the removal of the core elements and the spacers and produced by the spacers being closed by stopper elements.
In this case, the invention is based on the idea that a possible cause of defects during the production of the turbine blades can be seen precisely at those weak points which occur as a result of using tapered spacers when connecting the core elements. These weak points on the one hand impair the stability of the blade material at the location in question, but on the other hand can be identified only with difficulty, or cannot be identified at all, during a material test. Thus undiscovered weak points may remain in the material and may subsequently lead, due to crack formation at the location in question, to total failure of the turbine blade.
In order to effectively counteract this, cylindrical spacers are now used instead of conical or tapered spacers. Although these cylindrical spacers also leave behind weak points in the material of the cast turbine blade, these weak points can easily be discovered. While abandoning the principle of keeping the weak points small during the production of the turbine blades, provision is thus made, while tolerating comparatively larger weak points, for the latter to be made such that they can be discovered in an especially simple manner. The weak points, which can thus be reliably discovered, can then be closed effectively and in a manner which does not impair the subsequent operation of the turbine blade, by applying a closure element.
In this case, the spacers are preferably dimensioned in their longitudinal extent in such a way that their ends project beyond the blade profile produced, so that holes which pass completely through the respective structure are always produced during the casting of the turbine blade.
In order to ensure the tightness of the openings left by the spacers even during operation of the turbine blade under comparatively adverse operating conditions, the stopper elements, in an advantageous development, are upset, pressed, or otherwise manipulated after they have been inserted into the respective opening. Such pressing or upsetting ensures that the respective stopper element expands in its width in such a way that it forms an especially intimate positive-locking and frictional connection with the margin of the respective opening. The opening is thus closed in an especially effective manner.
To additionally secure the stopper element in its respective opening, it is advantageously brazed after it has been inserted into the respective opening.
The stopper element used may in each case be a suitable pin-shaped element. However, the stopper elements used are advantageously blind rivets or drive-in pins.
The advantages achieved with the invention consist in particular in the fact that, by deliberately tolerating comparatively large openings in the blade body cast to begin with, each weak point, caused by the spacers, in the blade body can be clearly identified. Concealed weak points are thus reliably avoided. In addition, by the subsequent insertion of the stopper elements, especially effective closure of the respective openings is ensured, so that the turbine blade can be loaded to a particular degree even under comparatively adverse operating conditions. In addition, the spacers may be dimensioned to be comparatively large, so that only a comparatively small number of spacers are required for reliable positioning of the core elements during the casting operation. Thus the number of openings or weak points produced overall is also reduced, so that the cost of closing these weak points again is kept especially low.
BRIEF DESCRIPTION OF THE DRAWING
An exemplary embodiment of the invention is explained in more detail with reference to a drawing, in which:
FIG. 1 shows a profiled turbine blade in cross section;
FIG. 2 shows a core element; and
FIG. 3 shows a number of stopper elements in different embodiments.
DETAILED DESCRIPTION OF THE INVENTION
The same parts are provided with the same reference numerals in all the figures.
The turbine blade 1 , which is shown in FIG. 1 in cross section, is intended for use in a gas turbine (not shown in any more detail). The turbine blade 1 comprises a blade body 2 extended along a blade axis and also designated as blade profile. As can be seen in FIG. 1, the blade body 2 is profiled or curved at its surface, so that especially favorable guidance of the working medium flowing through the gas turbine is ensured.
For thermodynamic reasons, the gas turbine is designed for a comparatively high outlet temperature of its working medium from the combustion chamber of, for example, 1200° C. to 1300° C. In order to also ensure high reliability and long service life of the respective components under these operating conditions, the turbine blade 1 , in addition to other components, is also designed to be coolable. To this end, the blade body 2 comprises a number of integrated cavities 4 , 6 which in each case serve as a flow passage for a cooling medium. In this case, the cavities 4 have a comparatively large cross section and serve as main flow path for the cooling medium. However, especially in the case of flow passages for the cooling medium which are to be kept comparatively large in cross section, a comparatively large wall thickness of the remaining structural parts of the turbine blade 1 is necessary for mechanical stabilization. On the other hand, it is attempted to keep the flow path of the cooling medium as close as possible to the top side of the turbine blade 1 , which top side is exposed to hot gas. In order to also ensure this with high mechanical stability of the turbine blade 1 , second cavities 6 are provided in addition to the first cavities 4 forming the main flow path for the cooling medium, these second cavities 6 running comparatively close below the surface of the turbine blade 1 . These second cavities 6 form secondary passages for the cooling medium and communicate with the first cavities 4 on the inlet side and outlet side.
During the production of the turbine blade 1 , a casting mold is used which has a cavity adapted to the desired outer contour of the turbine blade 1 . To produce the cavities 4 , 6 , “core elements” adapted in their outer contour to the desired cavities 4 and 6 , respectively, are positioned in this casting mold. The casting mold is then filled with blade material, the intended cavities 4 and 6 , respectively, being kept free of blade material by the core elements. After the solidification of the blade material, the core elements are removed again, so that the desired cavities 4 and 6 , respectively, remain in the cast turbine blade 1 .
A core element 10 provided for producing one of the second cavities 6 is shown in FIG. 2 . The core element 10 comprises a base plate 12 which is adapted in its shape to the contour desired for the respective cavity 6 . In addition, a number of spacers 14 are arranged on the base plate 12 for the spatial positioning and fixing of the core element 10 during the casting operation.
In this case, each spacer 14 is of essentially cylindrical configuration and is designed in its length in such a way that it completely passes through the blade profile provided in its spatial region. In the exemplary embodiment, the spacers 14 are therefore designed in their length in such a way that they exceed the thickness of the material walls surrounding the respective cavity 6 . In this case, the spacers 14 are each anchored with their free ends in the casting mold or in an adjacent core element, so that an essentially robust structure is also obtained during the casting operation.
After the casting operation and the solidification of the blade material, the blade body cast in this way has continuous openings at those points at which the spacers 14 were located. These openings can therefore easily be recognized and can therefore be subjected to a further treatment. In this case, the openings remaining in the turbine blade 1 after the removal of the core elements and the spacers and produced by the spacers 14 are closed by suitable stopper elements, as shown for a few different types of stopper elements in FIG. 3 .
FIG. 3, in the form of several alternative exemplary embodiments, shows a number of different stopper elements with which the openings left by the spacers 14 can be closed. In this case, the stopper element provided for the respective opening may be a drive-in pin 20 which comprises a conical shaped piece 22 like a barb in its center region. Alternatively, a drive-in pin 24 pressed or upset on one side may be provided, this drive-in pin 24 being especially suitable for the case in which the opening to be closed still has, on one side, projections 26 defining the actual opening passage. If there is a completely continuous opening, however, a continuous pin 28 may also be provided, this continuous pin 28 having been pressed or upset on both sides after it has penetrated into the respective opening. It is precisely due to the upsetting that an especially good sealing effect occurs in this case as a result of the thickening in the center region of the pin 28 .
Alternatively, a pin 30 inserted into a continuous opening may also be used, the respective opening having bevels in its end regions. If the pin 30 is upset, it is deformed in its end regions, in the course of which its pin material adapts itself to the corresponding bevels of the respective openings. Furthermore, it is also possible to use a pin 32 which is tightly closed in its end region by applying a brazing cap 34 and by subsequent brazing.
It is to be understood that while certain forms of the invention have been illustrated and described, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various, including modifications, rearrangements and substitutions, may be made without departing from the scope of this invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification. The scope if the invention is defined by the claims appended hereto. | In a method of producing a turbine blade in hollow section, an especially low defect or scrap rate is to be ensured. To this end, a first core element is connected via a number of approximately cylindrical spacers to a further core element and/or to a casting mold, the cavities left in the casting mold by the core elements being filled by blade material, and the openings remaining in the turbine blade after the removal of the core elements and the spacers and produced by the spacers being closed by stopper elements. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to a commonly assigned, concurrently filed application of Michael Timothy Cooke, and Laura Jean Hiscock for Porous Polymer Beads and Process, Ser. No. 07/275,256, and Michael Timothy Cooke and Laura Jean Hiscock for Porous Polyacrylonitrile Beads and Process, Ser. No. 07/275,317.
This invention relates to isotropic porous polymer beads of an acrylonitrile having controllable surface porosity pore diameters ranging from 0.002 to 5 microns and a pore volume of not substantially less than 1.5 ml/g. The beads are made from acrylonitrile polymer solutions by a thermally-induced phase separation process. The morphology of the beads makes them ideally suitable for use in chromatography applications especially in biomolecular separation processes such as protein separations.
BACKGROUND OF THE INVENTION
Phase separation processes of polymer solutions, including those of acrylonitrile, have been very useful for the preparation of porous low-density microcellular plastic foams, primarily in the form of fibers, sheets and blocks or slabs.
In U.K. Patent Specification No. 938,694, a microporous material is made by mixing a finely divided thermoplastic resin with a gel-forming solvent therefore, raising the temperature of the mixture above the gelling point thereof, decreasing the temperature to form a gel and removing the gel forming-solvent from the mixture by treatment with a solvent for the gel-forming solvent but not for the thermoplastic resin In the example of this U.K. patent, 35 percent by volume of polyethylene resin was heated with 65 percent by volume of xylene at 140° C. and allowed to cool to room temperature, whereupon a gelled mass was formed The mass was cut into sheets and the xylene was extracted with ethanol. After removal of the ethanol with water, microporous foam sheets were obtained, which had a pore size of below about 1.0 micron and a total porosity of about 65 percent, the sheets being useful as separators in a storage battery, for example.
In Young, et al., U.S. Patent No. 4,430,451, such a process was used to produce low density foams from poly(4-methyl-lpentene) resin and a solvent comprising bibenzyl and using, for example, methanol, to remove the bibenzyl leaving the resin in the form of a fragile, microcellular, low density foam, having a broadly disclosed pore volume of from 90 to 99 percent, and a specifically exemplified pore volume of about 94 percent. Such foams were machined into blocks for laser fusion targets.
In Castro, U.S. Patent Nos. 4,247,498 and 4,519,909, the thermally-induced phase separation technology was employed to make microporous foams in forms ranging from films to blocks to intricate shapes. In the '909 Patent, it is stated in Col. 6, lines 34-35, that "as the solution is cooled to the desired shape, no mixing or other shear force is applied while the solution is undergoing the cooling." This strongly suggests that beads were not contemplated. In the '909 Patent at Col. 27-28, microporous polymers containing functional liquids are disclosed. The polymers are said to have either a cellular or non-cellular structure in which the liquid is incorporated. A cellular structure is defined in Col. 7 as are having a series of enclosed cells having substantially spherical shapes with pores or passageways interconnecting adjacent cells, the diameter of said cells being at least twice the diameter of said pores. Such a morphology is not ideal for adsorbing large molecules because the passageways are not of uniform diameter and this represents a serious drawback for large molecule absorption and desportion.
Stoy, U.S. Patent No. 4,110,529, disclosed spherical polyacrylonitrile beads formed by a process in which a polymer solution is dispersed in a "liquid dispersing medium that is a nonsolvent for the polymeric material and and is immiscible with the solvent." The emulsion is added "with stirring into an excess of a coagulating liquid that coagulates the polymer material . . . and that is a non-solvent for the polymer material, is miscible with the solvent, and is immiscible with the dispersing medium." In adopting the classical method to making beads, applicants herein can, for example, form a hot emulsion of a polymer solution in mineral oil and quench the same by adding it to mineral oil at a lower temperature. Therefore, applicants do not use a "coagulating" bath which is immiscible with the polymer solution and miscible with the dispersing medium. The main drawback with the Stoy process, however, is that, even though up to or greater than 95 percent void content is obtained, as set forth in Col. 3, lines 39-41, "a non-sticky skin is formed on the surface of the droplets at the very beginning of the coagulation." Such a skin cannot be controlled by such a process and is only partially permeable, thus substantially interfering with the absorption and desorption of large molecules, and making very desirable the production of non-skinned or controllably skinned microporous beads. Additionally, as will be shown in the comparative examples hereinafter, beads made using the process disclosed in Stoy possess nonisotropic pores, with large pores concentrated in the interior and thus further contributes chromographic applications and the desorption of large molecules.
Matsumoto, in U.S. Patent No. 4,486,549 generally discloses porous fibers and filaments, but also teaches the formation of polyacrylonitrile particles having a porous structure by adding the polymer solution dropwise into an atomizer cup in Example 1 of the patent. However, beads produced in this method have low pore volume, 0.90 ml/g, as seen in Comparative Example 1A of this application, this is responsible for low capacity The particles tend to be flattened and non-spherical, as shown in FIG. 8, and this will cause excessive pressure drops.
Of general interest is Josefiak et al., U.S. Pat. No. 4,594,207, in which the technology is used to produce porous bodies, such as fibers, hollow filaments, tubes, tubing, rods, blocks and powdery bodies from polyolefins, poly (vinyl esters), polyamides, polyurethanes, and polycarbonates. Polyacrylonitriles were not used. There were adjustments in total pore volume, pore size, and pore walls made by varying solvent ratios; the pore volumes exemplified are in the 75-77.5 percent range. Josefiak discloses shaping the viscous solution by methods requiring no shearing during cooling. Examples 1-5 in the Josefiak patent describe the shaping of hollow filaments by spinning the solution through a hollow filament nozzle and then cooling; and Examples 5-7 describe the forming of membranes by coating a plate glass with the solution and then cooling. It is also noticed in Josefiak, U.S. Pat. No. 4,666,607, Col. 2, line 43 to Col. 3, line 14 that he teaches away from using strong shear forces during cooling. At no point in the disclosures does Josefiak contemplate the use of turbulence during cooling, thus, strongly suggesting that beads were not contemplated. In contrast to the present invention, shear is used in the solution prior to and during cooling, so as to form droplets which cool into beads These beads surprisingly provide a high degree of separation capability in in chromatographic applications, low resistance to chromatographic flow rates and excellent morphological advantages for column packing applications, such as having good compressive strength and being substantially spherical. In Zwick, Applied Polymer Symposia, No. 6, 109-149, 1967, a similar method was used to prepare microporous fibers using polymer concentrations in the wetspinning range, 10-25 percent, producing microporous structures with pore volumes in the 75-90 percent range.
In Coupek et al., U.S. Pat. No. 3,983,001, is described a method of isolating biologically active compounds by affinity chromatography. The compounds isolated include enzymes, coenzymes, enzyme inhibitors, antibodies, antigens, hormones, carbohydrates, lipids, peptides and proteins as well as nucleotides, nucleic acids and vitamins, such as Vitamin B. Among the porous carriers are mentioned polyacrylonitrile particles, but these are macroporous, require secondary shaping processes to form particles from the gel obtained by practicing this invention, and are inferior in other chromatographic processes, particularly for size exclusion chromotography.
The current state of the art of microporous beads for purification, chromatography, enzyme binding and the like, are represented by the highly porous hydrophylic resins for sale under the trademark SEPABEADS.sup.® by Mitsubishi Chemical Industries Limited. These are said to comprise hard spherical gel beads composed of highly porous hydrophilic vinyl polymer. They have an average diameter of 120 microns and a pore volume of less than 1.6 ml/g. Also to be mentioned, the same company produces DIAION.sup.® highly porous polymer beads comprised of styrene crosslinked with divinyl benzene. Such beads can have a narrow pore size distribution, their pore volume is less than 1.2 ml/g.
It is thus apparent from the state of the art set forth above that a major drawback of many microporous polymer structures has been the pore volume being less than desired, typically from 20 to 75 percent of the polymer structure, or up to 90 percent, but, as seen in Castro, mechanical strength difficulties arise. Lower void volume enhances mechanical strength, but produces low capacity when used in structures such as chromatography adsorbants. Other prior art structures are in the shape of fibers, filaments or membranes and cannot be effectively used to pack chromatographic columns, thus requiring costly secondary shaping equipment. Many of the prior art structures are not rigid and can swell with changes in ionic strength or solvent making column packing and control difficult.
It has now been discovered that microporous beads, substantially spherical in shape, having very high void volume, a surface of controlled porosity, large pore diameters and high mechanical strength can be produced in thermal-induced phase separation methods by judicious selection of process techniques. Such beads are novel and their valuable properties are entirely unexpected in view of the prior art and the best materials made commercially available to date. The non-skinned beads of this invention permit access of large molecules to their inner surface areas. They are made by a process which does not involve difficult to control chemical reactions, such as formation of beads from monomers. The morphology of the beads makes them ideally suited for most chromatography applications, especially for the chromatography of proteins. They can also be used for enzyme immobilization, hormone separations, and for many other applications.
DESCRIPTION OF THE DRAWINGS
The invention can be understood by reference to the drawings in which:
FIG. 1 is a photomicrograph at 500× magnification of microporous spherical poly(acrylonitrile) copolymer beads of this invention, and illustrates a skinless surface;
FIG. 2 is a photomicrograph at 2000× magnification of a cross section of a microporous bead of FIG. 1, illustrating high pore volume of 97 percent and uniform, non-cellular morphology;
FIG. 3 is a photomicrograph at 1,440× magnification of a section of a poly(acrylonitrile) copolymer bead in accordance with this invention, illustrating a uniform diameter non-cellular pore morphology, a pore volume of 97 percent and substantial matrix uniformity; and
FIG. 4 is a photomicrograph at 2000× magnification of a section of a prior art polypropylene foam, (Castro, U.S. 4,519,909, FIG. 67) showing a 75 pore volume, microporous non-cellular structure. The structure is not a bead.
FIG. 5 is a photomicrograph at lll× magnification of a section of a prior art polyacrylonitrile particle (Stoy, U.S. 4,110,529, Example 1) showing a non-spherical "disc" shaped bead having a skin on the exterior surface.
FIG. 6 is a photomicrograph at 442× magnifification of a section of a prior art polyacrylonitrile particle (Stoy, U.S. 4,110,529, Example 2) showing a bead with extremely large interior pores of 20 to 40 microns in diameter.
FIG. 7 is a photomicrograph at 50× magnifification, of a section of a prior art polyacrylonitrile particle (Stoy, U.S. 4,110,529, Example 2) showing a non-uniform pore structure.
FIG. 8 is a photomicrograph at 347× magnifification of a prior art microporous polyacrylonitrile particle (Matsumoto, U.S. 4,486,549) showing a nonuniform disc-shaped structure.
FIG. 9 is a photomicrograph at 2,570× magnification of a microporous polyacrylonitrile bead of this invention, illustrating a skinless exterior surface with substantially uniform pores.
FIG. 10 is a photomicrograph at 4,470× magnifification of a section of a microporous polyacrilonitrile bead of this invention illustrating a uniform pore interior structure.
FIG. 11 is a photomicrograph at 2,230× magnification of a microporous polyacrylonitrile bead of this invention, illustrating a partially skinless exterior surface with substantially uniform pores and the ability to control exterior pore size.
FIG. 12 is a photomicrograph at 4,640× magnification of a section of a microporous polyacrylonitrile bead of this invention (the bead being produced by the same procedure as in FIG. 11) illustrating a uniform pore interior structure and the abililty to control interior pore size.
FIG. 13 is a photomicrograph at 4,710× magnification of a microporous polyacrylonitrile bead of this invention, illustrating a partially skinned exterior surface.
FIG. 14 is a photomicrograph at 8,660× magnification of a section of a microporous polyacrylonitrile bead of this invention (the bead being produced by the same procedure as in FIG. 13) illustrating the ability to control the interior pore size of partially skinned beads.
FIG. 15 and FIG. 16 are photomicrographs at 2,270× and 2,290× magnification, respectively, of microporous polyacrylonitrile beads of this invention further illustrating the ability to control exterior pore size.
SUMMARY OF THE INVENTION
In accordance with the present invention there are provided highly porous beads with controlled surface porosity comprising a polymer or copolymer of an acrylonitrile, said bead being substantially non-swellable in water, and having substantially uniform pores of not substantially greater than about 5 microns in diameter and wherein the pore volume is not substantially less than about 1.5 ml/g.
The invention also contemplates such porous polymer beads, the pores being at least partially filled with a high molecular size compound, and the beads being substantially spherical.
In a preferred manner of making the beads, acrylonitrile polymer or copolymer is dissolved in a solvent mixture that can only solubilize the polymer at elevated temperatures. The solvent mixture contains a good solvent for the polymer mixed with at least one additive that decreases the solvating power of the solvent. This additive can be a non-solvent for the polymer. The homogeneous liquid solution is subjected to a shearing process to produce droplets of the polymer solution. Preferred methods of shearing the two phase liquid mixture to form droplets are homogenization, break up of laminar jets, atomization, static mixing, and ultrasonification. When using homogenization or static mixing, the homogeneous polymer solution is suspended in a hot inert dispersing liquid prior to shearing. Upon cooling the suspension, a phase separation occurs between the polymer and polymer solvent producing droplets of said polymer and polymer solvent. The droplets are introduced to a cool inert liquid with stirring. The droplets are then collected and the polymer solvent is extracted to produce the porous beads of this invention. The beads have uniform size pores (0.002-5 microns in diameter) and no cells connecting the pores are seen as described in much of the prior art. The cell diameter to pore diameter ratio C/P would be accordingly, 1.0, distinguishing them from the preferred embodiments of Castro. The uniform microporosity is believed to be due to selecting a proper solvent/non-solvent composition. Use of less than about 10 percent by weight of polymer in the solution is preferred to provide a substantially skinless bead with a pore volume of greater than 90 percent. The facts that the beads have controllable surface porosity that they do not stick together and that they possess good handling strength even at high pore volume are entirely unexpected.
DETAILED DESCRIPTION OF THE INVENTION
The porous beads of this invention are made from acrylonitrile polymers and/or copolymers. The acrylonitrile copolymers comprise polyacrylonitrile copolymerized with a (C 2 -C 6 ) mono-olefin, a vinylaromatic, a vinylamino aromatic, a vinyl halide, a (C 1 -C 6 )alkyl(meth)acrylate a (meth) acrylamide, a vinyl pyrrolidone, a vinylpyridine, a (C 1 -C 6 ) hydroxyalkyl(meth)acrylate, a (meth)acrylic acid, a (C 1 -C 6 ) alkyl (meth)acrylamide, an acrylamidomethylpropylsulfonic acid, an N-hydroxy-containing (C 1 -C 6 )alkyl (meth)acrylamide, or a mixture of any of the foregoing.
As solvents for acrylonitrile polymers, any organic or inorganic liquid capable of dissolving them without permanent chemical transformation can be used. These include dimethyl sulfoxide, dimethyl formamide dimethyl sulfone, aqueous solutions of zinc chloride and sodium thiocyanate.
Non-solvents can comprise any liquid medium which is immiscible with the polyacrylonitrile or copolymers. Non-solvents can comprise urea, water, glycerin, propylene glycol, ethylene glycol or mixtures thereof.
Non-solvent dispersants can comprise any liquid medium which is immiscible with the acrylonitrile polymers or copolymers and the polymer solvent. Usually, they will comprise liquids of low polarity, such as aliphatic, aromatic or hydroaromatic hydrocarbons and their halogenated derivatives, low molecular weight polysiloxanes, olefins, ethers and similar such compounds.
Preferred solvent-nonsolvent systems comprise a solvent mixture of dimethyl sulfone-urea-water or dimethyl sulfoxide or dimethylsulfone with water, ethylene glycol, or propylene glycol added and the hot inert liquids of choice are aliphatic, aromatic, or hydroaromatic hydrocarbons such as mineral oil, low odor petroleum solvents, or kerosene. As extraction solvents, preferred are lower alkanols, such as methanol, ethanol, or lower ketones, such as acetone, and water.
Control of the external porosity and pore size distribution are both functions of the composition of the solution of polymer, solvent and non-solvent(s). The ability to control porosity and pore size by these parameters can bee seen from FIGS. 9, 10, 11, 12, 13, 14, 15, and 16. Table A, below, sets forth the ratios of raw materials used to prepare the homogeneous polymer solution use in the preparation of these beads.
TABLE A______________________________________PORE CONTROL DIMETHYL* POLYACRY-FIG. WATER* UREA* SULFONE LONITRILE*______________________________________ 9 3 0 24 110 3 0 24 111 6 0 24 212 6 0 24 213 1 2 24 314 1 2 24 315 1 6 24 116 3 6 24 1______________________________________ *Units are in parts by weight.
The polymer concentration has a greater effect on the external porosity of the bead than on the interior, as shown in FIGS. 9, 19, 11, 12, 13 and 14. This allows flexibility for preparing morphologies useful for slow-release applications, where the rate of release can be controlled by the extent of bead "skin" while maintaining internal porosity. FIGS. 9 and 13 show how much control over the external porosity is available while maintaining uniform internal porosity. This is unexpected in light of prior art, wherein polymer concentration is claimed to change morphology throughout the structure. See W. C. Hiatt, et al. Materials Science of Synthetic Membranes, ACS Symposium Series 269, 1985, pp. 230-244, see pp. 239-243, type III and type IV membranes from PVDF. The morphology of the present invention is also very difficult to obtain by conventional solvent phase separation techniques. In those cases, the solvent diffusion either causes asymmetric morphologies to be formed or much smaller pores. See U.S. 4,486,549, Example 1, wherein porous polyacrylonitrile particles formed from an atomizer cup and quenched in aqueous dimethyl formamide using a solvent phase inversion process, gave low pore volumes and non-spherical particles.
The overall size of the pores can be controlled by choice of the proper non-solvent. Pore size is also effected by both the phase separation temperature of the system and solidification temperature of its components. A larger gap between the phase separation temperature and solidification temperature tends to produce beads having larger pores.
In a convenient way of proceeding, a poly acrylonitrile copolymer (98/2 acrylonitrile/methyl acrylate by weight) is dissolved in a hot (110°-140° C.) solvent/non-solvent mixture designed so that the copolymer is soluble only at elevated temperatures (50° to 110° C.). The composition of the mixture required to meet this condition is determined by running cloud point experiments to determine the temperature where phase separation occurs. Preferably, the solvent will be either dimethylsulfoxide or dimethylsulfone and the non-solvent will be chosen from water, urea, glycerin, ethylene glycol, propylene glycol, or a combination thereof. Typical total solvent/non-solvent ratios will vary from 95/5 to 65/35 by weight. Polymer concentrations will range from 0.5 to less than 20 percent total polymer solids in the solvent/non-solvent solution with 0.5 to about 10 percent on the same basis being preferred.
The hot polymer solution is dispersed with stirring in a liquid e.g., mineral oil, which is substantially immiscible with the solution. Typically 1 volume of polymer solution is dispersed in 4 volumes of the liquid. The dispersion is then pumped through a static mixer (such as the mixer manufactured by Kenics) at a rate sufficient to form small droplets. The droplet size distribution can be controlled by the rate of flow through the static mixer. Typical diameters of the droplets range from 20 microns to 400 microns. After the droplets exit the static mixer they are diluted with additional cool mineral oil, typically 4 volumes, to cool the droplets below the phase separation temperature. The polymer phase separates from the solvent/non-solvent solution and then precipitates as droplets of solid polymer and solvent. The solid droplets are then removed from the mineral oil.
Other methods for forming small droplets of polymer solution in the dispersion include the use of a homogenizer, laminar jets, atomization nozzle, and an ultrasonic mixer. It is essential to the practice of this invention that the dispersion be subjected to a high shear process, thus ensuring the formation of substantially spherical droplets of uniform size and thereby precluding the need for secondary shaping as required by much of the prior art processes for use of their products in chromatographic separation processes.
The collected droplets are then extracted with a material which is miscible with the solvent/non-solvent mixture but not a solvent for polyacrylonitrile to produce porous beads. Acetone or water can be used. The extracted beads are dried to produce a micro-porous product. The pore size of the bead can be varied from 0.002 micron to 5 microns by varying the polymer or copolymer composition or the concentration and type of non-solvent used. The total pore volume is determined by the original concentration of the polymer or copolymer in the solvent/non-solvent solution. It is also contemplated by this invention to remove the solvent material from the solidified beads by any convenient method such as in the case of liquid solvent usage, by simple washing.
Specific applications of this technique will be exemplified in detail hereinafter.
When used herein and in the appended claims, the term "pore volume" means milliliters of void per gram of polyacrylonitrile. Pore volume is directly a function of the polymer concentration. Beads with pore volume greater than 1.5 ml/g are especially preferred. Pore volume is measured by conventional means, such as mercury porosimetry.
The term "substantially non-swellable in water" means that in water, volume will increase through swelling by less than 5 percent. Non-swellable beads are preferred since the bulk volume remains essentially constant in column chromatographic applications thus resulting in consistent flow rates and negligible head pressure losses. The term "skinless" is intended to define porous particles which do not exhibit a surface skin and thereby are efficient for direct absorption of high molecular weight molecules. Bulk density of the polymer beads is measured in conventional ways, e.g., by tapping to constant volume. The beads of this invention will preferably have a bulk density of greater than about 5 ml/g. Lower bulk densities are not as desirable because they tend to have lower capacities. The upper limit of bulk density is about 15 ml/g. At levels above this no economic advantages are noted and mechanical strength is reduced. The average bead diameter can vary widely, depending on its use. Preferably it will be from about 5 microns to about 2 millimeters, more preferably from about 5 microns to about 150 microns. Special mention is made of bead diameters of about 5 microns; these are uniquely suitable for analytical high pressure liquid chromatography. For other chromatography uses, in general, bead sizes of from about 5 to about 150 microns are preferred, especially from 5 to 20 microns, and especially preferably from 20 to 100 microns. Bead sizes can be measured in conventional ways, for example, by use of a particle size analyzer. Although the pore sizes can vary widely, and are measured in conventional ways, for example by nitrogen adsorption or mercury intrusion, it is preferred that the average pore diameter be from about 0.002 to about 5 microns and, especially preferably, from about 0.1 to about 1 microns. Also preferable are beads with an average pore diameter from about 0.002 to about 0.1 microns. When the beads are used to contain a compound, it is preferred that the compound comprise a protein, an enzyme, a hormone, a peptide, a nucleic acid, a polysaccharide, a dye, a pigment, or a mixture of any of the foregoing. Especially preferred for this are proteins. The beads may be filled with such a compound by any convenient means, for example, by physical entrapment, physical adsorption or chemical bonding depending on the compound. In any event, the porous beads used preferably will have pore diameters of at least about 3 times the diameter of the compound.
Conventional techniques are employed to utilize the adsorptive capacity of the porous beads of this invention. The beads can be used, for example, to adsorb vitamins, antibiotics, enzymes, steroids and other bioactive substances from fermentation solutions. They can be used to decolorize various sugar solutions. They can be used to decolorize saccharified wood solutions. They can be used as column packing for gas chromatography, size exclusion chromatography, affinity chromatography, ion exchange chromatography, reverse phase of hydrophobic interaction applications. They are useful to remove phenol, and to remove various surface active agents. They can adsorb a variety of perfumes. They can decolorize waste effluents in paper pulp production, they decolorize and purify a variety of chemicals. The beads are also especially useful for slow release applications when they are made under such conditions as to cause partial skins on their surface.
The beads of this invention are especially useful for protein separation. Proteins especially suitable for purification using the beads of this invention are alpha-lactoalbumin, albumin, gammaglobulin, albumin interferon, and the like.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the present invention. The claims are not to be construed as being limited thereto.
COMPARATIVE EXAMPLE 1A
Five grams of a wet copolymer containing 99 mole percent acrylonitrile and 1 mole percent of methyl acrylate (1:1 copolymer:water by weight) were ground with 5 grams of urea and 30 grams of dimethylsulfone to form a powdered mixture. The mixture was placed in a 1 liter flask with 100 ml of mineral oil heated to 160° C. The mixture was stirred until two liquid phases were present, one phase being a homogeneous polymer solution, the other mineral. Rapid stirring of the mixture with an overhead paddle stirrer gave a suspension consisting of droplets of the hot (about 120° C.) polymer solution in mineral oil. The droplets were cooled by transferring the suspension via a canula to a second stirred mixture consisting of 500 ml of mineral oil, 6 grams of dimethylsulfone, and 1 grame of urea kept at 70° C. The droplets solidified upon contacting the cooler mineral oil. The mixture was cooled with stirring to room temperature, then diluted with methylene chloride to reduce the viscosity of the oil. The droplets were collected on a Buchner funnel and washed with methylene chloride, then the solvent was extracted with 200 ml of acetone for 1.5 hours at room temperature. The resulting beads were examined by scanning electron microscopy and were seen to be highly porous, with relatively uniform pore diameters of about 0.5 microns. The pores extended through the outer surfaces of the beads. The beads made by this process without high shear ranged in size from 10 microns to a few millimeters. A SEM photograph of a cross-section of these beads appears as FIG. 2.
COMPARATIVE EXAMPLE 1B
Particles are made by the procedure taught in EXAMPLE 1 of Matsumoto, U.S. 4,486,549. 120 Grams of polyacrylonitrile homopolymer is dissolved in 1800 ml of dimethylformamide and the resultant solution is added dropwise by a rotational atomizer cup model PPH 306 00D (supplied by Sames Electrostatic Inc.) at a rate of 20 ml per minute into a 20% aqueous dimethylformamide solution whereby there were obtained particles of polacrylonitrile.
An SEM photograph (FIG. 8) shows a different shape and morphology than obtained with the processes of the examples herein.
COMPARATIVE EXAMPLES 1C AND 1D
Beads were prepared following the teachings of Stoy, U.S. 4,110,529. Following the general procedure of Example 1 of the Stoy, polyacrylonitrile was dissolved in dimethyl sulfoxide, dispersed in paraffin oil, and poured in a thin stream into water at 15° C. The procedure was repeated following Example 2 of Stoy (pouring the emulsion into water at 60° C.). The spherical porous beads were separated and photographed with a scanning electron microscope. The photographs appear as FIGS. 5 and 6. The beads are seen to have a porous exterior and extremely large interconnected pores in the interior, unlike those of the present invention in which the beads were substantially isotropic.
EXAMPLE 1
Ten grams of dry copolymer consisting of 99 mole percent acrylonitrile and 1 mole percent of methyl acrylate were ground with 10 grams of dimethylsulfone with a mortar and pestle. The mixture was then stirred and heated to 125° C. to form a homogeneous polymer solution. Mineral oil, 600 ml, at 140° C. was stirred using a Ross homogenizer, model LABME at a setting of 3. The hot polymer solution was slowly added to the mineral oil. Five minutes after all of the polymer solution was added, the suspension was diluted with a hot (140° C.) mixture of 1800 ml of mineral oil, 24 grams of dimethylsulfone, and 4 grams of urea. After the mixture was uniformly homogeneous, the heat was removed and the flask placed in an ice water bath. When the suspension reached 110° C., the homogenizer was turned off and the droplets were allowed to settle.
After cooling the mixture to room temperature, methylene chloride was added to dilute the mineral oil, then the droplets were collected on a Buchner funnel. The droplets were washed with methylene chloride, then extracted with 600 ml of acetone at room temperature for 16 hours. The resulting beads were again collected, washed with methanol, then dried at room temperature under vacuum. The beads were examined by scanning electron microscopy. The majority of the beads ranged from 100-400 microns in diameter, with pore diameters of about 1 micron. The beads were skinless, surface porosity being as high as the interior porosity. Smaller beads (less than 200 microns) can be obtained by increasing the setting to 5 on the Ross homogenizer.
EXAMPLE 2
One gram of dry copolymer consisting of 99 mole percent acrylonitrile and 1 mole percent methyl acrylate was ground with a mortar and pestle with 1 gram of deionized water, 2 grams of urea, and 12 grams of dimethylsulfone. The mixture was heated to 125° C. to form a homogeneous polymer solution. Hot mineral oil (60 ml, 150° C.) was agitated in a Branson Sonifier Model S75 at setting 7 (tuned to 4 amps). The hot polymer solution was slowly added, which increased the current to 6 amps. The suspension was mixed for a few minutes, then diluted with 180 ml of mineral oil (120° C.) containing 2.4 grams of dimethylsulfone and 0.4 grams of urea. The flask was placed in a water bath to cool the suspension. When the suspension reached 110° C. the Sonifier was turned off. After cooling to room temperature, the oil was diluted with methylene chloride and the droplets are collected on a Buchner funnel, then washed with methylene chloride. The droplets were extracted with 60 ml of acetone for 16 hours at room temperature, then again collected, but this time washed with methanol. The resulting beads were dried at room temperature under vacuum. The beads were examined by scanning electron microscopy and were found have high pore volume, pore diameters about 1 micron, and high surface porosity. The average bead diameter was about 50 microns.
EXAMPLE 3
One hundred forty four grams of dimethylsulfone and 12 grams of urea were combined with 720 ml of mineral oil and heated to 130° C. in a one-liter resin flask equipped with a stirrer, thermometer and dip leg. After the sulfone and urea melted, 6 grams of dry copolymer consisting of 99:1 mole ratio acrylonitrile: methyl acrylate and 18 grams of water were added and dissolved to form a homogeneous solution of polymer, dimethylsulfone, urea and water dispersed in mineral oil. The dispersion was then pumped at the dip leg and through a hot 140° C., Kenics.sup.® static mixer (0.25 in. i.d., 6 in. length) at a rate sufficient to form droplets of polymer solution dispersed in mineral oil. The exit of the static mixer was placed three inches above a stirred quench bath of four liters of room temperature mineral oil in which the droplets solidified. The droplets were collected and washed with a low boiling hydrocarbon to remove the mineral oil and dried. Dimethylsulfone was extracted from the droplets by placing them overnight in either 900 ml of acetone or 900 ml of methanol. More preferably, the dimethylsulfone may be extracted by stirring the droplets in one liter of hot, 80°-95° C., water for one hour. The stirrer cannot be allowed to contact the vessel walls or grinding of the droplets may occur. Beads formed in this manner were skinless, with pore diameters ranging from 0.1 to 1.5 microns with the majority of beads ranging from 25 to 425 microns.
EXAMPLE 4
The procedure of Example 3 was repeated using 3 percent of a 99 mole percent acrylonitrile--1 percent methyl acrylate copolymer, and 11 percent water as a non-solvent. Skinless microporous polymer beads in accordance with this invention were obtained, as illustrated in FIG. 1.
EXAMPLE 5
The thermal phase separation technique of Example 3 can be repeated with polyacrylonitrile copolymers containing from 50 to 98 mole percent of acrylonitrile and using dimethyl sulfoxide, dimethyl sulfone, water, urea, ethylene glycol, glycerine, and propylene glycol as solvent mixture components to produce microporous beads in accordance with this invention.
EXAMPLE 6
The microporous beads of Example 4 (FIG. 1) are packed into chromatographic column. A buffered aqueous solution of albumin is passed through the column. Protein is adsorbed in the microporous beads. There is then passed through the column a desorbent comprising a buffered aqueous salt solution. A large part of the protein is recovered in a purified, undenatured state.
EXAMPLES 7-8
The procedure of Example 6 is repeated, substituting buffered aqueous solutions of alpha-lactoalbumin and gamma-globulin for the albumin. The beads take up the respective proteins from solution, and they can be displaced in an undenatured state by desorption with buffered aqueous solutions having a higher salt concentration.
EXAMPLE 9
A mixture of 3 parts of 99:1 mole ratio acrylonitrile: methyl acrylate, 25 parts propylene glycol and 72 parts dimethylsulfone was heated to 130° C. to form a homogeneous solution. The solution was charged to a Parr reactor equipped with a magnetically driven stirrer and dip leg. The reactor was heated to 150° C. and then the solution was forced through heated, 140° C., lines into a heated ultra-sonic horn using pressurized, 35 psig, nitrogen. The flow was kept at a constant rate of 32 ml/min. The ultrasonic nozzle operated at 35 kHz and was tuned at 150° C. (nozzle and power supply obtained from Sono-tek Corp.). The energy input on the nozzle was 22 watts. The liquid droplets were quenched in a mineral oil bath located three inches below the ultra-sonic horn. The oil was decanted and the solidified droplets washed with heptane and dried. The dimethylsulfone was extracted with hot water to provide microporous beads of from about 50 to 1000 micron in diameter.
EXAMPLE 10
Two hundred eighty-eight grams of dimethylsulfone, 12 grams of polyacrylonitrile copolymer consisting of 99:1 mole ratio acrylonitrile: methyl acrylate, and 100 ml of propylene glycol were combined and placed in a Parr reactor equipped with a magnetically driven stirrer and dip leg. The reactor was heated to 140° C. to form a homogeneous solution. The solution was forced through heated, 140° C., lines and an atomization nozzle (for example, Lechler Co. full cone "center jet" nozzle, 0.46 in. diameter orifice). using 150 psig nitrogen pressure. The nozzle was mounted 3 inches over 3 liters of stirred mineral oil or 4 inches over 4 liters of stirred heptane to quench the liquid droplets. The solidified droplets were washed with heptane to remove mineral oil, dried and extracted for one hour with 3 liters of 85°-90° C. water to produce microporous beads. Pore sizes ranged from 0.5 to 1.5 microns with the majority of the beads between 25 and 150 microns.
EXAMPLE 11
A mixture of 6 grams of copolymer comprising 99:1 mole ratio acrylonitrile: methylacrylate, 54 grams propylene glycol and 140 grams dimethylsulfone was heated to 130° C. to form a homogeneous solution. The solution was charged to a 500 ml Parr reactor equipped with a magnetically driven stirrer and dip leg. The solution was heated to 150° C. and forced through heated, 150° C., lines and out a heated, 150° C., nozzle which consisted of seventy-five 50 micron diameter holes using 20 psig nitrogen pressure. The solution was forced at a constant flow rate of 75 ml/min. The laminar jets broke into liquid droplets which were quenched in a 750 ml heptane bath located 3-4 inches below the nozzle. The solidified droplets were collected and dried. The dimethylsufone was extracted with hot water to produce microporous beads with 80 percent of their volume ranging in size from 70 to 200 microns.
EXAMPLE 12
The procedure of Example 11 is followed except that the flow rate was kept at 30 ml/min and the solution vibrationally excited at the natural resonance frequency of the jet velocity (as per J. G. Wissema, G. A. Davies, Canadian Journal of Chemical Engineering, Volume 47, pp. 530-535 (1969)) to form uniformly sized liquid droplets.
The above-mentioned patents and publications are incorporated herein by reference.
Many variations will suggest themselves to those skilled in this art in light of the above, detailed description. For example, glucose and sucrose solutions can be decolorized by contact with the microporous beads of this invention; fatty acids such as butanoic acid, propionic acid and acetic acid can be adsorbed from aqueous solutions with them. Soaps and detergents can be adsorbed from solutions using them. Enzymes can be adsorbed in them and then used to catalyze reactions in substrates such as fermentation broths passed through the beads containing such bound enzymes. All such obvious variations are within the full intended scope of the appended claims.
EXAMPLE 13
The procedure of Example 3 was repeated substituting 3 percent of a 99 mole percent acrylonitrile-1 mole percent methyl acrylate copolymer and 4 percent of water and 13 percent of urea. Microporous beads in accordance with this invention were obtained, a typical cross-section of the beads being illustrated at 1,440× magnification in FIG. 3. | Isotropic porous polymer beads having controllable surface porosity and large pore diameters from about 0.002 to about 5 microns are produced from solutions of an acrylonitrile polymer or a copolymer by a thermally-induced phase separation process including intensively shearing the polymer solution into small droplets. The use of mixed solvent non-solvent combinations as solvents for the polymers, and preferably reducing the polymer content in solution to below 10 percent produces high pore content, substantially spherical beads having a morphology ideally suited to the chromatography of large molecules, such as proteins, and for enzyme-binding. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit under 35 U.S.C. §119(e) of the U.S. Provisional Patent Application Ser. No. 61/277,453, filed on Sep. 25, 2009.
FIELD OF THE INVENTION
[0002] An attachment device used for attaching a cymbal to mounting hardware, such as a cymbal stand, or other percussion hardware that allows for a quick attachment and removal of the cymbal without the need to screw on and screw off a removeable nut, such as a wing-nut.
BACKGROUND OF THE INVENTION
[0003] Musicians typically use cymbals to enhance a musical performance. Cymbals are used in many ensembles ranging from an orchestra, percussion ensembles, jazz bands, heavy metal bands, and marching groups. Drum sets or percussion hardware usually incorporate at least one cymbal, such as a stand-mounted cymbal, a suspended cymbal, as well as a pair of hi-hat cymbals into the set or hardware.
[0004] Cymbals typically consist of thin, normally round plates made form various metal alloys, however, cymbals may also be made of other materials. As part of a drum set, it is desirable to be able to quickly remove cymbals during disassembly of a drum set. For example, there are times where a person needs to be able to disassemble a drum set quickly, as time to assemble and/or disassemble a drum set may be of the essence. For example, during a musical performance, such as a rock concert for example, various musicians typically prefer to use their own instruments. Therefore, between the time when a first musical group performs and the second musical group begins their performance, the instruments of the first musical group have to be disassembled and the instruments of the second musical group have to be assembled.
[0005] There is often little time to disassemble and then reassemble a second set of instruments because patrons of the musical performance cannot wait for an inordinate amount of time for the next performance to start. Because of the inherent larger size and various components and adjustments of a drum set, the drum player's assembly and disassembly of his/her equipment requires a longer period of time when compared with the time needed for most other instruments. In the interest of patrons and other performers during scheduled performances, strict time periods and promptness are required for assembly and disassembly of drum equipment during act changes. Also, the time spent assembling and disassembling drum equipment in a recording studio is charged for as part of the hourly recording cost.
[0006] Therefore, what is desired is to provide a device for quickly attaching and/or detaching a cymbal to mounting hardware, such as a cymbal stand, or other percussion hardware that allows for a quick attachment and removal of the cymbal. This enables the instrument assembly to be replaced and allows for the smooth transition from one musical performance to another where multiple musical groups perform.
[0007] It is further desirable to provide an effective locking device for holding the cymbal in place while still facilitating the almost momentary interchangeability of cymbals.
[0008] It is also further desirable to provide a cymbal holding device which allows for a cymbal to be held between cymbal felts (also known as cymbal felt bushings) and a cymbal seat whereby pressure is placed upon the cymbal and cymbal felts, and the pressure can be controlled by adjusting a retaining member, such as a nut, which is located on a mounting member, such as a bolt. The cymbal felts and cymbal seat may be biased based upon this pressure.
[0009] Prior art references involve various designs to allow for quick removal of the cymbal, however, these designs each have their shortcomings. Prior art designs typically use a wing-nut or another such permanent attachment element.
[0010] U.S. Pat. No. 3,336,827 (Gaylor) provides a cymbal mounted on shaft having a latch that is pivotable by means of a pin. The latch may be manually rotated so that a cymbal may be mounted or removed in one position and held in a second position. Gaylor, however, does not disclose the use of multiple cymbal felts and does not disclose a spring-loaded press and release operation. The spring-loaded, press and release operation of the present invention differs from the operation of the device of Gaylor, in that Gaylor only uses lower cymbal felt bushings on stands. In addition, Gaylor does not provide adjustable spring tension that allows for weight compensation with different cymbals, or for adjusting how loose, or tight the player wishes the felt bushings to hold the cymbal.
[0011] Thus, the prior art, such as Gaylor, does not offer a design as used in the present invention that involves a rotating stop arm and adjustable spring-loaded action.
[0012] Other disadvantages of the prior art include problems when regularly inserting and dismounting the mounting hole of a cymbal over a cymbal stand or other mounting devices with square, or angular surfaces/edges, abrasion from these surfaces against the cymbal hole can cause the metal edge to wear and erode unevenly, thereby displacing the cymbal's center-of-balance when mounted.
[0013] Therefore, there is a need for a self-contained device that offers drum and percussion players an easy, adjustable and quick alternative to the standard cymbal fixation methods that does not cause wear and erosion of cymbals. Such an ideal device shall not require the unscrewing and screwing on of a removeable member to secure the cymbal and it shall accommodate most types of cymbals available.
SUMMARY OF THE INVENTION
[0014] Accordingly, it is an object of the present invention to provide a device that may achieve these objectives, namely that the device provides for a unique, quick and adjustable method for mounting and dismounting a cymbal to a cymbal stand, or percussion hardware.
[0015] It furthermore is a unique feature that the device may be made an integrated part of a cymbal stand, or percussion mounting hardware—and as well, may also be made as a complete add-on accessory that may be attached to existing stands and hardware. Both embodiments and designs are contemplated by the present invention.
[0016] It is another object of the invention to provide a solution to the problem of cymbal wear and tear which results from regularly inserting and dismounting the mounting hole of a cymbal over a cymbal stand or other mounting devices with square, or angular surfaces/edges. These angular surfaces/edges cause the abrasion against the cymbal hole that can cause the metal edge to wear and erode unevenly, thereby displacing the cymbal's center-of-balance when mounted.
[0017] In one advantageous embodiment of the present invention, when inserting and dismounting the mounting hole of a cymbal over the semi-spherical, dome- or capsule-shape of the head nut/stop arm, a universally smooth, and broad contact surface area is provided that prevents abrasion and minimizes wear to the cymbal mounting hole. Also, by nature of the shape of the semi-spherical, capsule-shape of the head nut/stop arm, the head nut/stop arm acts to immediately center the cymbal when quick mounting is desired, or if the cymbal is being mounted when visual acuity is limited, such as assembly on a darkened stage.
[0018] In one advantageous embodiment of the present invention there is a spring-activated mechanism which applies an upward pressure against the stop arm. The present design involves having the tension element, such as a spring, provide a holding force to contain the cymbal felt bushings and cymbal up against the horizontal stop arm. The upward pressure against the arm is what keeps it in the horizontal position. This acts as a locking device to prevent the cymbal and the felt bushings from coming free during play. In addition, the adjustable spring tension allows for weight compensation with different cymbals, or for adjusting how loose, or tight the player wishes the felt bushings to hold the cymbal. These elements are not taught by Gaylor or any other prior art reference.
[0019] Other objects involve biasing the tension element, so that the tension element provides the holding force to contain the cymbal felt bushings and cymbal up against the horizontal stop arm.
[0020] These and other objectives are achieved by providing a self-contained cymbal attachment device, comprising: a head nut with a non-removable, rotating stop arm, a center bolt/base assembly, upper and lower (two) felt cymbal bushings, a bushing seat, a flattenable tensioning element, such as a compression spring, and a retaining member. The retaining member may be a nut.
[0021] Other objectives of the invention are achieved by providing an assembly for mounting a cymbal to a stand comprising: a mounting member having a longitudinal axis; a retaining member having a hollow section through its longitudinal axis, the retaining member being mounted through its hollow section onto the mounting member, the retaining member being secured onto the mounting member; a tension element having a hollow section through its longitudinal axis, the tension element being mounted through its hollow section onto the mounting member, the tension element being longitudinally adjacent to the upper surface of the retaining member; a cymbal felt seat having a hollow section through its longitudinal axis, the cymbal felt seat being mounted through its hollow section onto the mounting member, the cymbal felt seat being longitudinally adjacent to the tension element, such that the tension element fits between the upper surface of the retaining member and the bottom surface of the cymbal felt seat; a top nut having a body with an upper portion and lower portion, and a stop arm fixed to the upper portion of the body via a hinge, the stop arm rotatable into an open position and a closed position, and the lower portion of the top nut having a hollow section, the lower portion of the body being retained by the cymbal felt seat and being mounted through its hollow section onto the mounting member; a first cymbal felt and a second cymbal felt, the first cymbal felt having a hollow section through its longitudinal axis and the second cymbal felt having a having a hollow section through its longitudinal axis, the first and second cymbal felts having a diameter greater than the top nut; and a cymbal having a hollow section through its longitudinal axis, wherein the first cymbal felt, the cymbal and the second cymbal felt are mounted through their hollow sections through the top nut and onto the mounting member when the stop arm is in an open position, and are retained by the cymbal felt seat, the cymbal being positioned in between the first cymbal felt and the second cymbal felt, and wherein, in the closed position, the stop arm retains and secures the first cymbal felt, the cymbal and the second cymbal felt against the cymbal felt seat, wherein the tension element is biased against the retaining member and the cymbal felt seat to secure the cymbal. This provides pressure that compresses the tension element against the retaining member to secure the cymbal.
[0022] The assembly may have the retaining member being screwed to the mounting member, such that, the retaining member is fixed into place. The retaining member may be for example a nut. In one advantageous embodiment, the mounting member may be threaded. The mounting member may comprise a threaded upper portion and a lower body that may be fixed to the stand.
[0023] The cymbal felt seat may have an upper portion for receiving the top nut and a lower portion having a surface for receiving the tension element, such that when pressure is applied the tension element compresses.
[0024] It is contemplated that in one embodiment, the first cymbal felt and the second cymbal felt may be cylindrically shaped or substantially cylindrically shaped. Additionally, the retaining member may also be cylindrically shaped or substantially cylindrically shaped.
[0025] The lower portion of the top nut may have substantially the same diameter as the combination of the upper portion and the stop arm when the stop arm is in the open position. The lower portion of the top nut may also be cylindrically shaped or substantially cylindrically shaped. When the stop arm is in the open position, the combination of the upper portion of the top nut and stop arm may form a cylindrical portion.
[0026] In still another embodiment, the upper portion of the body of the top nut may be capsule shaped or flute shaped.
[0027] While only two cymbal felts are illustrated, it is understood that the assembly may comprise additional cymbal felts, i.e. have more than two cymbal felts stacked in the assembly.
[0028] The pressure that compresses the tension element against the retaining member securing the cymbal may provide an upward pressure against the stop arm. Additionally, the pressure that compresses the tension element against the retaining member securing the cymbal may present a downward pressure against the tension element. The tension element may be compressed fully by the downward pressure.
[0029] In one embodiment, it is contemplated that the retaining member may be adjustable along the longitudinal length of the mounting member. The movement of the retaining member along the longitudinal length of the mounting member may also increase or decrease the pressure to secure the cymbal.
[0030] The assembly may be an integrated part of a percussion stand or may be provided as an add-on accessory to a percussion stand. The assembly may be detachable from the percussion stand.
[0031] Other objectives of the invention are achieved by providing a nut for receiving a cymbal, the nut comprising: a rigid body, the rigid body having a lower portion and an upper portion; and a stop arm, the stop arm rotatable to an open position and a closed position, the stop arm being attached to the upper portion of the body via a hinge; wherein when the stop arm is positioned in the open position, the stop arm and upper portion of the body combined have the same diameter as the lower portion of the rigid body.
[0032] The nut may have a hinge that allows the stop arm to rotate 90 degrees or approximately 90 degrees. There may also be a semi-circular cut out or a stop, which prevents the stop arm from rotating more than 90 degrees in either direction. Such a cut-or stop may be used to provide pressure to help lock the stop arm horizontally in the closed position.
[0033] When the nut is in the open position, the nut is configured to receive or allow removal of a cymbal, and when the nut is in the closed position, the nut retains the cymbal securely in place.
[0034] The lower portion of the body of the nut may be cylindrically shaped or substantially cylindrically shaped. The upper portion of the body of the nut may be flute shaped or capsule shaped. The hinge holding the stop arm to the upper portion of the body of the nut may be a pin, a screw or a fastener.
[0035] Other objectives of the invention are achieved by providing a method for mounting a cymbal to a stand, the method comprising the steps of: providing an assembly for mounting the cymbal to the stand, the assembly comprising: a mounting member having a longitudinal axis; a retaining member having a hollow section through its longitudinal axis, the retaining member being mounted through its hollow section onto the mounting member, the retaining member being secured onto the mounting member; a tension element having a hollow section through its longitudinal axis, the tension element being mounted through its hollow section onto the mounting member, the tension element being longitudinally adjacent to the upper surface of the retaining member; a cymbal felt seat having a hollow section through its longitudinal axis, the cymbal felt seat being mounted through its hollow section onto the mounting member, the cymbal felt seat being longitudinally adjacent to the tension element, such that the tension element fits between the upper surface of the retaining member and the bottom surface of the cymbal felt seat; a top nut having a body with an upper portion and lower portion, and a stop arm fixed to the upper portion of the body via a hinge, the stop arm rotatable into an open position and a closed position, and the lower portion of the top nut having a hollow section, the lower portion of the body are retained by the cymbal felt seat and being mounted through its hollow section onto the mounting member; rotating the stop arm to the open position; mounting the first cymbal felt through the top nut and onto cymbal felt seat; mounting the cymbal through the top nut and onto the first cymbal felt; mounting the second cymbal felt through the top nut and onto cymbal; rotating the stop arm approximately 90 degrees to secure the cymbal between the first cymbal felt and the second cymbal felt.
[0036] The step of rotating the stop arm approximately 90 degrees may provide pressure onto the first cymbal felt, cymbal and second cymbal felt.
[0037] The step of rotating the stop arm approximately 90 degrees may cause the tension element to be compressed, securing the cymbal between the first cymbal felt and the second cymbal felt.
[0038] The method may further comprise a step of rotating the retaining member to relieve the pressure upon the first cymbal felt, cymbal and second cymbal felt.
[0039] Other objectives of the invention involve mounting and dismounting of a cymbal without having to remove a fastener, like a wing nut. The head nut (top nut) may be a cylindrically-shaped member of the device and its diameter may be designed to fit inside the mounting hole of a cymbal and felt cymbal bushings when the stop arm is rotated to the open or vertical position. The separate stop arm piece forms one half of the diameter at the top section of the head nut. A fastener attaches the stop arm through its center, which acts as a pivot that the stop arm rotates freely upon. When the stop arm is rotated to the closed or horizontal position, the arm may acts as a stopper to hold the felt cymbal bushings and the cymbal in place. The lower section of the head nut, or approximately half of its length, may be covered with a thin protective layer of a synthetic material, like nylon to cushion the cymbal metal from rubbing against the main body of the head nut. The head nut screws onto the center bolt/base assembly.
[0040] Below the head nut is the bushing seat (cymbal felt seat), which is disc-shaped with a slight conical raised middle to center the felt bushing. Both felt cymbal bushings and the cymbal rest upon the top of the bushing seat, which abuts the base of the head nut. The bottom of the bushing seat is the upper surface that the compression tension element compresses against. The bushing seat has a center hole designed to fit around and freely slide up and down the center mounting member/bolt.
[0041] When mounting, or dismounting the cymbal, the flatten-able compression tension element may be compressed by downward pressure applied to the upper felt bushing, thereby creating space for the stop arm to rotate to position. In addition the compression tension element may act as an adjustable shock absorber for the cymbal. The tension element sits between the upper compression surface of the bushing seat and the lower compression surface of the tension adjuster nut. The conical shape of the compression tension element allows the tension element to become flat when fully compressed.
[0042] The tension adjuster nut (retaining member) may be turned to apply more or less compression to the tension element to compensate for the different weights of various cymbals. The tension adjuster nut may be a coin-shaped, threaded nut which screws onto the center bolt/base assembly and serves as a lower compression surface for the tension element. The tension adjuster nut may have a knurled outer edge that allows it to be easily turned by fingers.
[0043] The center bolt/base assembly serves as the main attachment shaft of the device. The upper threaded bolt section of the center bolt/base assembly is what the tension adjuster nut and the head nut are threaded onto, and it is, as well, the center shaft that the tension element and bushing seat move up and down upon. Below the threaded center bolt of this assembly may either be: a permanently attached long base nut that allows the entire device to be screwed onto a threaded top of existing cymbal stand or percussion hardware. Or, in another embodiment, below the threaded bolt may instead be the coupling point where the center bolt is affixed as a permanent piece of a cymbal stand, or percussion hardware.
[0044] One advantageous embodiment of the present invention provides a self-contained cymbal fixation device, for quickly mounting and dismounting a cymbal to a stand, or to other types of percussion mounting hardware by swiveling a rotating stop arm. The stop arm may either hold or release the cymbal and cymbal felts depending on which position the arm is rotated. The device includes an adjustable compression tension element at its base that enables a retractable press-and-release function to create space for the stop arm to rotate to different positions. To support the different weights of various cymbals, the tension of the device's compression spring may be finger-adjusted, or the spring may be swapped with other weight springs. One advantageous embodiment of the present invention may be an integrated part of a cymbal stand, or as an integrated part of percussion mounting hardware. The complete device may also be an add-on cymbal mounting accessory that may be attached to existing stands and/or other hardware.
[0045] One advantageous embodiment of the present invention is an alternative to the standard cymbal fixation method and is designed to increase ease-of-use and speed when mounting and dismounting the cymbal. The standard or most common method of mounting a cymbal is by the use of a remove-able wing nut, or wing screw that acts as a holding device to keep a cymbal fixed to the top of a stand, or percussion mounting hardware. In this standard method, the wing nut or wing screw is unscrewed and temporarily removed so the cymbal may be slipped over a threaded shaft at the top of the stand/hardware. Then, the wing nut, or wing screw is screwed back on to secure the cymbal to the stand or hardware. Complaints often attributed to this standard cymbal mounting method include dropping and/or losing the removed wing nut, as well as the time spent screwing the wing nut on and off during mounting/dismounting.
[0046] Additionally, the invention is not limited to these embodiments. Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] Aside from FIG. 2 a , all drawings represent an add-on accessory embodiment of the invention.
[0048] FIG. 1 is a perspective view of a cymbal being mounted to the assembly of one embodiment of the present invention, where the cymbal is attached to the top of a stand;
[0049] FIG. 1 a is an perspective view of FIG. 1 , showing a cymbal mounted to the assembly of one embodiment of the present invention;
[0050] FIG. 2 is an perspective view showing the add-on accessory of an embodiment of the present invention;
[0051] FIG. 2 a is an perspective view showing the integrated stand/hardware embodiment of one embodiment of the present invention;
[0052] FIG. 3 is a exploded view of an embodiment of the present invention showing the individual components of the assembly;
[0053] FIG. 3 a shows rotated side views of an embodiment of the assembled present invention, in the open position, showing a transparent front, lateral and rear view.
[0054] FIG. 3 b shows rotated side views of one embodiment of the assembled present invention, in the closed position, showing a transparent front, lateral and rear view.
[0055] FIGS. 4 to 12 are a sequence of side views of an embodiment of the present invention showing the cymbal mounting procedure and how to adjust it.
DETAILED DESCRIPTION OF THE INVENTION
[0056] Referring to FIG. 1 , this perspective view shows the adjustable wing nut-less cymbal mount assembly 1 attached to the top tilter section 3 of a cymbal stand. This illustration depicts the open, or vertical position of the stop arm 6 that allows the cymbal 2 and upper cymbal felt bushing 4 a to slide over the head nut (top nut) 5 onto the lower cymbal felt bushing 4 b of the device. The combined illustrations of FIG. 1 and FIG. 1 a depict a basic overview of the procedure for mounting and fixing a cymbal 2 to the assembly 1 . A more detailed illustration of the procedure is depicted in FIGS. 4 through 12 . FIG. 1 and FIG. 1 a show in broken line form element 3 , that the assembly may be connected to a percussion stand or to various mounts. The invention involves the assembly being integrated into a cymbal or percussion stand and also involves the assembly being a part of an add-on to a cymbal or percussion stand.
[0057] FIG. 1 a is a perspective view showing the cymbal 2 mounted and fixed to the assembly 1 . The cutaway view of the cymbal 2 allows a complete view of the mounted cymbal fixed in place between the upper 4 a and lower 4 b cymbal felt bushings, and secured by the stop arm 6 , which is now rotated in the closed or horizontal position.
[0058] FIG. 2 is a perspective view showing the assembly 1 as an add-on accessory embodiment that may be screwed onto an existing cymbal stand 3 , or onto other percussion hardware.
[0059] FIG. 2 a is a perspective view showing the assembly 1 a in an optional embodiment as an integrated part of a cymbal stand tilter that may be a permanent piece of a cymbal stand 3 a , or other percussion hardware.
[0060] FIG. 3 is an exploded perspective view showing the individual parts of the invention, comprised of: the head nut (top nut) 5 and the rotating stop arm 6 which are both joined together by a fastener/pivot/hinge 7 , the upper cymbal felt bushing 4 a , and lower cymbal felt bushing 4 b , the bushing seat 10 , the compression spring 11 , the tension adjuster nut 12 and the center bolt 8 and base assembly 8 a.
[0061] FIG. 3 a is a series of three rotated side views of the assembly, showing from left to right, a front, lateral and rear view. All three views in FIG. 3 a depict the stop arm 6 rotated in the open, or vertical position where the upper and lower cymbal felt bushings 4 a , 4 b are dismounted and above the head nut. The leftmost or front view drawing depicts a transparent view to better illustrate the connecting relationship of the assembly parts. The head nut 5 is shown as internally threaded from the opening at its bottom, and the bolt of the bolt/base assembly 8 is screwed inside the head nut 5 . In the add-on accessory embodiment of the invention, as shown here, the base assembly 8 a is shown internally threaded from the opening at its bottom, which allows the invention to be screwed onto an existing stand or percussion hardware. The head nut as shown has internal threading, and is preferred to have internal threading, though some embodiments may provide a head nut without internal threading. In the integrated embodiment of the invention, as shown in FIG. 2 a , a part of an existing stand, or hardware would instead be in place of the base assembly 8 a . The parts indicated on all three views are comprised of: the head nut 5 , and the stop nut 6 , which are shown here rotated to the open or vertical position. The fastener or hinge 7 attaches the stop nut to the head nut and acts a pivot for the stop nut to freely rotate upon. A protective synthetic layer 9 may surround the lower section of the head nut to cushion the contact between the cymbal and the head nut. The bushing seat 10 , acts as a holder on which the lower felt bushings 4 b rests, and it is shown as slightly conical in shape to help to center the felt bushing. The bottom of the bushing seat 10 also acts as the upper contact surface of the compression spring 11 , which the spring compresses against when the cymbal bushings are depressed to rotate the stop arm 6 . The compression and expansion of the compression spring 11 allows the cymbal, the felt cymbal bushings 4 a , 4 b and the bushing seat 10 to move up and down the head nut and the center bolt 8 when downward pressure is applied, and when it is released. The tension adjuster nut 12 is threaded onto the center bolt 8 and it acts as the lower contact surface for the compression spring 11 . When turned up, or down the center bolt 8 , the tension adjuster nut 12 increases, or decreases tension respectively on the compression spring 11 , which may raise the mounted cymbal, or compensate for the added weight of heavier cymbals.
[0062] FIG. 3 b is a series of three rotated side views of the invention, showing from left to right, a front, lateral and rear view. All three views in FIG. 3 b depict the stop arm 6 rotated in the closed, or horizontal position and the upper and lower felt cymbal bushings 4 a , 4 b are installed. The leftmost or front view drawing depicts a transparent view to better illustrate the connecting relationship of the invention parts. All of the individual parts and descriptions are the same as the preceding paragraph describing FIG. 3 a , except for the following additional information: As depicted in all drawings of FIG. 3 b , when the stop arm 6 is rotated to the closed, or horizontal position, it acts a stopper that holds both felt cymbal bushings 4 a , 4 b in place between the stop arm 6 and the bushing seat 10 . The compression spring 11 provides upward pressure against the bushing seat 10 , which in turn holds the felt cymbal bushings 4 a , 4 b against the horizontally positioned stop arm 6 above. When a cymbal is added to the invention, as shown in the mounting procedure depicted in FIGS. 4 through 12 , the same pressure between the compression spring 11 and the closed stop arm 6 acts as the retainer that holds the cymbal in place.
[0063] FIGS. 4 through 12 are a series of drawings of the invention, as seen from the same frontal view. This sequence of drawings, from FIG. 4 through FIG. 11 shows the cymbal mounting procedure in eight steps. FIG. 12 illustrates the adjustment of the compression spring using the tension adjuster nut. The subsequent dismounting of the cymbal from the invention would be this same sequence followed in reverse, starting with FIG. 11 and following the figure drawings backwards to FIG. 4 . The action shown in each Figure is described as follows:
[0064] FIG. 4 shows the invention in the closed position, with the felt cymbal bushings retained by the horizontal stop arm.
[0065] FIG. 5 shows the hand-applied downward pressure on both felt cymbal bushings, which compresses the compression spring and creates ample space above the upper cymbal bushing to rotate the stop arm.
[0066] FIG. 6 shows that, while the downward pressure is being applied to the cymbal bushings, the stop arm may be freely rotated to the open or vertical position.
[0067] FIG. 7 shows that once the stop arm is positioned to the open or vertical position, the upper cymbal bushing may be slid over the top of the head nut and off of the invention.
[0068] FIG. 8 shows the top of the head nut being inserted through the center mounting hole of a cymbal 2 (or, the cymbal 2 being slid onto the head nut) and then down to rest on the lower cymbal bushing. The previously removed upper cymbal bushing is then also slid onto the head nut and down to rest on the top of the cymbal 2 .
[0069] FIG. 9 shows the downward pressure, hand-applied again on both felt cymbal bushings and the cymbal 2 , which compresses the compression spring and creates ample space above the upper cymbal bushing to rotate the stop arm.
[0070] FIG. 10 shows that, while the downward pressure being applied to the cymbal bushings and cymbal, the stop arm may be freely rotated to the closed or horizontal position.
[0071] FIG. 11 shows that once the stop arm is set in the closed or horizontal position and the downward pressure is released, the upward pressure from the expansion of the compression spring below holds the cymbal 2 and felt cymbal bushings in place, mounted and ready to play.
[0072] FIG. 12 shows how, when the cymbal 2 is mounted on the invention, the tension adjuster nut may be turned to increase, or decrease the tension of the compression spring. By increasing the tension, or winding the tension adjuster nut higher up the center bolt, this may raise the cymbal higher and compensate for the added weight of the cymbal.
[0073] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation and that various changes and modifications in form and details may be made thereto, and the scope of the appended claims should be construed as broadly as the prior art will permit.
[0074] The description of the invention is merely exemplary in nature, and thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | An adjustable, spring-activated wing nut-less cymbal mount having a rotating stop arm that may be quickly opened and closed for easy mounting and dismounting of a cymbal and cymbal felts. The device is hand operated without tools and can be adjusted for cymbal play action, as well to better adapt to different weight cymbals. The device is self-contained to avoid misplacing parts during cymbal changeovers. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of digital television (DTV) systems and digital broadcasting. More specifically, the present invention relates to the fields of digital broadcasting and web browsing.
[0003] 2. Related Art
[0004] Heretofore, television systems have mainly been used to receive and display broadcast television signals (e.g., audio/visual programs) for television viewers. In Europe, a data transmission format called “Teletext” has been used which enables compatible television sets to receive a special video signal having encoded therein pages of text based information that can be displayed to a viewer. The viewer can select to thereby view certain text-based pages from a keyboard console or remote device, which can include a cursor directing device. The text-based pages are broadcast from the television broadcaster and some high end television sets can store all the text-based pages in a memory device. Although helpful for obtaining mainstream information, e.g., stock prices and reports, sports information, general news, weather reports, etc., the Teletext system is very limited in the number of pages it can support, e.g., about 100 pages, is very limited in that only text is used and provides no intelligent information filtering mechanisms with respect to the text-based pages. It would be desirable to provide a system that can support enhanced information viewing and navigation within a television system.
[0005] In the United States, the digital satellite system (DSS) television broadcast standard offers an on-screen programming guide that decodes text-based programming information from the television broadcast signal. The DSS on-screen programming information describes the schedule of television programs and acts like an electronic television guide. Also included are some text-based extended information that describe the subject matter of a particular television show, program or movie. Much like the Teletext system, the DSS on-screen programming information is only text-based, it uses a television set, is limited in the number of pages it can support and provides no intelligent information filtering mechanisms. It would be desirable to provide a system that can support enhanced information viewing and navigation within a television system.
[0006] Recently, digital television broadcast standards and digital television sets have been introduced and used. The use of cable systems and digital audio/visual systems into the home has introduced the set-top-box device. The set-top-box device acts as an intelligent controller for accessing and decoding cable programs from digital cable, e.g., terrestrial cable or from a digital satellite system. In the recently proposed home audio/visual network systems, e.g., the HAVi and AV/C standards, the set-top-box also acts as an intelligent controller to control the activities and communications of other electronic devices that can be coupled to the network, like a digital television, a video cassette recorder (VCR), a compact disk (CD) unit, a tuner, a personal computer system, etc. These electronic platforms allow an enhanced ability to access and display information in digital form that was not before possible in the realm of television media. It would be desirable to provide a system that can take advantage of this enhanced ability to access and display digital information within a television system.
[0007] The internet protocol of the world wide web allows multiple computer systems to communicate and display information in a way not before possible. The internet protocol allows hypertext documents, e.g., documents in a hypertext markup language (HTML) format, to be communicated from a server to a client computer system for viewing and interaction therewith. In typical usage, a user interacts with a web browser of a host computer system that connects to the internet via a modem or via some other form of direct high speed digital connection. Once connected to the internet, the user can access information in the form of hypertext documents (web pages) that are stored on server computer systems located on the world wide web, which exists literally all over the globe. It would be desirable to provide a system that can take advantage of the enhanced ability to access and display digital information within a television system for displaying and accessing HTML documents.
SUMMARY OF THE INVENTION
[0008] Accordingly, the present invention takes advantage of the enhanced ability of a digital television system to access and display information to enhance a television viewer's entertainment and information gathering experience. The present invention provides a digital television (DTV) system capable of efficiently accessing and displaying viewer-selected web pages and other HTML documents to a viewer. The web pages and other HTML documents are sent over a digital broadcast to the DTV system of the present invention. These and other advantages of the present invention not specifically mentioned above will become clear within discussions of the present invention presented herein.
[0009] A client-side intelligent device having background caching of web pages within a digital television (DTV) system and method of same are described herein. The present invention includes a digital television system having an intelligent device for interfacing with a user/viewer and controlling the display of information on a display screen. The intelligent device, in one embodiment, is a set-top-box, but could be any intelligent electronic device or computer system. The set-top-box is configured to receive a digital TV broadcast signal (e.g., land based cable or digital satellite system) that may include audio/visual information as well as data signals in a datacast format. The datacast format includes web pages, e.g., in the HTML (hypertext markup language) format. The present invention allows a viewer to have his/her DTV set-top-box or HDTV (high definition TV) monitor and locally cache hypertext documents (and multi-media components), that are transmitted by digital broadcasters, to thereby enhance the internet connectivity performance. A forward caching process is used.
[0010] The DTV broadcasters support multiple channels of information on which digital content providers can supply a domain of web pages that are transmitted in round robin fashion on a periodic basis. The present invention is able to display viewer-selected hypertext documents on the DTV system from this domain. An intelligent filter is used to cache hypertext documents. The intelligent filter modifies itself based on user behavior, e.g., user history, and user preferences in terms of the web pages that a viewer routinely visits. The intelligent filter is used to identify certain web pages (or other HTML-based documents and multi-media components) of the data that are being broadcast and these identified web pages are stored in a cache memory for later use by the viewer. Hypertext documents are forward cached in that they are stored in the cache memory before they are displayed to the user. A second tuner can be used to poll multiple channels when updating the cached contents. Cached web pages avoid broadcast latencies (due to periodic updating) and thereby are displayed faster to the viewer. The use of cached web pages therefore enhances internet connectivity performance.
[0011] More specifically, embodiments of the present invention include a method of displaying information in a digital television system, the method comprising the steps of: a) maintaining an intelligent filter that records hypertext documents based on the frequency that hypertext documents were previously accessed by a viewer of the digital television system; b) monitoring datacast information decoded from a received digital television broadcast signal to identify newly received hypertext documents, the step b) comprising the steps of: b1) sequentially scanning a first tuner of the digital television system over channels of the digital television broadcast signal for a predetermined time period for each scanned channel; and b2) at each scanned channel, identifying newly received hypertext documents. The method further comprising the steps of: c) storing into a cache memory any of the newly received hypertext documents that are recorded in the intelligent filter; d) receiving, from a viewer, an identifier of a selected hypertext document; and e) provided the selected hypertext document is located within the cache memory, accessing the selected hypertext document from the cache memory and displaying the selected hypertext document on a display screen of the digital television system.
[0012] Embodiments include the above and further comprising the step of f) using a second tuner of the digital television system to display contents of a selected channel to the viewer on the display screen wherein the datacast information comprises a domain of hypertext documents that are periodically broadcast. Embodiments include the above and wherein the step a) comprises the steps of: a1) receiving and recording identifiers of hypertext documents accessed by the viewer; a2) recording a count associated with each identifier received by the step a1), the count indicating the number of times each recorded hypertext document was accessed by the viewer; and a3) ranking the identifiers of the intelligent filter based on their associated counts. Embodiments further include a digital television system implemented in accordance with the above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A illustrates a digital television system in accordance with one embodiment of the present invention.
[0014] FIG. 1B illustrates a digital television system in accordance with a second embodiment of the present invention that includes a digital modem connection to the world wide web.
[0015] FIG. 2 is a logical block diagram of an intelligent client device in accordance with one embodiment of the present invention.
[0016] FIG. 3 is a hardware and software data flow diagram of the logical components of the intelligent client device of the present invention.
[0017] FIG. 4 illustrates the background and foreground processes implemented within the intelligent client device of the present invention.
[0018] FIG. 5 is a flow diagram illustrating steps of the foreground process of the intelligent client device of the present invention for accessing and displaying selected web pages and other hypertext documents.
[0019] FIG. 6 is a flow diagram illustrating steps of the foreground process of the intelligent client device of the present invention for updating the intelligent filter based on viewer preferences and behavior, e.g., viewer history.
[0020] FIG. 7A illustrates steps in the background process of one embodiment of the present invention for storing web pages and other hypertext documents in the cache memory of the intelligent client device.
[0021] FIG. 7B illustrates steps in the background process of a two-tuner embodiment of the present invention for storing web pages and other hypertext documents in the cache memory of the intelligent client device.
DETAILED DESCRIPTION OF THE INVENTION
[0022] In the following detailed description of the present invention, an intelligent device within a digital television system for performing background caching of web pages, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one skilled in the art that the present invention may be practiced without these specific details or with equivalents thereof. In other instances, well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Notation and Nomenclature
[0023] Some portions of the detailed descriptions which follow are presented in terms of procedures, logic blocks, processing, and other symbolic representations of operations on data bits within an intelligent electronic media device. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, logic block, process, etc., is herein, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these physical manipulations take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a consumer electronic media device. For reasons of convenience, and with reference to common usage, these signals are referred to as bits, values, elements, symbols, characters, terms, numbers, or the like with reference to the present invention.
[0024] It should be borne in mind, however, that all of these terms are to be interpreted as referencing physical manipulations and quantities and are merely convenient labels and are to be interpreted further in view of terms commonly used in the art. Unless specifically stated otherwise as apparent from the following discussions, it is understood that throughout discussions of the present invention, discussions utilizing terms such as “processing” or “computing” or “generating” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a consumer electronic media device, or similar electronic computing device (e.g., dedicated or embedded computer system), that manipulates and transforms data. The data is represented as physical (electronic) quantities within the consumer electronic media device's registers and memories and is transformed into other data similarly represented as physical quantities within the consumer electronic media device memories or registers or other such information storage, transmission, or display screens.
Digital TV System
[0025] FIG. 1A illustrates one embodiment of the client-side digital television (“DTV”) system 170 a of the present invention. DTV system 170 a is coupled to receive a multi-channel digital television signal 150 from a digital TV broadcaster 190 . Digital system 200 a includes the broadcaster 190 and the client-side DTV system 170 a. Within system 200 a, the digital TV broadcast signal 150 can be delivered to DTV system 170 a using a terrestrial line (e.g., cable TV) or can be delivered via a wireless transmission mechanism (e.g., digital satellite system, etc.). In accordance with the present invention, a number of different and well known digital broadcast TV signal formats can be used to deliver the digital TV broadcast signal 150 to DTV system 170 a. In one format, each channel of signal 150 has a bandwidth of approximately 19.2 Megabits per second (2.5 Megabytes per second) in which audio/visual and datacast information can reside, In one implementation, the American Television Standard Committee (ATSC) digital TV format is used. Several well known ATSC signal formats support datacast information transmission. In other embodiments, the Digital TV Applications Software Environment (DASE) signal format can be used.
[0026] The client-side DTV system 170 a, of one embodiment, includes an intelligent client device (“intelligent device”) 112 which is coupled to receive information from a user/viewer input device 106 . The intelligent device 112 , in one implementation, is a set-top-box and is also coupled (via bus 124 ) to a display device (e.g., a television) 105 for generating images and rendering sound. Optionally, separate speakers (not shown) can be used to generate the sound. The user/viewer input device 106 can be a number of different well known user input mechanisms including, for instance, a remote control, a physical keyboard, a mouse or other cursor directing device, a joystick, etc., and/or any combination of the above. The components of the intelligent device 112 are described in more detail with respect to FIG. 2 .
[0027] DTV system 170 a of FIG. 1A allows a viewer to see (e.g., browse) hypertext documents that are broadcast within encoded datacast information of the digital TV broadcast signal 150 . The encoded datacast information can reside within a channel that also includes audio/visual programming or can reside within a channel dedicated to the transmission of digital datacast information. DTV system 170 a of the present invention implements a mechanism for caching frequently visited hypertext documents (e.g., web pages) in a cache memory to enhance the internet connectivity experience of the viewer. Specifically, hypertext documents are cached in advance of being seen by the viewer. However, these documents are cached based on prior viewing behavior of the viewer. Digital TV broadcasting allows networks to broadcast datacast information (e.g., hypertext documents, HTML-based media and documents, web pages, etc.) over the digital TV signal. In accordance with the present invention, this digital information includes HTML-based documents related to (or not necessarily related to) the programming of the broadcaster. The present invention provides a viewer with a browser in the intelligent device 112 (e.g., set-top-box) or HDTV monitor. The system of the present invention is capable of storing (in cache memory) the latest versions of the hypertext documents visited by the viewer thereby allowing the viewer to access this information in a timely fashion.
[0028] The datacast information within the digital TV broadcast signal 150 is broadcast periodically. Within the system 170 a of FIG. 1A , the digital TV broadcast signal 150 is therefore monitored by the intelligent device 112 for these hypertext documents. Based on the contents of an intelligent filter, those hypertext documents matching the filter are stored in a cache memory within the intelligent device 112 . If a viewer should select a stored hypertext document (e.g., a cache hit) to view, then that selected hypertext document is obtained from the cache memory and displayed on display device 105 . If the selected hypertext document is not stored in the cache memory (e.g., a cache miss occurs), then the intelligent device 112 access the selected hypertext document by monitoring the digital TV broadcast signal 150 until the hypertext document is next seen within the periodic broadcast.
[0029] FIG. 1B illustrates an alternative embodiment of the present invention that includes a digital modem 108 as a second source for receiving hypertext documents. The digital mode 108 is capable of receiving hypertext documents from the internet. Client-side DTV system 170 b includes the intelligent device 112 coupled to the digital modem 108 and to the user/viewer input device 106 . The display device 105 is also coupled to the intelligent device 112 . The digital modem 108 is coupled to the world wide web 180 that contains the internet protocol. Like the system 170 a, system 170 b of FIG. 1A is coupled to receive a digital TV broadcast signal 150 from a digital TV broadcaster 190 . The broadcaster 190 , the world wide web 180 and the client-side DTV system 170 b together constitute system 200 b.
[0030] System 170 b operates in an analogous fashion as system 170 a with one exception. Upon a cache miss, system 170 b can use the digital modem 108 to obtain the selected web page or hypertext document rather than waiting for its next occurrence over the periodic broadcast of datacast information of the digital TV broadcast signal 150 .
Broadcast of Datacast Information Within the Digital TV Broadcast Signal
[0031] With respect to system 170 a and system 170 b, the network broadcasters 190 broadcast a domain of hypertext documents in a periodic fashion, as discussed above. The number of documents within this domain is limited only by available channel bandwidth and expected latency. The document broadcast order is arbitrary, and typically established by the content provider. For instance, a 19.2 Megabit/second channel totally dedicated to the transmission of datacast information could broadcast about 200 hypertext documents per second. If a particular content provider wanted to establish a maximum latency of 20 seconds for any hypertext document, then about 200×20 or 4,000 hypertext documents would be the maximum number of documents within the domain for that channel. The broadcast order of the hypertext documents would be arbitrary and could be such that frequently visited documents get broadcast more often (e.g., with more frequency) than other lesser requested documents. In this case, different hypertext documents would have different maximum latencies.
[0032] However, many digital TV broadcast channels can share bandwidth between their audio/video information/programming and the datacast information. For instance, if a 19.2 Megabit/second channel contains audio, video and datacast information, it is likely that the datacast portion of the channel would contain far fewer than 200 documents/second because the bulk of the available channel width would be consumed by the audio/visual programming. This constraint would limit the document domain size for such a channel.
Hardware and Software Components of Intelligent Device (Computer System)
[0033] FIG. 2 illustrates the components of the intelligent device 112 in more detail. Any consumer electronic device can be provided with the appropriate computer system hardware to act as the intelligent device and thereby provide a platform for the processes of the present invention. For instance, a set-top-box device can be used. Another example of an intelligent device 112 is a digital television or computer system having the required hardware resources as described below. It is appreciated that certain aspects of the present invention, described below, are discussed in terms of steps executed on the intelligent device 112 (e.g., processes 400 , 450 , 480 , 500 a and 500 b ). Although a variety of different computer systems can be used as the intelligent device 112 , an exemplary system is shown in FIG. 2 .
[0034] Intelligent device 112 of FIG. 2 includes an internal address/data bus 100 for communicating digital information, one or more central processors 101 coupled with the bus 100 for processing information and instructions, a volatile memory 102 (e.g., random access memory RAM) coupled with the bus 100 for storing information and instructions for the central processor 101 and a non-volatile memory 103 (e.g., read only memory ROM) coupled with the bus 100 for storing static information and instructions for the processor 101 . A cache memory 102 a resides within memory 102 . As discussed more fully below, hypertext documents matching an intelligent filter are stored into the cache memory 102 a for later use by the viewer. Intelligent device 112 can also optionally include a data storage device (not shown) such as a magnetic or optical disk and disk drive coupled with the bus 100 for storing information and instructions. The intelligent filter discussed above is a memory resident data structure and therefore may reside within memory 102 .
[0035] Intelligent device 112 also includes a video decoder 120 coupled to bus 100 and coupled to supply a digital video signal 124 (e.g., to digital display device 105 ). A number of well known video decoders can be used for video decoder 120 . Intelligent device 112 also includes an audio decoder 122 (e.g., a sound card) that is coupled to bus 100 and generates a digital audio signal over bus 126 (which can be coupled to external speakers). The video decoder 120 processes video information from bus 100 and the audio decoder 122 processes digital audio information from bus 100 . Any of a number of well known audio decoders can be used for audio decoder 122 of the present invention. In one embodiment of the present invention, a two dimensional rendering engine 118 is also coupled to the bus 100 and coupled to the video decoder. The two dimensional rendering engine 118 processes graphics information and supplies the output as an overlay to the video decoder. In this way, graphics information can efficiently be overlaid with the other video information (including hypertext documents).
[0036] Digital TV broadcast information is received and processed by the intelligent device 112 from tuner 130 which is coupled to receive the digital TV broadcast signal 150 . Optionally, a second tuner 132 can also be used to receive digital TV broadcast information. In one embodiment of the present invention, the second tuner 132 is not used. The first tuner 130 is coupled to a modulator 140 via bus 160 and the modulator 140 is coupled to bus 100 . The modulator 140 performs analog to digital conversion of the signals of bus 160 and also acts as a bus interface for bus 100 . The modulator 140 and the tuner 130 are well known. In an alternative embodiment, the second tuner 132 is coupled to a modulator 142 via bus 162 and the modulator 142 is coupled to bus 100 . The modulator 142 performs analog to digital conversion of the signals of bus 162 and also acts as a bus interface for bus 100 .
[0037] As discussed further below, the first tuner 130 is used for processing digital information used in foreground processing tasks. For instance, the first tuner 130 is controlled by the viewer and its contents are displayed in real-time on the television screen 105 for the viewer to enjoy. However, the second tuner 132 is used to perform background processing to maintain the contents of the cache 102 a. In the embodiment that does not utilize the second tuner 132 , the first tuner 130 is used to perform both the foreground and background tasks.
[0038] Under processor control from processor 101 , digital audio/video information received from tuner 130 are directed over bus 100 to video decoder 120 and to audio decoder 122 for rendering on the display 105 and speakers via bus 124 and bus 126 . It is appreciated that bus 124 and bus 126 can be merged into one single larger digital bus carrying both video and audio data signals. Under processor control from processor 101 , digital audio/video information received from optional tuner 132 are directed over bus 100 and are initially processed by an intelligent processor as shown in FIG. 3 . Hypertext documents from tuner 132 can be stored in cache memory 102 a and if selected, are then transmitted on bus 100 to video decoder 120 and to audio decoder 122 , as discussed above.
[0039] FIG. 3 illustrates a data flow diagram of the intelligent controller 112 including hardware and software components. Tuner 130 and tuner 132 receive digital TV information from digital TV broadcast signal 150 . Modulator 140 receives analog information from tuner 130 and generates a digital signal which is received by a demultiplexer 250 . Modulator 142 receives analog information from tuner 132 and generates a digital signal which is received by a demultiplexer 250 . Demultiplexer 250 can be hardware or software implemented and sorts out the audio, video and datacast portions of the digital signals received from the modulators 140 and 142 . Digital video information is forwarded from demultiplexer 250 over data path 220 a to a video processor 260 . Video processor 260 can be software implemented, or alternatively, can be implemented in hardware, or can be a combination of both. Video processor 260 includes a video decoder 120 capable of decoding encoded video signals in well known formats such as MPEG (Motion Picture Expert Group) and MPEG II.
[0040] As discussed above, video processor 260 interfaces with a two dimensional rendering engine 290 which can be a hardware unit (as shown in FIG. 2 ) or can be implemented as a software process as shown in FIG. 3 . Rendering engine 290 interfaces with both the video processor 260 and with a data processor 270 to overlay graphics information. Rendering engine 290 also directly interfaces with the cache memory 102 a. The digital video signals are output over bus 124 . Demultiplexer 250 also forwards digital audio signals over data path 220 c to the audio processor 280 which generates audio signals over bus 126 .
[0041] Demultiplexer 250 of FIG. 3 also forwards digital datacast information over data path 220 b to the data processor 270 which processes hypertext documents. Data processor 270 contains a browser. Any of a number of well known browsers, e.g., as commercially available from Netscape or Microsoft, can be used by data processor 270 . Hypertext documents are rendered by data processor 270 and shipped to the rendering engine 290 for display over bus 124 . An intelligent filter 300 is coupled to the data processor 270 . Data processor 270 also directly interfaces with the cache memory 102 a. In accordance with the present invention, intelligent filter 300 is a software unit and receives an identifier of each hypertext document received by data processor 270 . In one embodiment, the identifier is the web address of a web page. The intelligent filter 300 has recorded therein a listing of identifiers corresponding to frequently visited web pages. This information is compiled based on past viewer behavior.
[0042] The intelligent filter 300 stores into cache memory 102 a each hypertext document that is received by data processor 270 and that also matches an identifier stored in the intelligent filter 300 . Hypertext documents not within the intelligent filter 300 are not stored in the cache memory 102 a. The size of the cache memory 102 a depends on the number of hypertext documents that are desired for storage and typically becomes an implementation choice depending on available memory resources. A 10 Megabyte cache memory 102 a can store about 1,000 web pages.
Caching Processes of the Present Invention
[0043] FIG. 4 illustrates the major processes of the present invention to implement a digital TV web caching system. Process 400 is the foreground process and responds to a user/viewer selecting a particular web page or other hypertext document for display. At step 450 , the intelligent device 112 accesses and displays a selected web page. At step 480 , the intelligent filter 300 is then updated based on the user/viewer selections. In this way, the intelligent filter 300 is updated based on the behavior and viewing patterns/history of the user. Process 400 then repeats.
[0044] In the background, process 500 updates the cache memory 102 a based on information received over the digital TV broadcast signal and based on the contents of the intelligent filter 300 . Process 500 is cyclic. It is appreciated that the intelligent device 112 caches web pages based on the intelligent filter 300 and that this caching activity occurs in the background. It is appreciated that the present invention performs “forward” caching in that web pages and other hypertext documents are cached before they are viewed using the browser. It is further appreciated that both process 400 and process 500 are implemented as instructions stored within computer readable memory units of intelligent device 112 and executed on processor 101 .
[0045] FIG. 5 is a flow diagram illustrating the steps within foreground process 450 . At step 452 , the intelligent device 112 receives a user/viewer originated request for a particular desired hypertext document (e.g., a particular web page). This request typically is received in the form of a web page address typed in (or otherwise selected) by a viewer using the user input device 106 . At step 454 , the present invention checks the contents of the cache memory 102 a to determine if this hypertext document is currently stored in the cache memory 102 a. At step 456 , a check is made if a cache hit occurs (e.g., the selected hypertext document is stored in the cache memory 102 b ) or if a cache miss occurs (e.g., the selected hypertext document is not stored in the cache memory 102 b ).
[0046] If a cache hit occurs at step 456 , then process 450 flows to step 464 where the intelligent device 112 obtains the selected hypertext document from cache memory 102 a. At step 466 , the intelligent device 112 then displays the selected hypertext document on the digital display screen 105 . Upon a cache hit, no latency is perceived by the user from step 452 to step 466 . Process 450 then returns.
[0047] If a cache miss occurs at step 456 , then process 450 flows to step 458 . At step 458 , if the DTV system of the present invention contains a digital modem, it can optionally be used to obtain the selected hypertext document from the internet. Within the preferred embodiment, the DTV system of the present invention, at step 458 , uses the digital TV broadcast signal 150 to obtain the selected hypertext document. At this step, the DTV system monitors the digital TV broadcast signal 150 until its periodic broadcast transmits the selected hypertext document. At step 458 , a latency can be detected by the viewer between the request and the display of the selected hypertext document. The duration of the latency depends on the maximum latency for hypertext documents as determined by the content provider of the currently tuned channel. The latency is also determined by the timing of step 458 within the periodic broadcast of hypertext documents. At step 460 and step 462 , the selected hypertext document is located and it is stored within a memory unit of the intelligent device 112 . At step 466 , the selected hypertext document is then displayed on the digital screen. Process 450 then returns.
[0048] The provision of the cache memory 102 a therefore increases the user's internet connectivity experience, in accordance with the present invention, by eliminating any perceived latencies for selected web pages that are associated with a cache hit.
[0049] FIG. 6 is a flow diagram illustrating the steps within foreground process 480 for updating the intelligent filter 300 based on user/viewer behavior. At step 482 , if the currently selected hypertext document is not recorded in the intelligent filter 300 , then it is recorded with an associated initial count (e.g., 1). At step 482 , if the currently selected hypertext document is already recorded in the intelligent filter 300 , then its associated count is incremented by one. In either case, an identifier of the selected hypertext document is recorded in the intelligent filter 300 . At step 482 , if the intelligent filter 300 becomes filled, as new hypertext documents are recorded, those recorded hypertext documents with the lowest count are dropped off. Optionally, at step 482 , a timestamp is recorded with each recorded hypertext document indicating the time and date that the user last visited the web page.
[0050] At step 484 , the present invention then ranks all of its recorded entries by count number with those hypertext documents with the largest count placed higher in the recorded list. At step 486 , the present invention then optionally drops off of the recorded list any hypertext document that has not been visited by the viewer for a predetermined time period. This optional function is facilitated by the timestamps discussed above.
[0051] FIG. 7A and FIG. 7B illustrate two different versions of background process 500 for filling the cache memory 102 a. Process 500 a and process 500 b are “background” processes in that they operate constantly whether or not the user/viewer is interacting with the DTV system. Process 500 a of FIG. 7A corresponds to DTV system 170 a ( FIG. 1A ) that has one tuner. Process 500 b of FIG. 7B is used with DTV system 170 b ( FIG. 1B ) that contains two tuners.
[0052] Process 500 a of FIG. 7A commences at step 502 where the first tuner 130 receives a web page or other hypertext document from the currently tuned channel of the digital TV broadcast signal 150 . The viewer can alter the currently tuned channel at any time while process 500 a is operating. During TV watching periods, the information received by tuner 130 is displayed in real-time on the display screen 105 . At step 504 , the intelligent device 112 compares the encoded identifier of the received hypertext document (e.g., the web page address) against the identifiers that are recorded in the intelligent filter 300 . At step 506 , if a match occurs then step 508 is entered, otherwise, step 502 is entered and this process continues for the next received hypertext document of the currently tuned channel.
[0053] At step 508 , the intelligent device 112 receives and stores the current hypertext document into the cache memory 102 a. If a previous older copy of the hypertext document is stored in the cache memory 102 a, then at step 508 , the present invention replaces the old copy with the new copy. If a previous same copy of the hypertext document is stored in the cache memory 102 a, then at step 508 , the present invention ignores the current hypertext document. It is appreciated that each hypertext document contains an identifier that can be used to determine if one hypertext document is the same or an older or a newer version of another hypertext document. After step 508 completes, step 502 is entered again to process the next received hypertext document. As described above, process 500 a is limited in that only the currently tuned channel (e.g., that is also used by the viewer) is used to update cache memory 102 a.
[0054] FIG. 7B illustrates the steps of process 500 b. Process 500 b utilizes the second tuner 132 to update the cache memory 102 a by continuously polling the available channels in a round robin fashion to update the cache memory 102 a . In this way, the particular program selected by the viewer does not limit the scope of information that can be used to update the cache memory 102 a. In other words, process 500 b allows the cache memory 102 a to be updated based on information that is being broadcast over one channel (e.g., using tuner 132 ) while the viewer is currently watching a program, or viewing other media information, on another channel (e.g., using tuner 130 ).
[0055] At step 510 of FIG. 7B , the present invention receives datacast information over the channel that is currently tuned by the second tuner 132 . The user/viewer is not allowed to alter the channel being tuned by tuner 132 . Only the processor 101 of the intelligent device 112 can alter tuner 132 by program control. At step 510 , a hypertext document is received by the intelligent device 112 from the second tuner 132 . At step 512 , the intelligent device 112 compares the encoded identifier of the received hypertext document (e.g., the web page address) against the identifiers that are recorded in the intelligent filter 300 . At step 514 , if a match occurs then step 516 is entered, otherwise, step 518 is entered.
[0056] At step 516 , the intelligent device 112 receives and stores the current hypertext document into the cache memory 102 a. If a previous older copy of the hypertext document is stored in the cache memory 102 a, then at step 516 , the present invention replaces the old copy with the new copy. If a previous same copy of the hypertext document is stored in the cache memory 102 a, then at step 516 , the present invention ignores the current hypertext document. It is appreciated that each hypertext document contains an identifier that can be used to determine if one hypertext document is the same or an older or a newer version of another hypertext document. After step 516 completes, step 518 is entered.
[0057] At step 518 , the intelligent device 112 checks if a predetermined time period has expired. Each available channel is scanned according to process 500 b only for a predetermined time period. Once this time period expires, a new channel is used. At step 518 , the present invention determines if the time period for the currently tuned channel has expired. If not, then step 510 is entered and the next hypertext document is received from the same tuned channel. In one implementation, the time period is 20 seconds for each channel but could be any reasonable period or could be programmable or could vary from channel to channel.
[0058] At step 518 , if the time period for the currently tuned channel expires, then at step 520 the second tuner 132 is tuned to the next channel and the time period is reset. Step 510 is then entered to obtain the next hypertext document from the newly tuned channel. Process 500 b repeats in this fashion. It is appreciated that the user can tune tuner 130 to any channel at any time during process 500 b and this action will not alter the results of process 500 b. Therefore, process 500 b is not limited to the particular channel being watched by the user (e.g., via tuner 130 ).
[0059] The preferred embodiment of the present invention, an intelligent device within a digital television system for performing background caching of web pages, is thus described. While the present invention has been described in particular embodiments, it should be appreciated that the present invention should not be construed as limited by such embodiments, but rather construed according to the below claims. | An intelligent device is configured to receive a DTV signal that includes audio/visual information as well as data signals in a datacast format. The datacast format includes web pages, e.g., in the HTML (hypertext markup language) format of the world wide web. An intelligent filter modifies itself based on user behavior and user preferences in terms of the web pages that a viewer routinely visits. The intelligent filter is then used to identify certain web pages of the pages that are being broadcast and these identified web pages are stored in a cache memory for later use by the viewer. A second tuner can be used to poll multiple channels when updating the cached contents. Cached web pages avoid broadcast latencies (due to periodic updating) and thereby are displayed faster to the viewer. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/969,561, filed Oct. 20, 2004, which in turn is a continuation-in-part of U.S. patent application No. 10/461,827, filed Jun. 13, 2003, which in turn claims the benefit of U.S. Provisional Application No. 60/388,287, filed Jun. 13, 2002, and U.S. Provisional Application No. 60/438,282, filed Jan. 6, 2003. The present application claims the benefit of U.S. Provisional Application No. 60/512,777, filed Oct. 21, 2003. The present invention is related to the invention described in co-owned U.S. Pat. No. 7,171,467, filed on Jun. 13, 2003 and issued on Jan. 30, 2007, which is incorporated herein by reference. The present invention is also related to the invention described in co-owned and co-pending U.S. patent application Ser. No. 11/611,210, filed on Dec. 15, 2006, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates in general to methods and apparatus used in managing devices or systems in a communication network and more particularly to methods and apparatus for remote management of these devices or systems in a secure manner.
BACKGROUND OF THE INVENTION
[0003] In distributed computer networks the vast majority of the networking elements are not in the same geographic location or easily accessible by the skilled technicians or network administrators typically responsible for normal maintenance of the elements. Not only do these technicians and administrators require regular access to the network elements for maintenance, but they also need timely access to the network elements when problems arise in order to perform trouble shooting and resolving problems. The more quickly a network administrator can access the elements in the network for troubleshooting the shorter the mean-time-to-repair (MTTR) an outage in the network.
[0004] In general, it is not practical to require physical access to the systems for general maintenance or troubleshooting and repair. The costs would be prohibitive, both in time and personal, to require a skilled technician to be dispatched for every required activity on a system. This has driven a strong requirement to provide for remote management of network elements and servers. A number of means have been developed to provide for remote management of these systems. Remote management of the elements can be provided in-band (the remote administrator communicates with the system using the same network as the user data for the managed system) or out-of-band (the remote administrator communicates with the system using a means other than the network utilized by the user data of the managed system). Typically, when out-of-band remote management is utilized, the administrator is connecting to a console or management port on the system.
[0005] However, the security of the network elements and servers is a concern when remote management is allowed. For a system to be secure, it must first of all be physically secure from attack. Without physical security, it is almost certain an attacker can compromise a system. If management of the system requires physical access to the system then the security of the management is as strong as the physical security. But, as stated above, in most networks this is not practical. It is important, though, to realize that opening up a device to remote management allows a larger window for attackers to utilize in an attack. The use and security of remote management must be carefully considered.
[0006] The struggle to find a workable compromise between the utility of remote management of devices and the need to maintain the security of the devices can clearly be seen in “The Router Security Configuration Guide” published by the National Security Agency. On page 49 of the guide it is recommended that a terminal (or computer) be a stand-alone device protected from unauthorized access. This goes back to requiring physical access to the network element in order to access the console or management port. On page 47 the guide also states, “Permitting direct dial-in to any vital piece of network infrastructure is potentially very risky . . . ” In-band management methods often depend to one degree or another on the security of the network the element is a part of to protect the management traffic. While this MIGHT provide a reasonable level of protection from external attacks (initiated from outside the network), it generally will not provide a sufficient level of protection from an internal attack (initiated from inside a network). To help reduce the vulnerability to internal attack, the “The Router Security Configuration Guide” has recommendation using a dedicated network or at least dedicated network segments for remote network administration of routers. Building out a dedicated network for management would be quite expensive for most networks.
[0007] There are definite advantages to having an out-of-band remote management connection to network elements that utilize connectivity that is diverse from the primary network connection. One of the primary purposes of the remote management connection is to assist the remote administrator or technician in troubleshooting network problems. With in-band management, if a network problem has hindered connectivity to a network element, management connectivity to that element could be lost when it is needed the most. An out-of-band management solution is more likely to allow the administrator or technician to still remotely access the network element to troubleshoot and resolve the network problem in a timely manner. Also, the out-of-band management connection providing connectivity to the console or management port of an element might be available for the initial configuration of the device whereas an in-band management connection might not be available for initial configuration. It is also possible that some functions can only be performed using the console or management port of the element. An example of this would be Password Recovery on a Cisco router. While a dedicated and secure out-of-band network would be the most preferable solution for out-of-band management from a security standpoint, the cost of such a solution is generally prohibitive. While some form of public shared network, such as the Public Switched Telephone Network (PSTN) or an Integrated Services Digital Network (ISDN) provides the most cost effective solution for a diverse out-of-band connection, the security of such solutions is a major concern.
[0008] The most straightforward means of providing out-of-band connectivity to a network element is to place a modem on the console port of a networking element connecting it to the PSTN. However, any perimeter security for the network such as firewalls and access-lists has just been completely bypassed, providing a vulnerable point for intruders to attack. If an attacker knows or can determine the phone number of the modem then the only security is the logon protection on the networking element itself. War dialers will generally find phone numbers connected to modems.
[0009] It is important to realize that most protocols used for assisting in the remote management of network elements do not provide for the confidentiality or integrity of the information being transmitted between the remote administrator and the network element or strong authentication of the parties involved. This is especially critical if a public shared network such as the PSTN is utilized for the out-of-band connectivity. For instance, the protocol most frequently utilized for remote login to network elements (Telnet) transmits traffic in the clear (any one who can tap into or sniff the network can capture and understand the traffic). It would not be uncommon for a remote administrator to be transmitting passwords and device configurations over such a connection. If an attacker were able to insert himself in the middle of such a connection, even more attacks would be possible.
[0010] In order to control the cost of remote management solutions, user traffic and management traffic are being commingled at multiple locations throughout the management path. The use of the user data network for the transport of management traffic is one place this commingling of data occurs. There is also a commingling of user and management data in the device itself. User traffic and device management traffic comes in over the same user interface, uses the same memory and buffers, and is processed by the same processor. The commingling of user traffic and management traffic can compromise the security of the device management.
[0011] Maintenance and troubleshooting of network element problems can often be facilitated by having the element maintain an accurate time clock. One way of keeping the clock accurate on an element is to allow the network to set the clock utilizing a protocol such as Network Time Protocol (NTP). If an attacker were able to alter or interfere with NTP, the smooth operation of the network could be interfered with.
[0012] Some network elements utilize Hypertext Transfer Protocol (HTTP) or Hypertext Transfer Protocol over Secure Socket Layer (HTTPS) for managing the network element. HTTP transmits information in the clear and is susceptible to impersonation and data compromise. Often HTTPS is only authenticating the server to the client. For remote management, mutual authentication can be important.
[0013] A common difficulty in maintaining the elements of a network is keeping the software on the elements updated with patches that protect them from new exploits by hackers and crackers. One of the functions of firewalls is to protect the elements behind them from these exploits so that it is not as critical to keep protected elements updated. However, this does require the firewalls to be updated regularly to protect the elements from new exploits. Keeping the firewalls updated can be difficult.
[0014] Some of these concerns can be addressed by technology existing today. A firewall/Virtual Private Network (VPN) appliance could be utilized to protect management traffic that flows from a user interface on the managed device to a central location providing services for the management of the device. This would protect the management data while it flows over the in-band network. A terminal server could be utilized to allow an administrator to dial into the managed device over an out-of-band network. Some terminal servers will even allow the connection from the administrator to the terminal server to be encrypted for protection of the management data. However, this does not solve all the concerns. The terminal server does not fully support a centralized mechanism to verify an administrator should have access to the managed device, especially if the in-band network is down. The VPN/Firewall does not support connection to the console port of the managed device. Even having both a VPN/Firewall and a terminal server would leave gaps in the protection.
[0015] It would take a number of different devices configured to work together to address most of the concerns. This would require a number of additional devices in an environment where rack space is very expensive. Having another two or three devices in the rack is quite expensive in more ways than just the cost of the equipment.
[0016] An object of the invention is to provide for the secure management of devices without requiring additional devices taking up additional rack space by embedding the necessary hardware and software for secure management of the device in the device to be managed.
[0017] Another object of the invention is to separate user traffic from device management traffic, logically and/or physically, both in the device and while in transit over a network.
[0018] Another object of the invention is to establish a network enabled management interface for the secure remote management of the device. While similar to a console interface, the secure interface is to be engineered to secure remote access.
[0019] Another object of the invention is to define a virtual management interface for controlling management traffic that will flow over the in-band interfaces. The virtual management interface provides for logical separation of the management data from the user data even when the management data and the user data will transit the same physical network.
[0020] Another object of the invention is to utilize standard packet filtering firewall methods to restrict access to the management interfaces of the device, both real and virtual, based on factors such as the source address of the connection request.
[0021] Another object of the invention is to use a means of authentication, including the possibility of strong authentication, to verify the identity of the administrator and restrict access to the management interfaces based on the identity of the administrator.
[0022] Another object of the invention is to use an Access Control Server (ACS) to allow for centralized authentication and authorization of administrators as well as to log accounting information.
[0023] Another object of the invention is to restrict functions and protocols allowed to access the management interfaces to those necessary for remote management of that network element.
[0024] Another object of the invention is to dynamically update the rules used for restricting access to the management interfaces.
[0025] Another object of the invention is to provide for the confidentiality and integrity of the information transmitted between the remote administrator and the management interfaces.
[0026] Another object of the invention is to monitor the management interfaces for proper functioning and alert management software upon failure.
[0027] Another object of the invention is to monitor management interfaces for possible attacks and report possible attacks to Intrusion Detection System management software.
[0028] Another object of the invention is to provide for secure connections to a network providing network services both utilizing the managed device's user data connections and over a dedicated secure network enabled management connection.
[0029] Another object of the invention is to access network services such as ACS, Domain Name Server (DNS), NTP, Network Management Stations, Logging Servers, and Intrusion Detection Systems management stations over either an in-band network connection or over the network enabled management connection (or both) and dynamically switch between which network is being utilized for the service.
[0030] Another object of the invention is to allow a remote administrator or technician to access the management interfaces via either an in-band connection or a network enabled management connection (or both).
[0031] Yet another object of the invention is to provide auditing information about attempted connections (successful and unsuccessful) to the management interfaces.
[0032] Yet another object of the invention is to alert management software on unsuccessful attempts to connect to management interfaces.
[0033] Yet another object of the invention is to be able to securely manage the device through in-band connections to the virtual management interface, the network enabled management connection, or the console port.
[0034] A further object of the invention is to enable securing a plurality of management protocols for managing the device, both over in-band connections to the virtual management interface and over the secure network enabled management connection. Exemplary protocols to be secured include telnet, ssh, http, https, snmp, dns, tftp, ftp, ntp, and xml.
[0035] A further object of the invention is to provide the end-point for an in-band or out-of-band connection between the network segments providing network services and the management interfaces on the managed devices which can be secured using protocols such as IPSec or may be unsecured.
[0036] A further object of the invention is to provide the ability for the managed device to switch which management path is being utilized for management network services, in particular, the managed device can utilize in-band connections for management network services when available and switch to using a network enabled management connection for management network services when an in-band connection is not available.
[0037] A further objective of the invention is to enable the secure management of other devices that are collocated with the managed device.
[0038] A further objective of the invention is to provide for the ability to easily upgrade existing hardware to support secure management of the device.
[0039] Finally, it is an object of the present invention to accomplish the foregoing objectives in a simple and cost effective manner.
BRIEF SUMMARY OF THE INVENTION
[0040] The present invention addresses the foregoing problems, as well as other problems, by providing an exemplary embodiment of a Secure Management Access Control for Computer Chipset (SMACC) for inclusion in devices that are to be enabled for remote management. In this preferred exemplary embodiment, the SMACC functions are implemented on a separate processor with separate flash and memory; however, this is not intended to limit the implementation of these features to separate chipsets in a device. These features also can be combined with other hardware and software features such as being integrated with a modem or with the main processor of a device. Some of the features of the SMACC can also be implemented separately. Such implementations would still be within the spirit and scope of this invention.
[0041] An additional exemplary embodiment of the invention implements the SMACC processor and supporting chips on a card that can be inserted into the device to be managed. In this implementation, management of the device is controlled by the card and the administrator must connect to the card to manage the device. The administrator will be able to connect to the SMACC card through the Virtual Management Interface (VMI) or directly through a SMACC interface on the SMACC card.
[0042] A primary function of the SMACC is to provide for the separation of management data from user data both within the device being managed and while the management information is in transit. Within the device, the SMACC sets up a separate processor for receiving management information and interacting with the control functions of the device. Remote management functions will pass through the SMACC processor. The SMACC also provides for a separate interface for management functions that is network enabled to facilitate remote management. Various embodiments of the invention allow for different types of interfaces to be utilized for the network enabled management interfaces. Exemplary interfaces could include POTS connections to the PSTN, Packet Cellular connections to a cellular provider's infrastructure, an Ethernet interface to a broadband modem and the Internet, or a wireless connection. The types of interfaces are not limited to those in this list to be within the scope of this invention. A VMI is also established for logically separating management traffic from user data when the in-band path is to be used for management data. The VMI is the interface between the SMACC chipset and the user data interfaces. The VMI utilizes existing and developing technology such as VPN to build secure tunnels between the SMACC chipset and the management center while utilizing the user data interfaces of the managed device and the user network to provide the transport of the management data cost effectively. The VPN technology provides the logical separation, confidentiality, and integrity of the management traffic while it is in transit.
[0043] Another primary function of the SMACC is to protect the management interfaces from attack. This is accomplished through a combination of firewall, VPN, and authentication and authorization applications. The SMACC chipset implements the logic to support VPN tunnels to the management center, thus protecting the management traffic between the management interface on the SMACC (VMI or SMACC interface) and the management center. The firewall functionality protects the SMACC chipset from access by unauthorized parties, both internal and external, and from unauthorized protocols. An exemplary embodiment of the SMACC can be configured to only allow the protocols necessary for managing the device to access the SMACC. No other protocols will be allowed through the interface. The authentication and authorization of administrators can either be configured and accomplished locally to the SMACC, and/or centralized services can be accessed at the management center utilizing the secure management interfaces to the management center (VMI or SMACC interface). The SMACC implements the client protocol for exemplary services such a Remote Authentication Dial-In User Service (RADIUS) protocol Terminal Access Controller Access Control System (TACACS+), or Lightweight Directory Access Protocol (LDAP).
[0044] The SMACC allows the use of shared networks including public networks such as the Internet, the Public Switched Telephone Network (PSTN), or a corporate backbone network for secure network management while still providing for the confidentiality, integrity, and logical separation of the management data. In an exemplary embodiment, this is accomplished by utilizing Virtual Private Networking (VPN) technology to build secure tunnels between one or more management interface on the SMACC and the management center providing network resources for management. The VPN tunnels provide for logical separation of the management traffic from any other traffic utilizing the network. The VPN tunnels also utilize encryption to provide for the confidentiality and integrity of the management traffic utilizing the network. SMACC increases both the security and the availability of remote management of devices.
[0045] The SMACC allows for access controls both on what remote devices can connect to the management interfaces of the SMACC (and can therefore access the management functions of the managed device), and what administrators (users) are allowed to connect to the management interfaces of the SMACC. In an exemplary embodiment of the invention, what devices are allowed to connect to the SMACC can be filtered by network level addresses such as Internet Protocol (IP) addresses or calling telephone numbers, as well as by presenting valid credentials such as a certificate or proof of a shared secrete. Administrators can also be challenged for valid credentials and authorization. The SMACC can check these credentials either in a locally maintained database on the SMACC or by utilizing centralized authentication services at the management center. The SMACC optionally implements one or more authentication clients such as a RADIUS, TACACS+, or LDAP client to utilize the centralized authentication services.
[0046] In a preferred exemplary embodiment of the SMACC, the SMACC can be configured to monitor the various management interfaces for connectivity and report the loss of connectivity to the management center. This includes interfaces that are to be available even if they are not currently being utilized to transport management data. One example of this is when a POTS line is connected to a SMACC interface and is configured to be a backup for management data if the connection to the management center via the VMI is not available. In this situation, the SMACC can be configured to be checking the available of the connection to the PSTN even when it is not being utilized for management data. It is critical for that POTS connection to be there if it is needed. Other types of interfaces can also be checked for availability by the SMACC processor. If the SMACC detects a management interface that it is monitoring as being unavailable, it reports this to the management center over another available management interface using protocols such as Simple Network Management Protocol (SNMP), trap or syslog.
[0047] In a preferred exemplary embodiment of the SMACC, the SMACC can utilize network services to provide a centralized and scalable solution for secure remote management of the network. Some of the network services accessed can include an ACS to provide for centralized authentication and authorization at the user level, a NTP server to provide time synchronization for the managed device, a DNS to provide secure name resolution for the managed device, a logging server to provide for centralized logging, a network management station to provide for centralized management of the managed device utilizing a protocol such as SNMP, and an intrusion detection/prevention management system.
[0048] The SMACC implements the clients to access and utilize these services. The SMACC can access the centralized service via the VMI and through a connection to the backbone network (or an operations support network) or via a SMACC interface through an out-of-band network, such as the PSTN or a packet cellular network, to the management center. In a preferred exemplary embodiment of the SMACC, the clients running on the SMACC can access the servers at the management center over any available management interface and the interface being utilized can change depending on the conditions at the time.
[0049] The SMACC may have information it can configure to send to the management center concerning its own operation and the operation of the managed device (or proxy managed devices). This information can be sent to the management center utilizing protocols such as SNMP traps, or remote syslog records as well as other possible proprietary or stands based protocols. The SMACC will utilize the first available management interface in a preferred priority list for transporting this information back to the management center. This information can include auditing information, operational information, and alerts as well as other possible information.
[0050] A preferred exemplary embodiment of the SMACC will detect attempts to access the management interfaces by unauthorized systems or users. The SMACC can be configured to report these attempts to the management center. The SMACC can also be configured to detect and report attempts to utilize unauthorized protocols to access the management interfaces to the SMACC.
[0051] An exemplary embodiment of the SMACC enables remote administrators to access the managed device via the SMACC by first accessing the management center and then connecting to the SMACC via the secure tunnel from the management center to the SMACC. The plurality of possible paths may exist from the management center to the SMACC, both utilizing the VMI on the SMACC and SMACC interfaces on the SMACC. The remote administrator will be able to utilize any of these interfaces to connect from the management center to the SMACC.
[0052] A variety of exemplary embodiments are possible supporting various protocols for the management of the managed device via the SMACC. These protocols can utilize any of the SMACC management interfaces. Example management protocols that can be supported include: telnet, ssh, http, https, snmp, dns, tftp, fip, ntp, and xml. This is not intended to be an exhaustive list of possible protocols for which there might be requirements for supporting for the management of a device.
[0053] An additional exemplary embodiment of the SMACC allows the SMACC processor to be utilized as a secure management proxy for other devices collocated with the device containing the SMACC. User interfaces on the managed device can be specified as proxy management interfaces. Proxy Management Interfaces can be either Console Interfaces or Dedicated Management Segments and will connect to a proxy managed device. A proxy managed device does not have a SMACC, but is being managed via a collocated device that does have a SMACC. Since the communications between the proxy managed device and the SMACC enabled device may not be secure, it can be important for the proxy managed device and the SMACC enabled device to be physically secured together.
[0054] The SMACC processor will control data in and out of the interfaces configured as proxy management interfaces for the passing of management information between the proxy managed device and the SMACC. In a preferred exemplary embodiment, proxy console management interfaces will be restricted to management data only and will be serial interfaces providing a terminal emulation program type of access to the console or management interface on the proxy managed device collocated with the SMACC enabled device. In an exemplary embodiment of the invention, the proxy dedicated management segment is also restricted to management data only in order to provide for physical separation of management data from user data, however, an additional exemplary embodiment of the invention would allow the segment to support both user data and management data. In the exemplary embodiment in which the management segment will support both management data and user data, the SMACC and optionally support utilizing VPN technology to logically separate the management data from user data. The VPN technology could also be utilized to ensure confidentiality and integrity of the management data between the SMACC and the proxy managed device.
[0055] In a preferred exemplary embodiment of the SMACC that supports proxy management of collocated devices, the SMACC can implement both application level proxies for the management protocols to be supported as well as an application level tunnel for passing management traffic between the proxy managed device and the management center.
[0056] An additional exemplary embodiment of the current invention implements the SMACC chipset on a card that can be connected to a system. In the illustrated exemplary embodiment, the card connects to the managed system via a Peripheral Component Interconnect (PCI) bus, but this should not be taken to limit the current invention to a PCI implementation. Any connection of the card to a system to be managed is within the scope of the current invention. The use of a card connecting to a system provides for greater opportunity to utilize the SMACC with existing hardware and hardware designs.
[0057] The SMACC provides for the separation of management data from user data both in the device being managed and while the management data is in transit. Since there is a very strong need for securing remote management and for separating management data from user data, yet this has not been done primarily because it has been considered too expensive to implement, this invention is clearly not obvious to one of ordinary skill in this area. This invention combines existing building blocks along with additional new and innovative features and concepts to solve the shortcomings in remote management in an integrated and affordable solution.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0058] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0059] FIG. 1 is a block diagram for an exemplary embodiment of the embedded SMACC chips set within a device to be monitored;
[0060] FIG. 2 is a block diagram for an exemplary embodiment of the embedded SMACC chip set within a device to be monitored along with a power supply;
[0061] FIG. 3 illustrates the interfaces to the SMACC processor;
[0062] FIG. 4 illustrates network connectivity to the management interfaces;
[0063] FIG. 5 illustrates an additional design for connectivity to the management interfaces;
[0064] FIG. 6 illustrates the packet filtering for access to the SMACC;
[0065] FIG. 7 illustrates the selection of a secure path for management services;
[0066] FIG. 8 illustrates changing which management path is used for management services;
[0067] FIG. 9 is a block diagram of an exemplary embodiment of the embedded SMACC chipset including an integrated modem;
[0068] FIG. 10 is a block diagram of an exemplary embodiment of the embedded SMACC chipset including an Ethernet SMACC interface;
[0069] FIG. 11 is a block diagram of an exemplary embodiment of the embedded SMACC chipset including an integrated packet cellular interface;
[0070] FIG. 12 is a block diagram of an exemplary embodiment of the embedded SMACC chipset including an slot interface for an interchangeable card for a SMACC interface card;
[0071] FIG. 13 is a block diagram of an exemplary embodiment of the embedded SMACC chipset including multiple SMACC interfaces;
[0072] FIG. 14 is a block diagram of an exemplary embodiment of the embedded SMACC chipset without dedicated flash, NVRAM, or RAM chips;
[0073] FIG. 15 illustrates a sample circuit for monitoring the voltage on a telephone line;
[0074] FIG. 16 illustrates a process for monitoring a telephone line for connectivity to a central office;
[0075] FIG. 17 is a block diagram of an exemplary embodiment of the embedded SMACC chipset with an external UPS;
[0076] FIG. 18 is a block diagram of an exemplary embodiment of a SMACC card for interfacing to a managed device;
[0077] FIG. 19 is a depiction of the system architecture of an exemplary embodiment of a system with a SMACC card;
[0078] FIG. 20 is a block diagram of an exemplary embodiment of a system with an embedded SMACC showing a user interface configured as a proxy management interface;
[0079] FIG. 21 illustrates a user interface configured as a proxy management interface;
[0080] FIG. 22 illustrates a SMACC enabled device acting as a proxy management system for another collocated device providing both a console connection to the collocated device and a management segment connection to the collocated device;
[0081] FIG. 23 is a block diagram of an exemplary embodiment of the SMACC card including an Ethernet SMACC interface;
[0082] FIG. 24 is a block diagram of an exemplary embodiment of the SMACC card including a Packet Cellular SMACC interface;
[0083] FIG. 25 is a block diagram of an exemplary embodiment of the SMACC card including an analog modem based SMACC interface;
[0084] FIG. 26 is a block diagram of an exemplary embodiment of the SMACC card including multiple SMACC interfaces;
[0085] FIG. 27 is a block diagram of an exemplary embodiment of the SMACC card in which dedicated proxy management interfaces are included on the card;
[0086] FIG. 28 is a block diagram of an exemplary embodiment of the SMACC processor connecting to a PCI bus in which a controller chip is required for the SMACC processor to access the PCI Bus;
[0087] FIG. 29 is a block diagram of an exemplary embodiment of the SMACC processor connecting to the system Central Processing Unit (CPU) bus of the system the SMACC is being embedded in which a controller chip is required for the SMACC processor to access the system CPU bus;
[0088] FIG. 30 is a block diagram of an exemplary embodiment of the SMACC chipset with an additional chip to implement the VPN technology;
[0089] FIG. 31 illustrates an exemplary power up sequence for a system that has both a SMACC processor and a main processor; and
[0090] FIG. 32 illustrates Fast Hangup.
DETAILED DESCRIPTION OF THE INVENTION
[0091] The present invention now will 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.
[0092] FIG. 1 illustrates the positioning of the SMACC chipset within the managed device. In a preferred exemplary embodiment, the SMACC processor has its own flash, Non-Volatile Random Access Memory (NVRAM), and Random Access Memory (RAM) for operating, however, an alternative exemplary embodiment as illustrated in FIG. 14 is also possible in which the SMACC processor utilizes the same flash, NVRAM, and RAM chips as the main processor and such implementations are not excluded. In these exemplary embodiments, it may be necessary to utilize a controller chip for the SMACC processor to access the necessary bus as illustrated in FIGS. 28 and 29 .
[0093] The Flash chip is intended to safe the programs and microcode for the SMACC processor, the NVRAM to store operating parameters and configurations, and the RAM to act as the operating memory for the SMACC processor. It should be noted that additional chips can be included for additional security or to offload processing from the SMACC processor while still being included in the intent of this invention. An additional exemplary embodiment of the SMACC chipset, as illustrated in FIG. 30 , included a dedicated chip for providing IPSec.
[0094] It is also likely in time that system on chip (SOC) capabilities will continue to expand to the point where it could be economical to use a processor for the SMACC processor that includes some or all of the flash, or NVRAM on the same chip as the SMACC processor. To do so is still considered to be within the scope of this invention.
[0095] FIG. 2 illustrates the option of the SMACC processor and supporting chips having a power circuit from the power supply that is different from the circuit utilized for the main processor of the SMACC enabled device. This would enable a couple of significant features. It would allow the inclusion of a small Uninterruptible Power Supply (UPS) that could then selectively provide power only to the SMACC when there is a power loss. The SMACC could then report the power loss over the SMACC interface that could still be operational even in the event of a loss of power (such as could be the case with a PSTN connection or if the SMACC interface is a cellular network connection). This way the UPS would not have to be large enough to provide power for the entire device while reporting the power outage. An additional feature enabled by a separate circuit for the SMACC chipset is the ability to reload and power cycle the SMACC chipset and the main device discreetly. The main device can be reloaded while the SMACC remains operational allowing for the secure remote monitoring and control of the device boot process over the SMACC interface. The SMACC processor can also be reloaded without the main device being reloaded at the same time.
[0096] A preferred exemplary embodiment as illustrated in FIG. 31 allows for the device to be configured such that on power up, the SMACC chipset receives power first and is allowed to load before the main device is powered up. This allows the main device boot process to be monitored over the SMACC interface on power up. An alternate exemplary embodiment provides for separate power switches for the two circuits such that they could be powered up separately. An additional exemplary embodiment includes separate connections to an external power source or outlets such that common remote power management solutions could be utilized to power up the SMACC separately from the main device.
[0097] In a preferred exemplary embodiment of the SMACC, as shown in FIG. 3 , the SMACC has two types of interfaces for transporting management traffic between the SMACC and the management center:
[0098] Virtual Management Interface (VMI)—logically separates management traffic from user data traffic when a user interface on the managed device is going to be utilized for the network connection, and
[0099] SMACC Network Enabled Management Interface—provides a physically separate interface for the management network connection rather than the user interfaces on the managed device.
[0100] Virtual Management Interface (VMI)
[0101] The Virtual Management Interface (VMI) logically separates management traffic from user data when they are going to utilize the same interfaces on the managed device and the same physical network. In a preferred exemplary embodiment of the current invention, the VMI will utilize a Virtual Private Network (VPN) mechanism such as IPSec to encrypt, protect and logically separate the management traffic before the traffic is passed to the user interfaces. The managed device is designed such that management traffic is not allowed to be sent directly to the user interfaces. All management traffic must go through one of the management interfaces (the VMI or the SMACC interface). The VMI allows any of the user interfaces to be utilized for management traffic while still protecting the management interface and traffic.
[0102] SMACC Network Enabled Management Interface (SMACC Interface)
[0103] The SMACC interface is an interface that is dedicated for management traffic for management of the device. The SMACC interface is a network enabled interface and therefore is able to support the full range of protocols that are typically utilized for management of a device such as SNMP, Trivial File Transfer Protocol (TFTP), File Transfer Protocol (FTP), DNS, SysLog, Telnet, Secure Shell (SSH), or HTTP. The SMACC interface will also control access to the management functions of the device and protect the management traffic in transit through the utilization of VPN technology such as IPSec. The SMACC interface can be utilized to connect to a central location that provides for these network services as well as for remote administrator access.
[0104] Several embodiments of the SMACC with different types of physical interfaces for a SMACC interface are illustrated. FIG. 9 illustrates an embodiment in which the physical SMACC interface is an integrated analog modem for connection to a PSTN. FIG. 10 illustrates an embodiment of the SMACC in which the physical SMACC interface is an integrated Ethernet interface. This embodiment would be particularly useful it the SMACC interface is going to be connected to a broadband modem and the out-of-band connection is going to be over the Internet. FIG. 11 illustrates an embodiment of the SMACC in which the SMACC interface is an integrated cellular interface for connectivity to a packet cellular network. This embodiment would be both for inclusion in transmission equipment where it would be difficult to break out a circuit for monitoring the equipment, and where the primary circuit is a Digital Subscriber Line (DSL) where disruption of the DSL circuit could also disrupt a POTS line. FIG. 12 illustrates an embodiment of the SMACC in which the SMACC interface includes a card slot such as a Personal Computer Memory Card International Association (PCMCIA) card for inclusion of different types of interface cards. There are exemplary embodiments only are not intended to limit the SMACC to these types of interfaces. Other types of interfaces are also within the scope of this invention.
[0105] A SMACC is not limited to only one SMACC interface in implementation. FIG. 13 illustrates an embodiment of the SMACC that includes multiple SMACC interfaces.
[0106] SMACC Card
[0107] The SMACC can also be implemented as a card for insertion into a device to be SMACC enabled. An exemplary embodiment of a SMACC card is depicted in FIG. 18 . FIG. 19 illustrates the architecture of a system that has a SMACC card inserted into a slot. In this situation, it is likely that the SMACC card would not be on the same bus as the main CPU and the main CPU could well already have its own console port.
[0108] There are also a number of exemplary embodiments of SMACC cards with different exemplary embodiments included. FIG. 25 illustrates an embodiment in which the physical SMACC interface is an integrated analog modem for connection to a PSTN. FIG. 23 illustrates an embodiment of the SMACC card in which the physical SMACC interface is an integrated Ethernet interface. This embodiment would be particularly useful it the SMACC interface is going to be connected to a broadband modem and the out-of-band connection is going to be over the Internet. FIG. 24 illustrates an embodiment of the SMACC card in which the SMACC interface is an integrated cellular interface for connectivity to a packet cellular network. This embodiment would be both for inclusion in transmission equipment where it would be difficult to break out a circuit for monitoring the equipment and where the primary circuit is a DSL line where disruption of the DSL circuit could also disrupt a POTS line. There are exemplary embodiments only are not intended to limit the SMACC to these types of interfaces. Other types of interfaces are also within the scope of this invention.
[0109] A SMACC card is not limited to only one SMACC interface in implementation. FIG. 26 illustrates an embodiment of the SMACC card that includes multiple SMACC interfaces.
[0110] Proxy Management Interfaces
[0111] In an additional exemplary embodiment of the SMACC in which the SMACC can be utilized to manage additional devices collocated with the SMACC enabled device, there is a third type of management interface as illustrated in FIGS. 20 and 21 . A proxy management interface is not utilized for communicating management data between the SMACC and the remote management center. Rather, a proxy management interface is utilized for communicating management data between a collocated device and the SMACC in which the SMACC is going to act as a proxy for the device providing it with a secure connection to the management center. The SMACC may also provide the proxy managed device with proxy applications for the management of the device.
[0112] The connections between the SMACC enabled device and the proxy-managed device (as illustrated in FIG. 22 ) can be either connections to the console port on the proxy managed device, and or a dedicated management segment.
[0113] When the connection between the SMACC enabled device and the proxy-managed device, illustrated in FIG. 22 , is to a console or management interface on the proxy-managed device, the interface is generally a serial interface and is dedicated for management data. This interface is also typically only used to provide a command line interface for the device.
[0114] The dedicated management segment, also illustrated in FIG. 22 , typically can support some sort of networking protocol. In this exemplary embodiment of the SMACC, the dedicated management segment supports the Transmission Control Protocol/Internet Protocol (TCP/IP) protocol for networking. This allows a more complete suite of management protocols to be utilized for the management of the proxy managed device. The SMACC enabled device can be utilized to protect Telnet, SSH, TFTP, FTP, HTTP, HTTPS, DNS, NTP, Extensible Markup Language (XML), syslog records, RADIUS transactions, TACACS+ transactions, LDAP transactions, or other protocols for the proxy managed device. Some protocols or services might be configured to be passed through from the proxy-managed device to the management center utilizing an application level gateway on the SMACC for passing this information on. Other applications, such as SNMP, might be implemented as a proxy on the SMACC.
[0115] In a preferred exemplary embodiment of the SMACC with proxy management capabilities, the proxy management segments to the proxy managed devices (as illustrated in FIGS. 20-22 ) should be dedicated for management data between the SMACC and the proxy managed device. This provides the separation of the management data as recommended in the NSA guidelines. The interface type for the dedicated management segment can be any type of interface supported by both the SMACC enabled device and the proxy managed device.
[0116] However, in some environments, the dedication of an interface for management data may be greater than a customer can support. For this environment, and alternative embodiment of the SMACC proxy function supports the use of proxy management segments that allows both management data addressed and routed to the SMACC and user data over the same interface. Another alternative embodiment for the SMACC proxy function when the proxy interface is a Local Area Network (LAN) interface is the use of Virtual LANs (VLANs) for separating management traffic from user traffic. VLANs are not as secure as utilizing physically separate interfaces, but for many customers this would be acceptable. One VLAN would point to the SMACC and another VLAN would be utilized for user data. Another alternative embodiment for the SMACC proxy function would be to utilize a VPN tunnel between the SMACC and the proxy managed device. This is an option when the proxy managed device supports the VPN technology on the interface and allows some aggregation of the VPN tunnels at the SMACC enabled device so that every device does not need a VPN tunnel back to the management center.
[0117] An additional exemplary embodiment of the SMACC illustrated in FIG. 26 includes additional interfaces as part of the SMACC chipset dedicated as proxy management interfaces. This would be especially useful when a SMACC card is being utilized to SMACC enable a device that does not have an abundance of native user interfaces (for example, a server). This would allow a card to be inserted into a system to manage that system and would allow the card to also manage other collocated systems even if the SMACC enabled system does not have the additional interfaces. These interfaces could be a combination of serial interfaces to be utilized as console proxy management interfaces and interfaces of any type to be utilized as dedicated management segments.
[0118] Access to Network Services
[0119] To effectively manage a large number of devices, it is important for the devices to have access to a set of services provided through a network. These services are often centrally located at a network operations center (NOC) or management center, as depicted in FIG. 4 , or at an Application Service provider (ASP). A SMACC enabled device will be able to be configured to securely access these network services over the user interfaces utilizing the VMI or over the SMACC interfaces. There are significant advantages in a network design that allows the management service to be accessed over either type of interface. Typically the network services like an ACS server, a DNS server, a logging server, a network management station, or an NTP server will need to be accessed.
[0120] There are a number of ways the management interfaces of a SMACC enabled device can be utilized in a network for remote management of the network elements. Some of the sample configurations include:
Secure Management Access via remote administrator dial over PSTN; Secure Management Access via Gateway or Network Access Server (NAS) to Out-of-Band Network; and Network Services provided via Out-of-Band Network.
[0124] Secure Management Access Via Remote Administrator Dial Direct to SMACC
[0125] In this scenario shown in FIG. 4 , the remote administrator is using his work station to directly dial the PSTN phone number for the managed device in order to access a SMACC interface on the managed device. In a preferred exemplary embodiment, the SMACC sets up a point-to-point Internet Protocol (IP) connection to the remote administrator and the remote administrator would run a secure client such as secure shell or an HTTPS client on his workstation for communicating with the SMACC interface. This would secure the communications between the remote administrator and the SMACC.
[0126] The SMACC can and should be configured to perform authentication and authorization of the remote administrator before allowing access to the management functions for the managed device. While the SMACC could be configured with a database of authorized administrators, it is also possible to utilize an ACS to authenticate and authorize a remote administrator. The SMACC utilizes its VMI to access network services such as an ACS in the network using a protocol such as RADIUS, TACACS+, or LDAP. This would allow centralized authentication and authorization of the administrators. In this type of configuration, if connectivity to the network services is down, the SMACC would not be able to utilize a central ACS and would have to revert to allowing access based on a locally maintained database.
[0127] Secure Management Access Via Gateway to Out-of-Band Network
[0128] FIG. 5 shows another configuration that can be used to allow remote administrators access to a SMACC enabled managed device. A gateway or Network Access Server (NAS) is utilized to dial out to the SMACC interface on the managed device from a secure network that provides the needed network services. When the administrator initiates a connection to the address of the SMACC interface, the gateway will initialize a connection to the SMACC interface (using a VPN tunnel) if a connection is not already up. The SMACC interface can then also utilize the VPN tunnel back to the management center to access the needed network services (including an authentication/authorization server) if the services are not available over the VMI.
[0129] The out-of-band network does not have to be a PSTN network. For instance, in FIG. 5 , if the SMACC's connection to the out-of-Band network is a DSL connection to an Internet Service Provider (ISP) and the Network Operations Center Network has a gateway to the internet this diagram would work as well.
[0130] Network Services Provided Via Out-of-Band Network
[0131] One difficulty with using a centralized ACS is that, on occasion, a network administrator is attempting to access a network element during problem determination when the network connectivity is down. Requiring an administrator to know a locally configured password on the managed device to access the management interface to a network element every time network access was down would risk the security of the system. Too many people would have access to the password.
[0132] A major advantage of the network design in FIG. 5 is the utilization of the out-of-band network connection for connectivity to the ACS for authentication and authorization as well as other network services. If the SMACC interface is utilizing a broadband connection such as DSL to access an ISP and then is utilizing a VPN client to connect to a VPN gateway on the in-band data network, not only can this VPN tunnel be used for remote administrator access to the SMACC interface, but the VPN tunnel can also be used by the SMACC interface to access network services at the network operations center. The managed device can be configured to always utilize the out-of-band connection for network services, or only to utilize it when they are not available over the VMI because the user network connections are down. The connection between the User Data Network and the Internet would be able to utilize VPN services that exist today for VPN gateways.
[0133] In the configurations where a VPN tunnel is being built across the out-of-band network as shown in FIG. 5 , the network administrator may decide to allow the remote administers to use the telnet protocol to access the managed device if they trust the security of the Network Operations Center Network. The telnet traffic would travel in the clear between the remote administer and the gateway. In the exemplary embodiment, the gateway would encapsulate the traffic in an Internet Protocol Security (IPSec) tunnel providing for data confidentiality and integrity as it travels across the “untrusted” out-of-band network. The SMACC would then receive the traffic from the IPSec tunnel and would proxy the management of the rest of the device.
[0134] The SMACC can be configured to filter packets on various criteria such as origin IP address or telephone number. For example, as shown in FIG. 6 , if a packet is not from a valid source, log information will be recorded and the packet will be discarded. If the destination of the packet is for the managed device, the packet will continue to be processed. If the destination is not for the managed device, the packet may optionally be logged and will be discarded. The management interfaces of the SMACC can also be configured to only allow the specific interfaces necessary for management of the device. If the packet is not for a necessary protocol, it will optionally be logged and discarded.
[0135] The SMACC can make extensive use of network services in order to facilitate the remote management of SMACC enabled devices. These services can include a centralized authentication server, a network time server (utilizing a protocol such as network time protocol (NTP)), remote logging servers, and network management stations for reporting. The SMACC is set up to be able to access these network servers over the VMI interface or over the SMACC interface. There are circumstances where it would be useful to utilize the VMI interface when connectivity is available and only use the SMACC interface when the in-band connections for the VMI are not available. The SMACC can be configured to attempt to connect to network services according to a priority list starting at the top of the list, see FIG. 7 .
[0136] In the event that an existing connection of a network service is lost, the SMACC can attempt to reestablish a connection to the network service over another interface, as shown in FIG. 8 . The SMACC can be configured to give preference to the VMI or to the SMACC interface.
[0137] An exemplary embodiment of the SMACC interface may include an integrated modem, as illustrated in FIG. 9 , consisting of an interface to a telephone line and a Data Circuit-terminating Equipment (DCE) interface for a connection to Data Terminal Equipment (DTE). Additional exemplary embodiments of the SMACC interface may include one or more of the network interfaces illustrated by FIGS. 10 and 11 which include but is not limited to an Ethernet interface or a cellular interface. In particular, this application would be well suited for cellular packet data.
[0138] An additional exemplary embodiment is depicted in FIG. 12 in which the SMACC interface on a device can be a card where the user can select the type of interface they want for the SMACC interface by plugging the appropriate card into the SMACC slot.
[0139] An additional alternate exemplary embodiment is illustrated in FIG. 13 in which there can be multiple SMACC interfaces for dedicated management access. This provides for additional redundancy and reliability of the SMACC interface functionality over multiple networks.
[0140] FIG. 14 depicts an additional exemplary embodiment in which the SMACC processor does not have its own dedicated Flash, RAM, or NVRAM, but rather shares these resources with the main processor. In this embodiment, segments of these resources would be dedicated for use by the SMACC processor.
[0141] Command, Control, and Monitoring functions for the device being managed are passed through the SMACC processor. This will include configuration commands, operational commands, monitoring commands and updates, etc. Only user data will not have to pass through the SMACC processor. SNMP traps and remote syslog messages will also be passed through the SMACC and sent on either the VMI or a SMACC interface.
[0142] When an administrator is logged into the SMACC processor for controlling the managed device, there will also be commands for configuring and controlling the SMACC processor itself. This will include configuration of parameters for the SMACC interface, the Virtual Management Interface, configuration of connectivity parameters for the gateway device at one or more management centers, configuration of network services located at the management center, configuration of access controls restricting what administrators are authorized to access the management functions of the device, as well as other possible functions and commands. Among the possible services to be configured on the SMACC for utilizing are network management stations utilizing SNMP or XML, TFTP servers, FTP servers, remote syslog servers, NTP servers, and DNS servers.
[0143] The availability of multiple and diverse paths for reporting status information to monitoring stations or allowing for remote configuration of the device are significant advantages of designs where only one or non-diverse paths are utilized. The use of the SMACC interface to connect to and protect traffic over a diverse network allows the device to regularly report on the status of the device and its connections even in the face of a loss of the network connection. This status information can be reported via standardized means such as Simple Network Management Protocol (SNMP), or via private protocols, or a combination of both either over the VMI when it is available and/or over the SMACC interface. This is especially important if status information is to be communicated when the user interfaces are down.
[0144] It is also possible to configure the SMACC processor to receive console messages and log messages, filter the messages, and send an alert over either the VMI and/or the SMACC interface for certain error conditions such as a particular interface going down. If the interface that went down were the interface the router would normally utilize for connectivity to the management center, the SMACC interface might be the only way the alert gets sent.
[0145] The use of the VMI for connecting to the SMACC processor for management of the device allows the management data to logically isolated from user data, but still physically use the user data network. This has the possibility of reducing charges for the secondary network utilized by the SMACC interface, especially if charges for the secondary network are based upon connect time or packet/byte counts. The normal operational method of reaching the SMACC processor would be through the in-band network to the VMI, and only then a path to the VMI is not available would the secondary network need to be utilized. Since the secondary network often has lower performance characteristic, it is likely that the in-band path through the VMI will also provide for a faster connection when the in-band data network connections) are available.
[0146] The exemplary embodiment of the SMACC interface includes a POTS connection to the PSTN depicted in FIG. 9 . An additional exemplary embodiment includes a means of automatically monitoring the status of the connection to the telephone network. This monitoring can be accomplished by measuring the voltage levels of the telephone line with a circuit similar to FIG. 15 and/or by periodically taking the line off-hook and checking for dial tone as shown in the flow chart in FIG. 16 . If the SMACC detects the connection to the telephone network is malfunctioning it will notify a monitoring station using the management connection over the VMI or if additional SMACC interfaces are operational, over another SMACC interface.
[0147] In the exemplary embodiment depicted in FIG. 2 where a UPS is incorporated to supply a limited amount of power to the SMACC processor and chipset on the loss of power to the managed device, an additional exemplary embodiment allows the SMACC processor to monitor the supply of external power to the power supply. The exemplary embodiment depicted in FIG. 17 utilizes an external UPS to provide a limited supply of power in the event of a power outage and provide a management connection from the external UPS to the SMACC for management of the UPS. This would include notification by the UPS to the SMACC on the loss of external power. If the SMACC detects a power loss from the external power source, it will notify the management center of the loss of power. It is likely that the VMI will not be able to be utilized for this notification if power has been lost, but for certain secondary networks such as the PSTN network or a cellular network, it is likely that the SMACC interface to that secondary network would be able to be used to report the outage.
[0148] In yet another exemplary embodiment of the SMACC processor as depicted in FIG. 2 , the SMACC processor can provide a means of “cycling” the power for the managed device. When logged into the SMACC processor, the administrator could issue the “power cycle” command to cycle the power for the circuit for the main processor (circuit 2 in FIG. 2 ). Allowing an administrator to power cycle device while connected to SMACC processor over a SMACC interface allows the remote administrator to see all the boot commands for the managed device.
[0149] In order to defend against denial-of-service attacks on the PSTN line the SMACC Interface receives Caller ID on the calls it receives. Filtering of calls based on Caller ID can be performed by the SMACC processor. In an exemplary embodiment, calls from an unauthorized source will be answered and immediately disconnected as illustrated in FIG. 32 . Notification of the attack can be made to the management center (over the VMI or a SMACC interface). If the VMI does not have an operational path to the management center and a SMACC interface is not available, the SMACC processor can be configured to bring up a SMACC interface to report the attack to the management center.
[0150] The VMI allows the SMACC processor to utilize data network ports to securely tunnel management traffic to the management center. The SMACC will run a suitable Virtual Private Network (VPN) protocol such as IPSec over the VMI. This allows the SMACC to take advantage of many services available at the management center such as network management applications, Network Time Protocol Servers, Log Server, Access Control Servers, and provide remote access to the managed device and more specifically the SMACC over the data network. Examples of protocols exemplary embodiments of the SMACC could utilize to allow an administrator access to the SMACC include but are not limited to HTTP, HTTPS, Telnet, or Secure Shell.
[0151] The SMACC has the capability to provide management information to a network management station. This could be implemented via standardized protocols such as SNMP or via proprietary protocols. The SMACC can be configured to allow a remote network management station to query the SMACC for information and/or for the SMACC to initiate sending information to the network management station. The SMACC can be configured to send selected information on a periodic basis as well as send selected information when specified threshold conditions are met or error conditions occur. This is referred to as setting traps for information to be sent. Some management protocols also allow operating parameters of the SMACC to be changed by the remote administrator using the protocol. This information will be sent over either the VMI or over a SMACC Interface and will be encrypted using a VPN protocol.
[0152] SMACC access to the management center servers allows the SMACC to access an NTP Server and a log server. The NTP server allows the SMACC to maintain an accurate time source and to use the time source for time stamping log information. The SMACC could also log events both locally and remotely at a log server over the network. Keeping proper log and audit information is a vital part of network management.
[0153] An additional service the SMACC can utilize through the VMI or the SMACC Interfaces is an Access Control Server (ACS). The SMACC will run a client for authentication and can communicate with one or more ACS using standardized protocols such as RADIUS or proprietary protocols. This would allow the SMACC to authenticate and authorize users connecting to the SMACC and determine their privileges on the SMACC. If a protocol such as TACACS+ is being used the SMACC would also be able to provide accounting information to the ACS.
[0154] The advantages of using an ACS connected over the network is the user information, passwords and privileges can be configured on one central system rather than having to be configured in every device in the network. For larger networks with a large number of administrators centralized authentication is mandatory. The SMACC would be able to perform authentication and authorization using the connection to an ACS over the VMI or SMACC Interface. Allowing the SMACC to connect to the ACS over either the VMI or a SMACC Interface greatly improves the availability of the ACS to the managed device and the SMACC.
[0155] In an exemplary embodiment the SMACC might typically report ongoing network status information and alerts to a network management station using a protocol such as SNMP over the VMI. However, there are times when the SMACC will report network status information and alerts over a secondary network such as the PSTN using a SMACC interface. Typically, this would occur when the SMACC has lost connectivity to the Network Management Station via the VMI. One primary condition the SMACC might want to report in this manner would be the failure of all of the managed device interfaces that could provide a path to the VMI to the management center. A secondary network and a SMACC Interface would then be the only way the SMACC could report the outage. Another event might be the loss of power to the site since the in-band connections could well be down due to the loss of power. To send the alert via a secondary network, the SMACC would initiate a connection using a SMACC Interface to the Management Center. Once this connection is established, the SMACC can send the alerts or status information to the Network Management Station over a secondary network not affected by the power outage (such as a PSTN or cellular network).
[0156] As indicated above, one of the events that it might make sense to report over SMACC interface would be the loss of power at the site. The SMACC can be configured to report the loss the main external power source to the power supply. Upon detecting loss of power from the main power supply, the SMACC would be configured to bring up a connection to the management center over a SMACC interface utilizing a secondary network resistant to the affects of a power failure and send the alert to the log server and/or management station. This would provide a Network Management Center quick notification that the underlying cause of a network problem is a power outage at the remote location. This can save significant time during the problem determination process and help get the proper personal involved more quickly.
[0157] An exemplary embodiment as depicted in FIG. 2 for providing the SMACC with power for reporting the power outage would include building a power supply with a small UPS and multiple circuits for the power. One circuit would provide power to the SMACC processor and its supporting chips including at least one SMACC Interface. This circuit would be backed up by the UPS. The second circuit would provide power to the rest of the managed device. When power is lost, the UPS would then only have to supply power to the SMACC chips allowing a smaller UPS to be utilized. The SMACC will monitor the power supply for loss of external power and send the alert when that event occurs.
[0158] An additional exemplary embodiment in which there is only one circuit or the UPS backs up both circuits would have the SMACC shutting down the main device when there is a power outage saving power and allowing a smaller UPS to be utilized to enable reporting power outages. Yet another exemplary embodiment would utilize an external UPS as depicted in FIG. 17 . The SMACC can be configured to designate a user interface as a UPS monitoring interface. Data from that interface would then be sent to the SMACC and the SMACC would be notified when external power has failed. At that point the SMACC can do a controlled shutdown of the main processor and report the outage over a SMACC interface. Shutting down the main processor right away would reduce power requirements and allow a smaller extern UPS to be utilized. The SMACC could also be configured to forward any other log information or problem determination information. The SMACC could also be configured to keep the SMACC interface active for a specified length of time or as long as sufficient power remained in the UPS
[0159] The SMACC can also be configured to provide notification to the Management Center when power is restored to the site. When power is restored the SMACC can be configured to wait a determined length of time (perhaps on the order of minutes) to give the network device time to boot and the in-band connection time to reestablish. At the end of that time the SMACC will check the VMI. If the VMI is able to access the Management Center via the in-band connection, the SMACC will send the notification of power restoration to the Management Center via the VMI. If the VMI is not up, then the SMACC will establish a connection over a SMACC Interface to report the power restoration.
[0160] An exemplary embodiment of the SMACC that utilizes a POTS connection can monitor the physical connectivity of a telephone line to the SMACC interface that includes an integrated modem and send an alert if the telephone line is disconnected. Access to the SMACC can assist with problem determination and resolution when there is an outage in the network. It might be that the telephone connection to the SMACC interface does not get used very often. It is not unheard of for a telephone line to a modem on a console port to have stopped working for weeks and months before being needed and then discovered to not be functional. When it is needed, such as when there is an outage, it is important to know that the telephone connection will be there and working. Monitoring the connection to the line assists in doing this.
[0161] When a telephone line is in the on-hook state, the line generally carries a voltage. In the USA this is in the vicinity of −48V. To monitor a line that is in the on-hook state it is important to draw very little current if any at all. A FET transistor circuit as depicted in FIG. 15 would be a good candidate for this circuit. A connection from the telephone line would be connected to the gate of the FET transistor. While a high enough negative voltage was maintained on the line, the FET would be in pinch off state and no current would flow between the source and the drain. If the negative voltage was removed from the line and the voltage at the gate went to zero, the FET would allow current to begin flowing between the source and the drain on the transistor. The circuit could detect the flowing current or the circuit could be designed so that the current flow caused a voltage drop at the output to the circuit. This voltage drop could be noted and used to trigger an alert that the line has been disconnected while at the same time drawing very little if any current in the steady state condition. This circuit would provide the most accurate indication of the status of the connectivity of the telephone line when the integrated modem portion of the SMACC interface is in the on hook state.
[0162] In situations where it is desirable not to physically monitor the voltage on the telephone line, a method for periodically monitoring the status of the telephone line is possible as depicted in FIG. 16 . The SMACC can be configured to periodically request the SMACC interface to go off-hook and dial a telephone number to test for line status. If no telephone number is provided to dial the SMACC interface can go off-hook and monitor for dial tone. If dial tone is returned the SMACC will consider the line still connected. While this will not provide for continuous monitoring of the connectivity, it will still detect the line being disconnected in a timely manner. If the telephone line is currently in use for a connection, the SMACC will consider the line connected and will not need to do the test. The frequency at which this test is performed can be configured.
[0163] For a SMACC interface to be as beneficial as possible, it is important for the access connection to the secondary network to be available for legitimate traffic. In the case of a POTS connection, this access could be taken away by an attack on the local loop connecting the SMACC interface to the PSTN local service provider. If an unauthorized user dials in repeatedly, even though they do not get authorized, they are still tying up the local loop connecting the SMACC interface to the central office. In fact, large ISPs have come under attack by Distributed DoS attacks where illegitimate traffic ties up their modem pools so the legitimate users cannot get access to the ISP.
[0164] A first step is to monitor caller-id and to note the caller-id of connections that failed to authenticate. In some situations, it is reasonable to limit allowed calls to a set of preconfigured origination numbers. In other situations the originating number can be monitored and if a number of failures to authenticate originate from the same number then the SMACC can be configured for fast failure for some length of time. When a number is not in the list of authorized originating numbers or is flagged for fast failure, the SMACC interface will not attempt to authenticate the user, but will perform a fast hang-up as illustrated in FIG. 32 . The SMACC will simply answer the call and immediately hang up on that call. The SMACC can also be configured to reject calls that are marked as P (Private) or O for a set length of time when the SMACC interface is under attack.
[0165] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A computer network management apparatus and method for remotely managing a networked device. The apparatus and method includes a management processor which is in direct communication with the networked device. The apparatus and method provides access for remotely and securely managing a networked device. The apparatus and method further separates management communications from user communications to ensure the security of the management communications. The apparatus and method further includes network and power monitoring and notification systems. The apparatus and method further provides authentication and authorization capabilities for security purposes. | 7 |
BACKGROUND OF THE INVENTION
[0001] The invention proceeds from a pump, in particular a high-pressure fuel pump.
[0002] Such a pump in the form of a high-pressure fuel pump is known from DE 101 15 168 C1. This pump comprises at least one pump element which has a pump piston driven in a lifting movement at least indirectly by a drive shaft. A tappet with a tappet body is arranged between the drive shaft and the pump piston and is guided displaceably in the direction of the lifting movement of the pump piston in a receptacle and is supported on the drive shaft via a supporting element in the form of a roller. Lubricant is fed into the receptacle for the tappet body via a feed line and lubricant is conducted out of the receptacle via a discharge line into the tappet body to the supporting element, in order to ensure lubrication between the supporting element and tappet body. When the tappet body and/or the receptacle or other components of the pump or internal combustion engine experience wear, the lubricant may contain particles which may then also infiltrate between the supporting element and the tappet body and cause increased wear there. If the discharge line in the tappet body has a small throughflow cross section, the risk furthermore exists that the discharge line may be blocked by particles, and therefore sufficient lubrication of the supporting element is no longer ensured.
Disclosure of the Invention
SUMMARY OF THE INVENTION
[0003] The pump according to the invention has, by contrast, the advantage that the possible ingress of particles between the supporting element and the tappet body is prevented or at least reduced by the annular-gap filter and therefore the wear of the pump is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] An exemplary embodiment of the invention is illustrated in the drawing and is explained in more detail in the following description.
[0005] FIG. 1 shows a pump in a longitudinal section.
[0006] FIG. 2 shows a detail, designated by II in FIG. 1 , of the pump in an enlarged illustration.
[0007] FIG. 3 shows a further-enlarged detail III from FIG. 2 .
DETAILED DESCRIPTION
[0008] FIGS. 1 to 3 illustrate a pump which is, in particular, a high-pressure fuel pump for a fuel injection system of an internal combustion engine. The pump has at least one pump element 10 which in turn has a pump piston 12 which is driven in a lifting movement at least indirectly by a drive shaft 14 in an at least approximately radial direction with respect to the axis of rotation 15 of the drive shaft 14 . The drive shaft 14 may be part of the pump, or alternatively there may also be provision whereby the pump has no dedicated drive shaft and the drive shaft 14 is part of the internal combustion engine. The drive shaft 14 may in this case be, for example, a shaft of the internal combustion engine by means of which the gas exchange valves of the internal combustion engine are also actuated. The drive shaft 14 may have a cam 16 or eccentric for driving the pump piston 12 .
[0009] The pump piston 12 is guided sealingly in a cylinder bore 20 of a housing part 22 of the pump. The pump piston 12 , with its end facing away from the drive shaft 14 , delimits a pump working space 24 in the cylinder bore 20 . The pump working space 24 has, via an inlet nonreturn valve 26 opening into the latter, a connection to an inflow 28 which comes, for example, from a feed pump and via which the pump working space 24 is filled with fuel when the pump piston 12 executes a suction stroke directed radially inward with respect to the axis of rotation 15 of the drive shaft 14 . Moreover, the pump working space 24 has, via an outlet nonreturn valve 30 opening out of the latter, a connection to an outflow 32 which leads, for example, to a high-pressure fuel accumulator 34 and via which fuel is displaced out of the pump working space 24 when the pump piston 12 executes a feed stroke directed radially outward away from the axis of rotation 15 of the drive shaft 14 .
[0010] The pump piston 12 is supported on the cam 16 of the drive shaft 14 indirectly via a tappet 40 . The tappet 40 comprises a tappet body 42 in which is arranged a supporting element 44 which is preferably designed in the form of a roller. The tappet body 42 has an at least essentially circular-cylindrical outer contour and is guided displaceably in the direction of the lifting movement of the pump piston 12 in a receptacle 46 . The receptacle 46 may be designed in the form of a bore which is introduced in a housing part of the pump or in a housing part of the internal combustion engine. A feed line 48 for lubricant, which is designed, for example, in the form of at least one bore, issues into the receptacle 46 . Lubricant is fed via the feed line 48 into the receptacle 46 for lubrication between the tappet body 42 and the receptacle. Fuel or lubricating oil of the internal combustion engine may serve as lubricant.
[0011] The supporting element 44 may be directly mounted rotatably in the tappet body 42 or in a carrier element, for example a roller shoe, inserted into the tappet body 42 . In the exemplary embodiment illustrated, the supporting element 44 is designed in the form of a cylindrical roller which is mounted rotatably in the tappet body 42 via a bolt 50 . The axis of rotation 45 of the roller 44 runs in this case at least approximately parallel to the axis of rotation 15 of the drive shaft 14 . The roller 44 is of hollow form and, where appropriate, is mounted on the bolt 50 via a bearing bush 52 . The tappet body 42 has, in its end region facing the drive shaft 14 , a bottom region 54 and, adjoining the latter away from the drive shaft 14 , a jacket region 56 . The jacket region 56 is of at least essentially hollow-cylindrical form, and the pump piston 12 projects into this with its end region emerging from the cylinder bore 20 . The pump piston 12 may have in its end region projecting out of the cylinder bore 20 a piston foot 58 which is enlarged in diameter in relation to the cylinder bore 20 and which bears against the bottom region 54 of the tappet body 42 . A sealing element 59 may be tension-mounted between the pump piston 12 and the housing part 22 , as is provided especially when the lubricant used for the tappet body 42 in the receptacle 46 is lubricating oil from the internal combustion engine. The sealing element 59 serves for preventing intermixing of lubricating oil and fuel or for at least keeping this intermixing as low as possible.
[0012] Between the tappet body 42 and a fixed support, for example the housing part 22 of the pump or a housing part of the internal combustion engine, is arranged a prestressed spring 60 by means of which the tappet body 42 is pressed toward the drive shaft 14 . The spring 60 is designed, for example, as a helical compression spring and projects into the jacket region 56 of the tappet body 42 . The spring 60 surrounds the pump piston 12 approximately coaxially and bears via a spring plate 62 against the radially outer margin of the bottom region 54 of the tappet body 42 . The spring plate 62 is of disk-shaped form and has in its central region an orifice 64 , the diameter of which is somewhat larger than the diameter of the shank, arranged in the cylinder bore 20 , of the pump piston 12 and smaller than the diameter of the piston foot 58 of the pump piston 12 . The spring plate 62 is thus supported in its central region on the piston foot 58 of the pump piston 12 and keeps the latter in bearing contact against the bottom region 54 of the tappet body 42 . Thus, by means of the spring 60 , the tappet body 42 and the pump piston 12 are pressed toward the drive shaft 12 . An antitwist device for the tappet body 42 may be provided, which prevents the tappet body 42 from being able to twist about its longitudinal axis in the receptacle. Such an antitwist device may be formed, for example, in a known way by a pin which is arranged in the receptacle 46 and which engages into a recess in the outer jacket of the tappet body.
[0013] The tappet body 42 has in its bottom region 54 , on its side facing the drive shaft 12 , a recess 66 for the roller 44 , and the bolt 50 on which the roller 44 is mounted is mounted in bores 68 in the walls of the bottom region 54 of the tappet body 42 which laterally delimit the recess. Alternatively, there may also be provision whereby the bolt 50 is dispensed with and the roller 44 is mounted directly via its outer jacket in the recess 66 designed as a half shell.
[0014] The tappet body 42 has in its outer jacket an annular groove 70 which extends in the axial direction, for example starting from the bottom region 54 , into the jacket region 56 of the tappet body 42 . The annular groove 70 is arranged in the axial direction such that it is in overlap with the issue of the feed line 48 of the lubricant into the receptacle 46 constantly, that is to say throughout the entire lifting movement of the tappet body 42 and therefore of the pump piston 12 . A discharge line 72 for lubricant leads from the annular groove 70 through the tappet body 42 into the recess 66 . The discharge line 72 may be formed by at least one bore, although a plurality of bores, in particular two bores lying diametrically opposite one another, may also be provided, which in each case issue into the recess 66 in the region of the axial ends of the roller 44 . Lubricant is thus fed via the discharge line 72 to the mounting of the roller 44 in the tappet body 42 .
[0015] The tappet body 42 has on both sides of its annular groove 70 guide portions 71 , by which the tappet body 42 is guided with slight radial play in the receptacle 46 and which have a diameter D 1 , the diameter of the tappet body 42 in the region of the annular groove 70 being designated by D 2 .
[0016] According to the invention, a radial web 74 or collar is arranged in the annular groove 70 and has a larger diameter D 3 than the annular groove 70 , although the diameter D 3 is only a little smaller than the diameter D 1 . The web 74 , together with the receptacle 46 surrounding it, forms an annular-gap filter 76 for the lubricant flowing via the discharge line 72 into the tappet body 42 for the purpose of lubricating the roller 44 . The web 74 is arranged near the issue of the discharge line 72 on the tappet body 42 in the annular groove 70 , as seen in the axial direction of said tappet body 42 . Throughout the entire lifting movement of the tappet body 42 , that part of the annular groove 70 which is not connected to the discharge line 72 is in overlap with the feed line 48 , and that part of the annular groove 70 which is connected to the discharge line 72 does not come into overlap with the feed line 48 .
[0017] The difference between the diameter D 1 of the guide portions 71 of the tappet body 42 and the diameter D 3 of the web 74 is determined such that, on the one hand, a sufficiently large throughflow cross section for the lubricant is present and, on the other hand, particles are retained from the lubricant to a sufficient extent, so that they cannot infiltrate into the discharge line 72 and into the tappet body 42 . | The pump comprises at least one pump element which has a pump piston that is at least indirectly driven in a stroke movement by a drive shaft. A plunger having a plunger body is arranged between the drive shaft and the pump piston and is movably guided in a receiving device in the direction of the stroke movement of the pump piston and is supported on the drive shaft by means of a support element. Lubricant is supplied to the receiving device via a supply line and lubricant is conducted out of the receiving device via a discharge line into the plunger body to the support element. An annular gap filter is provided between the plunger body and the receiving device and is arranged between the supply line for supplying lubricant to the receiving device and the discharge line for discharging lubricant into the plunger body. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a disposable multipurpose catheter making it possible in particular to introduce into the human body, at the operating site, surgical mandrins or to inject liquid such as serum or methylene blue in order to perform various pre-operative and intra-operative tests.
2. Description of Background and Relevant Information
Multipurpose catheter is understood as meaning a catheter/trocar having the function of a tool for perforating the walls and the function of a catheter for introducing, into the operating site, either liquid products or a range of surgical mandrins or other instruments, or both simultaneously.
Catheters of this type are known which comprise a cylindrical body integral at one of its ends with a head which is equipped with two access routes or inlets, while the other end is provided with a balloon which can deform elastically under the effect of a pressure.
This type of catheter makes it possible to perform certain tests or operations but it cannot simultaneously receive surgical mandrins and injection of liquids or passage of a miniature endoscope on account of the fact that the channels formed in the cylindrical body are coaxial to each other and centred in relation to the main axes of the body.
A first channel, centred about the main axes of the body, permits the insertion of a miniature endoscope or the passage of a liquid or the insertion of a surgical mandrin. All of its elements being introduced separately and independently. The second channel coaxial to the first one is provided solely to elastically deform the balloon.
U.S. Pat. No. 5,437,637 likewise discloses a catheter which comprises a flexible cylindrical body having, in its inner part, several non-coaxial channels for the passage of stiffening elements, instruments and/or liquids. This catheter comprises, on its outer periphery, a balloon which can dilate under the effect of a pressure.
It will be noted that, because of its flexibility, this type of catheter cannot be used as a trocar for perforating walls. Moreover, the connection means permit introduction, into each non-coaxial channel, either of instruments or liquids, but they do not allow the surgeon to hold the catheter in order to be able to use it as a tool.
It is these disadvantages which the present invention is intended to eliminate in particular.
SUMMARY OF THE INVENTION
The invention provides for a multipurpose catheter intended to permit various interventions, comprising a cylindrical body of small diameter which has, at one of its ends, a connection mechanism which communicates with non-coaxial channels formed in the inner part of the cylindrical body in such a way that at least one of the channels supplies, to the end remote from that bearing the connection mechanism a balloon which is able to deform elastically under the effect of a pressure, characterized in that the connection mechanism includes a monobloc head made of rigid plastic material which is injection-molded to attach itself in a sealed manner around the cylindrical body, while the head includes independent inlets which communicate with the non-coaxial channels via bores, so that the channels permit introduction either of liquids or of a range of surgical mandrins and/or other instruments, or both simultaneously at the different operating sites.
The invention also provides for a multipurpose catheter characterized in that the head consists of a slightly bulged wall receiving the independent inlets joining opposite the wall via another wall of inwardly curved profile in such a way that the head has an ergonomic profile facilitating the gripping of the catheter.
The invention also provides for a multipurpose catheter characterized in that each wall has surfaces of different inclinations.
The invention also provides for a multipurpose catheter intended to permit various interventions, comprising a cylindrical body of small diameter which has, at one of its ends, connection mechanism which communicates with non-coaxial channels formed in the inner part of the cylindrical body in such a way that at least one of the channels supplies, to the end remote from that bearing the connection mechanism, a balloon which is able to deform elastically under the effect of a pressure, characterized in that the cylindrical body has, remote from the connection mechanism, an end with a conical profile.
The invention also provides for a multipurpose catheter characterized in that the conical profile of the end of the cylindrical body has its axis on the main channel.
The invention also provides for a multipurpose catheter characterized in that the main channel is eccentric in relation to the external diameter of the cylindrical body.
The invention also provides for a multipurpose catheter characterized in that the inclination of the conical profile of the end is intended to lie in the continuation of the instruments or mandrins when they have a conical end.
The invention also provides for a multipurpose catheter characterized in that the balloon is fixed on the cylindrical body in immediate proximity to the cone of the end and more particularly at the widest base of the cone, that is to say the one furthest from the end of the catheter.
The invention also provides for a multipurpose catheter intended to permit various interventions, comprising a cylindrical body of small diameter which has, at one of its ends, connection mechanism which communicates with non-coaxial channels formed in the inner part of the cylindrical body in such a way that at least one of the channels supplies, to the end remote from that bearing the connection mechanism, a balloon which is able to deform elastically under the effect of a pressure, characterized in that the connection mechanism includes a head made of rigid plastic material and equipped with three independent inlets which each communicate by way of a sealed mechanism in one of the channels of the cylindrical body, in order to permit introduction either of liquid products or of a range of surgical mandrins and/or other instruments, or both simultaneously at the different operating sites.
The invention also provides for a multipurpose catheter characterized in that the connection mechanism includes a head made of rigid plastic material and equipped with three independent inlets which each open into an internal bore via bores, the bores being provided to receive through a sealed mechanism the external profile of the cylindrical body such that the bores of each independent inlet communicate via holes passing through the cylindrical body and/or the sealed mechanism with the non-coaxial channels so that the channels permit introduction either of liquid products or of a range of surgical mandrins and/or other instruments, or both simultaneously at the different operating sites.
The invention also provides for a multipurpose catheter characterized in that the sealed means consist of a first ring which is arranged around the cylindrical body opposite the inlet in a shoulder of the bore, and a second ring which is placed around the said cylindrical body in the continuation of the first, in such a way as to cooperate with the bores of the head.
The invention also provide for multipurpose catheter characterized in that the sealed mechanism includes a ring which is arranged around the cylindrical body opposite the inlet in a shoulder of the bore, while the external diameter of the body is directly fixed in the bore of the head.
The invention also provides for a multipurpose catheter characterized in that the rings are bonded on the external profile of the cylindrical body and on the internal periphery of the bores in order to make the head integral with the body.
The invention also provides for a multipurpose catheter characterized in that the ring has a length which is defined in order to delimit, in the shoulder of the bore, a chamber which communicates with the bore of the inlet of the head via a space.
The invention also provides for a multipurpose catheter characterized in that the space is provided solely on the inlet side of the head, while the outer wall of the cylindrical body is in tight contact, on the one hand with the internal periphery of the bore and, on the other hand, opposite the space, with the internal periphery of the bore.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body has two non-coaxial channels of different diameters which are offset in relation to each other and laterally in relation to the main axes of the body, in such a way that the first channel communicates with two inlets of the head, while the second channel cooperates with the third inlet for supplying the sealing mechanism.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body has at least three non-coaxial channels of different diameters which are offset in relation to each other and laterally in relation to the main axes of the body, in such a way that the first channel of greater diameter communicates with the first inlet of the head, the second channel with the third inlet of the head for supplying the sealing mechanism, and the third channel with the second inlet for emerging from the body at the same level as the first channel.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body has a hole to permit communication between the channel and the bore of the inlet.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body has a hole permitting communication between the channel and the bore of the inlet.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body has two channels which communicate via holes in the chamber connected to a space in order to open into the bore of the second inlet of the head in order to supply the sealed mechanism.
The invention also provides for a multipurpose catheter characterized in that the range of instruments includes of mandrins cooperating with the channels of the cylindrical body in order to perform various tests or operations.
The invention also provides for a multipurpose catheter characterized in that the surgical mandrins include a head integral with a rod whose free end varies in its geometric shape and its material.
The invention also provides for a multipurpose catheter characterized in that the mandrin has a free end designed with a hemispherical profile.
The invention also provides for a multipurpose catheter characterized in that the mandrin has a rod of curved profile whose free end is designed with a hemispherical profile.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body is rigid.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body is flexible.
The invention also provides for a multipurpose catheter characterized in that the cylindrical body is transparent.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention also provides for a multipurpose catheter comprising a cylindrical body including a first end, a second end, and at least three internal non-coaxial channels, a connection mechanism disposed adjacent the first end for communicating with the at least three non-coaxial channels, the connection mechanism comprising an ergonomic monobloc head which is sealingly attached to the first end of the cylindrical body, the ergonomic monobloc head comprising a bulged wall having at least three independent inlets for communicating with the at least three non-coaxial channels via bores, two walls which continue from the bulged wall, and a concave inwardly curved connecting wall, the connecting wall being disposed adjacent the first end of the cylindrical body and connecting the two walls, wherein the two walls comprise first opposite facing inclined surfaces and second opposite facing inclined surfaces having a different inclination, one of the at least three internal non-coaxial channels being adapted to provide communication between at least one of the at least three independent inlets and an elastically deformable balloon disposed adjacent the second end, and two of the at least three internal non-coaxial channels being adapted to allow the respective introduction of a liquid and a surgical mandrin, wherein the ergonomic monobloc head is adapted to be gripped by a user.
The catheter may be adapted for use in various medical interventions. Each of the at least three independent inlets may communicate with a corresponding internal non-coaxial channel via a corresponding bore. The catheter may be adapted to simultaneously deliver the liquid and the surgical mandrin via separate internal non-coaxial channels while the balloon is expanded via a different internal non-coaxial channel. The ergonomic head may comprise an injection moldable rigid plastic material. The first opposite facing inclined surfaces may comprise a shorter length than the second opposite facing surfaces and each of the first and second opposite facing inclined surfaces may be inclined inwardly and towards one another. The second end of the cylindrical body may comprise a conical profile. One of the at least three internal non-coaxial channels may comprise a large main channel, the large main channel comprising an axis which corresponds to an axis of the conical profile. The large main channel may be eccentrically disposed with respect to an external diameter of the cylindrical body.
The second end may comprise a cone shaped profile and the balloon may be fixedly disposed in an immediate proximity to the cone shaped profile. The balloon may be disposed in the immediate proximity to a widest diameter portion of the cone shaped profile. The bores of the connection mechanism may comprise separate internal bores, each of the bores providing separate sealed communication between the at least three independent inlets and the at least three internal non-coaxial channels. The first end of the cylindrical body may extend into the connection mechanism. The catheter may be adapted to introduce one of a range of surgical mandrins and a range of surgical instruments into a patient.
The connection mechanism may be connected to the first end of the cylindrical body via a sealing mechanism which comprises a first ring arranged around the cylindrical body. The first ring may be disposed in a bore of the connection mechanism wherein the bore has a shoulder. The connection mechanism may further comprise a second ring arranged around the cylindrical body, the second ring being disposed in another bore of the connection mechanism. The first and second rings may be bonded to each of the cylindrical body and the connection mechanism in order to make the ergonomic monobloc head integral with the cylindrical body. The sealing mechanism may be disposed adjacent the inwardly curved connecting wall. The connection mechanism may comprise a chamber disposed in the area of the first ring and the shoulder of the bore. The connection mechanism may comprise a space which communicates with the chamber and at least one of the at least three independent inlets.
Two of the at least three internal non-coaxial channels may comprise different diameters, and wherein each of the two internal non-coaxial channels are offset in relation to each other. Each of the two internal non-coaxial channels may be laterally offset relative to a main center axis of the cylindrical body and wherein one of the two internal non-coaxial channels communicates with two of the at least three independent inlets and wherein another channel of the two internal non-coaxial channels communicates with another of the at least three independent inlets and the balloon. The at least three internal non-coaxial channels may have different diameters which are offset in relation to each other and offset laterally in relation to a main center axis of the cylindrical body. The at least three internal non-coaxial channels may comprise a first channel, a second channel and a third channel and wherein the at least three independent inlets comprise a first inlet, a second inlet and a third inlet, wherein the first channel communicates with the first inlet, the second channel communicates with the third inlet and the balloon, and the third channel communicates with the second inlet.
The cylindrical body may comprise at least one bore which cooperates with at least one bore in the connection mechanism to permit communication between at least one channel of the at least three internal non-coaxial channels and at least one inlet of the at least three independent inlets. The cylindrical body may comprise a plurality of bores which cooperate with corresponding bores in the connection mechanism to permit communication between the at least three internal non-coaxial channels and the at least three independent inlets. The surgical mandrin may comprise a head which is integral with a rod, the rod having a free end. The free end may comprise a hemispherical profile. The rod may comprise a curved profile. The cylindrical body may comprise a rigid cylindrical body. The cylindrical body may comprise a flexible cylindrical body. The cylindrical body may comprise a transparent material.
The invention also provides for a multipurpose catheter comprising a small diameter cylindrical body including a handle end, a balloon end, and at least a first, a second, and a third internal non-coaxial channel, a connection mechanism disposed adjacent the handle end for communicating with the first, second and third internal non-coaxial channels, the connection mechanism comprising an ergonomic handle head which is sealingly attached to the handle end, the ergonomic handle head comprising a bulged wall having a first, a second and a third independent inlet, each of the first, second and third independent inlets communicating with a corresponding first, second, and third internal non-coaxial channel via first, second, and third bores, two walls which extend from the bulged wall, and a concave inwardly curved connecting wall, the connecting wall being disposed adjacent the handle end of the cylindrical body and connecting the two walls, wherein the two walls comprise first oppositely facing inclined surfaces and second oppositely facing inclined surfaces having a different inclination, the first internal non-coaxial channel communicating with the first independent inlet and an elastically deformable balloon disposed adjacent the balloon end, and the second and third internal non-coaxial channels being adapted to respectively allow introduction of a liquid and a surgical mandrin, wherein the ergonomic handle head comprises an ergonomic shape which is adapted to be gripped by a user.
The description which follows with reference to the attached drawings, given as nonlimiting examples, will permit a better understanding of the invention, of its characteristic features and of the advantages it is likely to afford:
FIG. 1 is a general view representing the multipurpose catheter according to the present invention.
FIG. 2 is a cross section illustrating a first variant of the catheter in which the inlets of the head open into channels of the cylindrical body.
FIGS. 3 and 4 are cross sections along III—III and IV—IV in FIG. 2, showing the position of the channels formed in the cylindrical body of the catheter according to the first variant.
FIG. 5 is a cross section representing a second variant of the multipurpose catheter according to the present invention.
FIGS. 6 and 7 are cross sections along VI—VI and VII—VII in FIG. 5, illustrating another configuration of the channels formed in the cylindrical body of the catheter.
FIG. 8 is a view showing a third variant of the multipurpose catheter, more particularly as regards the profile of the connection head.
FIGS. 9 and 10 are cross sections representing the connection head according to FIG. 8 and more particularly the position of the independent inlets which cooperate with the non-coaxial channels of the multipurpose catheter.
FIG. 11 is a cross section illustrating the profile of that end of the multipurpose catheter remote from the end with the connection head, and the position and the profile of the balloon.
FIG. 12 is a cross section similar to that in FIG. 11 showing another profile of the balloon.
FIGS. 13 a , 13 b and 14 a , 14 b are views showing mandrins provided to cooperate with the channels of the catheter in different operations.
FIG. 15 is a view illustrating an example of use of the multipurpose catheter according to the present invention.
FIG. 16 is a view similar to that of FIG. 15, but representing another example of use of the catheter according to the present invention.
FIG. 17 is a view showing the use of the multipurpose catheter as a trocar during laparoscopy.
FIG. 18 is a view representing another application concerning the use of the multipurpose catheter according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, a catheter 1 is shown which utilizes a cylindrical body 2 of translucent plastic material which is substantially flexible or rigid and integral at one of its ends with a head 3 forming a connection mechanism and including three independent inlets 30 , 31 and 32 .
At the end remote from the one bearing the head 3 , the cylindrical body 2 has sealing mechanism 4 utilizing a balloon 40 which can deform elastically under the effect of a pressure.
Near the balloon 40 , the free end of the cylindrical body 2 , ends with a tapered profile 20 in a point (FIGS. 11, 12 ).
The connection head 3 is made of a rigid plastic material which may or may not be transparent and whose inner part is hollow in such a way that each inlet 30 , 31 and 32 opens into channels formed in the cylindrical body 2 .
The connection head 3 is monobloc and has a double Y-shape forked profile, that is to say the inlet 30 is on the same longitudinal axis as that of the cylindrical body 2 , while the other two inlets 31 and 32 are offset laterally so as to be arranged to each respective side of the inlet 30 .
The inlets 30 , 31 and 32 are each integral with a joining element 33 which permits sealed attachment, for example, of a valve 5 for introduction of liquids, a stopper 6 obstructing an inlet, and the positioning of a series of surgical mandrins 7 whose profiles vary depending on the intervention.
In FIGS. 2 to 4 , a first variant of the multipurpose catheter 1 is shown whose cylindrical body 2 has two channels 21 and 22 running along its length, and along longitudinal axes offset in relation to the main axes XX′ and YY′.
It will be noted that the diameter of the main channel 21 is greater than that provided for the channel 22 and that these channels are arranged on at least one main axis ZZ′ of the cylindrical body 2 (FIG. 4 ). The channels 21 and 22 are also offset in relation to one another. Furthermore, the channel 21 is eccentric in relation to the external diameter of the cylindrical body 2 .
The head 3 has an internal bore 34 which opens out into each inlet 30 , 31 and 32 via a bore 35 , 36 and 37 . The inlets 30 , 31 and 32 each comprise a chamber 38 into which opens, on the one hand, each bore 35 , 36 and 37 , and on the other hand, the joining elements 33 .
The joining elements 33 have an internal bore 39 which communicates with the chamber 38 of each inlet 30 , 31 and 32 of the head 3 .
The head 3 is attached to the cylindrical body 2 in a sealed manner by way of a first ring 24 which is arranged around the body and opposite the inlet 30 in a shoulder of the bore 34 which is provided with a diameter greater than this bore.
A second ring 23 is placed around the cylindrical body 2 in the continuation of the first one, in such a way as to cooperate with the bores 34 and 35 of the head 3 . The rings 23 and 24 are bonded on the external profile of the cylindrical body 2 and on the internal periphery of the bores 34 and 35 in order to Lake the connection head 3 integral with the body.
The two rings 23 and 24 are provided with different external diameters, while their internal diameter is identical in order to cooperate coaxially around the cylindrical body 2 .
The cylindrical body 2 passes through the chamber 38 of the inlet 30 to allow the channel of large diameter 21 to open into the bore 39 of the corresponding joining element 33 .
At the opposite end, the main channel 21 emerges from the cylindrical body 2 along the tapered profile 20 of pointed or conical shape.
It will be noted that the end 20 of the cylindrical body 2 has a conical profile which is arranged on the axis of the main channel 21 . The latter is eccentric in relation to the external diameter of the cylindrical body 2 , which gives this particular profile to the end 20 (FIGS. 11, 12 ).
Thus, the end 20 has a conical profile which has an inclination of about 30° [sic] degrees.
The conical profile of the end 20 is intended to be disposed in the continuation of the instruments or mandrins 7 whose end is also conical.
It will be noted that the balloon 40 is fixed on the cylindrical body 2 of the catheter in immediate proximity to the cone of the end 20 , and more particularly at the widest base of the cone, that is to say the one furthest from the end of the catheter (FIGS. 11, 12 ).
The ring 23 and the cylindrical body 2 have a first through-hole 25 allowing the bore 37 of the inlet 31 to communicate with the channel of large diameter 21 .
The inlet 31 cooperates with a leaktight stopper (not shown) which, by being clamped onto the threaded part of the inlet 31 , forms a leaktight seal with the mandrin or the instrument introduced into the channel 21 .
Thus, it will be noted that two inlets 30 and 31 open into the same channel 21 formed in the inner part of the cylindrical body 2 .
Likewise, the ring 23 and the cylindrical body 2 have another through-hole 26 situated opposite the first one 25 for allowing the bore 36 of the inlet 32 to communicate with the channel of smaller diameter 22 . The latter, arranged parallel to the channel 21 , is intended to open out in the area of the sealing mechanism 4 in order to inflate the balloon 40 .
It will be noted that the multipurpose catheter 1 described above is of the type with three inlets and two routes, that is to say two inlets open into the same channel.
In FIGS. 5 to 7 , a second variant of the multipurpose catheter 1 is shown whose cylindrical body 2 has, in addition to the channels 21 and 22 , another channel 27 arranged on axes which are offset laterally in relation to the main axes XX′and YY′ of the cylindrical body 2 , and offset in relation to those of the channels 21 and 22 .
In this variant there are two channels 22 which run, on either side of the channel 27 , between the latter and the channel 21 . It will be noted that the channels 22 are on one and the same axis which is parallel to the axis XX′ of the cylindrical body 2 , but arranged in a different vertical plane, as is shown in FIG. 7 .
It will be noted that the channels 21 and 27 are arranged on the same axis ZZ′ of the cylindrical body 2 (FIG. 7 ).
The cylindrical body 2 is integral with the head 3 described above and equipped with its three independent inlets 30 , 31 and 32 .
It will be noted that the inlets 30 , 31 , 32 are integral with the joining element 33 , in order to delimit the chamber 38 .
The cylindrical body 2 is integral with the head 3 by way of the ring 24 , as has been described above, while in this variant the external diameter of the body 2 is bonded directly into the bore 35 .
It will be noted that the ring 24 is shorter in length than that described above in order to delimit, in the shoulder of the bore 34 , a chamber 8 which the cylindrical body 2 passes through.
Removal of the ring 23 makes it possible to form a longitudinal channel 10 (FIGS. 5 and 6) in the bore 34 in such a way as to bring the chamber 8 into communication in order to supply the channels 22 for inflating the balloon 40 .
The longitudinal channel 10 is provided solely on the inlet side 32 , so that the outer wall of the cylindrical body 2 is in tight contact on the one hand on the internal periphery of the bore 35 and, on the other hand, opposite the longitudinal channel 10 , on the internal periphery of the bore 34 so that the bore 37 of the inlet 31 cannot communicate with the chamber 8 .
At the bore 37 of the inlet 31 , the cylindrical body 2 has a first through-hole 28 which permits communication between the bore 37 and the channel 27 .
In this variant, the channels 21 and 27 emerge at the side remote from the head 3 and more particularly at the tapered pointed end 20 .
It will be noted that the cylindrical body 2 has, in the area of the chamber, through-holes 29 which communicate with the channels 22 . Thus, the inlet 32 is connected via its bore 36 , the longitudinal channel 10 , the chamber 8 , holes 29 and channels 22 , with the balloon 40 which is arranged on the cylindrical body 2 at the opposite end from the head 3 , in order to deform it elastically under a pressure.
The catheter 1 described above and shown in FIGS. 5 to 7 has three inlets and three routes or channels compared to the preceding one which had only two routes or channels.
FIGS. 8 to 10 show a third variant of the multipurpose catheter 1 concerning the profile of the connection head 3 on the cylindrical body 2 .
The connection head 3 has a highly ergonomic profile allowing the surgeon to easily hold the catheter 1 between the fingers of one hand during various interventions.
The head 3 includes a slightly bulged wall 14 receiving the three independent inlets 30 , 31 , 32 . The wall 14 , is arranged perpendicular to the cylindrical body 2 and is continued on each of the said body by a wall 15 , 16 with inclined surfaces. Each wall 15 , 16 has, in proximity to the inlets 31 , 32 , an inclined surface 17 of short length which is oriented in the direction of the cylindrical body 2 . Each inclined surface 17 is continued by another inclined surface 18 of different inclination and oriented away from the cylindrical body 2 . Each inclined wall 18 of the walls 15 , 16 meets, at the area of the cylindrical body 2 and opposite the wall 14 , via a wall 19 curved inwards in the direction of the body.
Thus, the profile of the connection head 3 permits a better grip by the surgeon in order to precisely introduce the cylindrical body 2 into the different operating sites.
FIG. 9 shows the inner part of the connection head 3 whose inlets 30 , 31 , 32 cooperate with the non-coaxial channels 21 , 22 of the cylindrical body 2 , as has been described in FIGS. 2 to 4 .
Thus, the connection head 3 allows the inlet 30 to communicate with the channel 21 , called the main channel, while the inlet 32 cooperates with the channel 22 to supply the balloon 40 .
It will be noted that the inlet 31 also cooperates with the channel 21 of the cylindrical body 2 . It will be noted that the inlet 30 comprises an internal bore 35 which is axially offset in order to cooperate with the channel 21 , given that the latter is eccentric in relation to the external diameter of the cylindrical body 2 (FIG. 4 ).
In this embodiment of the connection head 3 , it will be noted that the chambers 38 have been omitted, so that each bore 35 , 36 , 37 of the inlets 30 , 31 , 32 opens directly into the non-coaxial channels of the body 2 and at the end of the head 3 .
In FIG. 10, the inner part of the connection head 3 has been illustrated, where the inlets 30 , 31 , 32 cooperate with the non-coaxial channels 21 , 22 , 27 of the cylindrical body 2 , as has been described for FIGS. 5 to 7 .
Thus, the connection head 3 allows the inlet 30 to communicate with the channel 21 , while the inlets 31 and 32 cooperate, respectively, with the channel 27 , called the operator channel, for the passage of instruments, and the channels 22 for supplying the balloon 40 .
It will be noted that the inlet 31 has an internal bore 37 whose inclination permits communication with the channel 27 via a hole made through the cylindrical body 2 .
By contrast, the inlet 32 has an internal bore 36 which is also inclined and turned a quarter of a turn about the axis of the cylindrical body 2 so as to come into communication via holes in the channels 22 . This position makes it possible to omit the chamber 8 and the longitudinal channel 10 , shown in FIG. 5 .
In the solutions described above and shown in Figures [sic] 9 and 10 , the connection head 3 is made of injection-molded plastic which attaches directly at the moment of molding around the cylindrical body 2 , thereby guaranteeing perfect sealing of the head 3 on the body 2 .
In FIG. 11, the end of the cylindrical body 2 is integral with a balloon 40 whose external profile depends on the distance between the points of attachment of the said balloon on the body 2 .
Thus, it will be noted that the zones of attachment of the balloon 40 are close together allowing the balloon, when inflated, to present a very rounded profile like a tire, around the cylindrical body 2 .
In FIG. 12, the zones of attachment of the balloon 40 are further apart than those shown previously, making it possible to define a volume of the balloon which is different when it is inflated.
The balloon 40 provided at the end of the cylindrical body 2 of the catheter 1 permits sealing by bearing against the wall of the operating site, as will be better seen below. Also, the balloon 40 provides a bearing and a sort of pivoting mechanism which facilitates the movements of the catheter 1 in the space of the operating site and prevents expulsion from the site.
FIGS. 13 a , 13 b and 14 a , 14 b show a series 7 a , 7 b , 7 c , 7 d of surgical instruments, or mandrins 7 , making it possible to carry out the examinations illustrated in FIGS. 15 and 11.
The mandrins 7 in each representation have a head 70 of plastic integral with a metal rod 71 of small diameter.
It will be noted that only the free end opposite the head 70 varies in its geometric shape and its material in order to permit different types [sic] of examination.
In FIG. 13 a , the mandrin 7 a has at the end of its rod 71 a free end 72 designed with a hemispherical profile.
In FIG. 13 b , the mandrin 7 b has a rod 70 presenting a curved profile, but whose free end 72 is designed with a hemispherical profile.
In FIG. 14 a , the mandrin 7 c has at the end of its rod 71 a free end 73 with a very tapered point or conical shape whose inclination is similar to that of the end 20 of the cylindrical body 2 so as to lie in its continuation (FIG. 11 ).
Finally, in FIG. 14 b , the last mandrin 7 d of the series has a free end 74 of conical profile, but the end is slightly rounded. In the same way as before, the conical profile of the end 74 lies in the continuation of the conical end 20 of the body 2 .
The multipurpose catheter 1 described above and its mandrins 7 a , 7 b , 7 c , 7 d are designed to perform a number of procedures coming under the term FERTILOSCOPY and having of several stages permitting:
evaluation of the state of the uterus,
evaluation of the permeability of the tubes,
evaluation of the ovarian and tube environment,
unparalleled visualization of the distal part of the fallopian tubes and the ovaries,
evaluation of the quality of the fallopian tubes by associated salpingoscopy.
FIG. 15 illustrates a first example of an examination using the multipurpose catheter 1 including a head 3 with three inlets and two channels 21 and 22 .
The catheter 1 is introduced into the uterus a of a patient P in order to perform, for example, a methylene blue test so as to verify permeability of the fallopian tubes b.
The head 3 , and more particularly the inlet 31 , is integral with a valve 5 connected to a syringe 9 filled with a liquid comprising methylene blue, while the inlet 30 is closed tight by the head 70 of a mandrin 7 .
The inlet 32 is connected via a nonreturn valve to a source of air or liquid under pressure 11 in order to inflate the balloon 40 inside the uterus a so as to obstruct the latter and seal it for introduction of the methylene blue.
The mandrins 7 a or 7 b are introduced via the inlet 30 which communicates with the same channel 21 as that of the inlet 31 used for introducing methylene blue so that the end 72 is accommodated in the operating site of the uterus a. The introduction of a mandrin 7 a or 7 b permits mobilization of the uterus a in order to facilitate its examination upon joint laparoscopy.
FIG. 16 shows another intervention using the multipurpose catheter 1 with three inlets and two channels for FERTILOSCO
This operation provides for making an incision in the vaginal pouch c under local anesthetic. This FERTILOSCOPY is performed using the multipurpose catheter 1 combined with a mandrin 7 such as 7 c which is introduced into the operator channel 27 of the cylindrical body 2 .
The FERTILOSCOPY provides for creating an artificial ascites with serum which is injected using the multipurpose catheter into the operating site in order to permit observation of the adnexa under the most physiological conditions possible.
It is also possible, using the catheter 1 with three inlets and three routes or channels, to perform a FERTILOSCOPY by introducing surgical mandrins into the channel 27 of the cylindrical body, and in particular a clamp stabilizing the infundibulum, a FERTILOSCOPE with which it is possible to perform independent salpingoscopy.
The same channel 27 can be used to perform biopsies, hydrosalpinx incision before deciding whether to operate.
FIG. 17 shows another application of the multipurpose catheter 1 as a trocar during laparoscopy for a salpingoscopy.
The multipurpose catheter 1 is introduced into the infundibulum of a fallopian tube b which is lifted by a clamp 12 . The balloon 40 is inflated by a source of air or liquid under pressure 11 which is connected to the inlet 32 via a nonreturn valve 5 . A miniature endoscope 13 is introduced via the inlet 30 so that its lens is accommodated inside the infundibulum to be auscultated. This miniature endoscope is placed after the withdrawal of a mandrin 7 c at end 73 making it possible to pierce the skin of the patient P.
A syringe 9 is arranged on the inlet 31 which includes another valve 5 in order to fill the infundibulum with serum, facilitating visual examination.
After withdrawing the miniature endoscope 13 , salpingotomy can be performed if necessary using the balloon 40 .
FIG. 18 illustrates still another application of the multipurpose catheter 1 for performing salpingoscopy. The catheter used has three inlets and three routes, so that when it has been introduced into the operating site, it is possible to move a clamp 41 through the operator channel 27 , while a miniature endoscope 13 is arranged in the eccentric channel 21 . The dimensions of the latter make it possible to inject a liquid around the miniature endoscope 13 during examination of the fallopian tube held by the clamp.
It will be noted that the diameters of the channels 21 and 27 are adapted to receive the rods 71 of the mandrins 7 a , 7 b , 7 c , 7 d or surgical instruments while permitting injection of a liquid in the same channel.
It will be noted that the multipurpose catheter 1 , when used as a trocar, replaces the liquid infiltration sheath which is obligatory when using miniature optical endoscopes 13 . In addition, the diameter of the channel 21 can receive any miniature endoscope 13 whose external diameter does not exceed 4 mm when the infiltration sheath is withdrawn.
Moreover, the cylindrical body 2 is made of a transparent plastic material permitting monitoring of the descent of the lens 13 inside the catheter 1 .
It will be noted that the multipurpose catheter according to the present invention replaces the sheaths necessary when using miniature endoscopes.
Finally, it will be noted that the multipurpose catheter 1 may be most commonly used in the field of gynecology for performing all the examinations performed to date. | Multipurpose catheter including a small diameter cylindrical body including a first end, a second end, and at least three internal non-coaxial channels. A connection mechanism is disposed adjacent the first end for communicating with the non-coaxial channels. The connection mechanism comprises an ergonomic monobloc head which is sealingly attached to the first end of the cylindrical body. The monobloc head comprises a bulged wall having at least three independent inlets for communicating with the three non-coaxial channels via bores and two walls which continue from the bulged wall. An inwardly curved connecting wall is also included. The connecting wall is disposed adjacent the first end of the cylindrical body and connects the two walls. The two walls comprise first opposite facing inclined surfaces and second opposite facing inclined surfaces having a different inclination. One of the at least three channels is adapted to provide communication between at least one of the independent inlets and an elastically deformable balloon disposed adjacent the second end. Two of the at least three channels are adapted to allow the introduction of one of a liquid and a surgical mandrin. The ergonomic monobloc head is adapted to be gripped by a user. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a coating method and apparatus in which a desired coating solution is supplied to an extrusion-type coating head and the coating head applies the coating solution to a running support. More particularly, the invention relates to a coating method and apparatus suitable for the manufacture of a magnetic recording medium in which a coating solution such as a magnetic coating solution is applied to the surface of a belt of paper or an elongated web (support) of soft synthetic resin or the like which is being run.
Heretofore, a magnetic recording medium such as a magnetic tape or a photographing film has been formed by applying a coating solution, selected according to the purpose of use, to the surface of a support, drying the support thus treated, and cutting the support to a desired width and length. The term "support" as used herein is intended to mean a belt-shaped material made of a macromolecular compound such as polyethylene terepthalate, cellulose acetate, polyimide or polyamide, paper, copper or metal foil. The "coating solution" includes magnetic material dispersion solutions. photo-sensitive material coating solutions, heat-sensitive material coating solutions, and macromolecular molten solutions.
A coating apparatus using such a coating solution may use an extrusion-type coating head as disclosed, for instance, in Japanese patent application (OPI) No. 84771/1982.
The structure of an extrusion-type coating head and a coating method using the coating head will be discussed with references to FIGS. 6 through S.
A coating solution A is supplied through a coating solution supplying device 3 such as a pipe into a pocket 2 formed in an extruder 1. The pocket 2 is substantially circular in cross section; that is, it is a solution pool whose length is substantially equal to the width of the extruder 1. The effective length of the pocket 2 is, in general, equal to or slightly longer than the coating width.
A slot 4 is formed in the extruder 1 in such a manner that it is communicated with the pocket 3, thus providing a flow path for the coating solution A. The length of the slot 4 is substantially equal to that of the pocket 2.
The pocket 2 is filled with the coating solution A applied through the coating solution supplying device 3 under pressure, as a result of which the coating solution A is caused to flow from the pocket 2 towards the outlet with a uniform liquid pressure distribution.
The extruder 1 has a doctor edge 5 located downstream of a support 7 to which the coating solution A is applied, and a back edge 6 located upstream of the support 7.
The levels of the end faces of the edges 5 and 6 are established depending on the configuration, curvature, etc. of the support 7, for instance, as shown in FIGS. 6 and 7.
The extrusion-type coating heads thus constructed are arranged according to the actual use. For example. as shown in FIG. 6, a coating solution A is applied to a support 7 which is run while being supported by a back-up roller 11, as shown in FIG. 7, a coating solution A is applied to a support 7 which is not backed up, and, as shown in FIG. 8, a coating solution is applied to a support with the aid of rollers 12 and 13. In each case, the coating solution A is supplied to the pocket 2 through a solution delivering device such as a pump and a coating solution supplying device such as a pipe.
However, if dust or the like is mixed in the coating solution A. it may scratch the support 7 or make the coated surface of the support uneven. In such instances, the resultant product may be unacceptable.
In order to overcome this difficulty, i.e., to remove the dust or reduce the amount of dust, heretofore a filter has been provided in the path of the coating solution supplying device.
However, relatively large particles can still pass through the conventional filter, or large particles formed in the coating solution supplying line between the filter and the pocket 2, such as deposits stuck to the inner walls of the pipes, can be delivered into the pocket 2 together with the coating solution A.
These large particles can be trapped between the support 7 and the end face of the extruder 1, thus forming longitudinal stripes on the coated surface of the support 7.
In the case where a thin film layer is formed on the support by applying a coating solution A thereto, the gap between the support and the end face of the extruder is so small that the probability of trapping large particles therebetween, which results in the formation of longitudinal stripes on the coated surface of the support, is increased.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to eliminate the above-described difficulties accompanying a conventional coating method and apparatus using an extrusion-type coating head. More specifically, an object of the invention is to provide a coating method and apparatus using an extrusion-type coating head in which the probability of damaging the surface of the layer formed on the support by coating is decreased.
The foregoing and other objects of the invention have been achieved by the provision of a coating method and apparatus in which a desired coating solution is supplied to an extrusion-type coating head by coating solution supplying means, and the coating solution is applied by the extrusion-type coating head directly or through a coating roll to a support being run, in which, according to the invention, at one end of the coating solution supplying means a filtering element is provided at or near the coating solution supplying inlet of the extrusion-type coating head, the filtering elements having openings whose diameter is smaller than the coating clearance between the doctor edge of the extrusion-type coating head and the support or the coating roll, and the coating solution is supplied to the extrusion-type coating head after being filtered by the filtering element.
In the coating method and apparatus of the invention the diameter of the openings of the meshes or the like of the filtering element is smaller than the gap between the doctor edge of the extrusion-type coating head and the support. Therefore, large particles which otherwise would be caught in the gap are not supplied to the coating head.
The filtering element is positioned immediately before the coating head; that is, no long coating solution supplying path exists between the filtering element and the coating head. This eliminates the difficulty of large particles formed by coagulation of the coating solution in the path being mixed into the coating solution.
Thus, the coating method and apparatus of the invention is free from the difficulty that, in coating the support with the coating solution, dust or large particles form longitudinal stripes on the layer formed on the support. Accordingly, the resultant product is higher in reliability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory diagram for a description of the operation of a coating solution supplying system for practicing a coating method and apparatus according to this invention;
FIG. 2 is a perspective view showing the structure of a filter coupled to a coating head in the coating solution supplying system in FIG. 1;
FIG. 3 is an enlarged view of a part of a filtering element;
FIG. 4 is a sectional vieW for a description of the operation of the filter shown in FIG. 2;
FIG. 5 is a sectional view showing a coating operation with an extrusion-type coating head shown in FIG. 1; and
FIGS. 6, 7 and 8 are sectional vieWs for a description of the structures of examples of an extrusion-type coating head and coating methods with such coating heads.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the invention will be described with reference to the accompanying drawings.
FIG. 1 is an explanatory diagram showing a coating solution supplying system embodying a coating method and apparatus according to the invention. FIG. 2 is a perspective view showing essential components for a description of the construction of a filter and the installation of a coating head. FIG. 3 is an enlarged view showing a part of a mesh forming the filter. FIG. 4 is a sectional view for a description of the filtration of the filter. FIG. 5 is a sectional view for a description of a coating operation according to the invention.
In this embodiment, a coating operation is carried out with a conventional extrusion-type coating head as described above with reference to FIGS. 6 through 8. In FIGS. 1 through 5, parts corresponding functionally to those which have been described with reference to FIGS. 6 through 8 are designated by the same reference numerals or characters.
First, the coating solution supplying system will be described with reference to FIG. 1.
A coating solution 22 such as a magnetic solution is stored in a coating solution tank 21. The coating solution 22 is supplied, under a predetermined pressure, to a first filter 25 by a solution supplying pump 24 which is provided in the path of the coating solution supplying device, namely, a pipe line 23.
The filter 25 is provided to filter out large particles in the coating solution 22, thereby to make the latter uniform in quality. The filtered coating solution 22 is applied through the pipe line 23 to a second filter 26.
The second filter 26, as shown in FIGS. 1 and 2, is disposed at or near the coating solution supplying inlet of the extrusion-type coating head 1 so that the coating solution 22 is filtered by the filter 26 is directly supplied into the coating head 1 without passing through a pipe line. In general, the coating solution supplying system of the invention should be located within one meter from the coating head 1.
The internal structure of the filter 26 is as shown in FIGS. 2 and 4. That is, the filter 26 is composed of a cylinder 27 and a filtering element 28 in the form of a net.
The filtering element 28 is disposed in the cylinder 27 with a predetermined gap therebetween.
The filtering element 28 is circular in section, and one end thereof is connected to the above-described pipe line 23 to receive the coating solution 22. At the other end of the filtering element 28, the mesh part has a semi-spherical shape so that the filtering area is large enough to allow the coating solution 22 to flow smoothly.
Upon operating the solution supplying pump 24, the preliminarily filtered coating solution 22 is forced through the pipe line and the injecting section of the filter into the filtering element 28 under a predetermined pressure.
As a result, the coating solution 22 is caused to flow through the meshes (holes) 29 of the filtering element 28 into the space 30 between the cylinder 27 and the filtering element 28. The space 30 is communicated with a pocket 1 in the coating head 1 so that the coating solution filtered secondarily by the filtering element 28 is supplied into the pocket under a certain pressure.
The meshes (openings) of the filtering element 28 are sized to pass the coating solution but to block the passage of large particles in the coating solution, that is, to filter the coating solution. The size of the meshes of the filtering element 28 is determined to meet the following condition:
D.sub.min >D.sub.max
where D min is the width of the gap 31 between the end face of the coating solution and the support 7 as shown in FIG. 5, and D min is the diameter of each mesh. Accordingly, if large particles ar contained in the coating solution injected into the filtering element 28, those larger in diameter than D min are trapped. The coating solution thus filtered is supplied into the pocket 2. Therefore, the coating solution 22 flowing s out of the pocket 2 through the slit 4 contains no particles larger than the gap width D min . Thus, in applying the coating solution 22 to the support 7, no large particles can be caught in the gap, and accordingly no longitudinal stripes formed in the surface of the film layer on the support.
In the above-described embodiment, the diameter D min of each mesh 29 is smaller than the gap width D min ; however, in the case where the width w of the slit 4 is smaller than the gap width D min , the following conditions may be used:
w>d.sub.min
That is, the diameter d min of the meshes (openings) 29 is set to smaller than the minimum width of the coating solution path from the pocket 2 to the support 7.
With the diameter d min of the meshes of the filtering element determined as described above, large particles or foreign matter which could produce longitudinal stripes on the surface of the layer formed on the support are filtered out of the coating solution, and hence the resultant product is satisfactory in quality.
The filtering element 28 may be a metal net having uniform meshes, or it may be made of uniform metal particles or a uniformly sintered material having openings (pores) substantially uniform and of a known configuration and area to allow filtration on the surface thereof.
It is preferable that the filtering element 28 be of the in-line type so as to not detain the coating solution 22 in the pipe line 23. However, the configuration of the filtering element 28 is not limited thereto or thereby: that is, the filtering element 28 may be freely shaped if it will not detain the coating solution.
As described above, in the inventive coating method and apparatus, using an extrusion-type coating head, a filtering element having openings whose diameter is smaller than the minimum gap width of the coating solution path formed between the coating head and the support is arranged near the coating head, for instance, immediately before the coating head, so that the coating solution passed through the openings is supplied to the coating head to coat the support. Therefore, no particles larger than the coating solution path or the gap width will be contained in the coating solution supplied to the coating head. Accordingly, the coating method and apparatus of the invention is free from the difficulty of large particles being caught in the gap and scratching the surface of the layer formed on the support.
Furthermore, in the coating method and apparatus of the invention, unlike the conventional coating method and apparatus in which the filtered coating solution is supplied through a long coating solution supplying pipe to the coating head, the finally filtered coating solution is directly supplied into the coating head. Therefore, particles stuck to the inner wall of the pipe will not newly enter the coating solution; that is, the effect of filtration is greatly improved.
As conductive to a full understanding of the effects of the invention, an example thereof will be described.
In this example, the composition of the coating solution was as indicated in the following Table 1:
TABLE 1______________________________________γ-Fe.sub.2 O.sub. 3 (acicular particles 0.5 μm 100 parts by weightin average diameter in directionof major axis, coercive force =350 Oe. S.sub.BET =29 m.sup.2 /g)polyurethane resin 10 parts by weightepoxy resin 15 parts by weightpolyisocyanate 9.5 parts by weightcarbon black 2 parts by weightmysistic acid 1.5 parts by weightcyclohexanone 325 parts by weight______________________________________
The coating solution thus prepared was disperse mill for 7.5 hours, as a result of which its viscosity was set to 85 cp.
The support 7 was made of PET, having a thickness of 15 μm and a width of 350 mm. It was conveyed at 200 m/min.
A coating head 1 as shown in FIG. 5 was used. The dimensions of the coating head were as follows: clearance D min =0.03 mm, slot gap w=0.6 mm, pocket diameter t=25 mm, L 1 =2.5 mm, and L 2 =5.0 mm. The coating solution 2 was supplied in the manner described with reference to FIG. 1. A gear pump was used as the pump 24, and a type CP-5 filter manufactured by Chisso Co., Ltd., of Japan, which can remove 90% of particles down to 40 μm in diameter. Was employed as the first filter 25.
A filter the same in construction to the above-described second filter 26 was used. The net of the filtering element 28 was made of SUS 304 type wire mesh. More specifically, three filters different in the diameter d min of meshes or openings 29 as shown in the following Table 2 were used. The filters were substantially in the form of a test tube 7.5 mm in diameter and 95 mm in length. Each filtering element was positioned within 100 mm from the coating head 1.
TABLE 2______________________________________Filter No. Mesh size______________________________________1 0.040 mm2 0.025 mm3 0.015 mm______________________________________
The amount of coating solution applied to the support 22 was 15 cc/m 2 .
Under the above-described conditions, the coating solution was applied to a 2,000 m length of the support with the mesh size changed. The results of the coating operations are indicated in the following Table 3.
TABLE 3______________________________________Presence or absence of filteringelement 28 in filter 26, and Number of scratchesmesh size formed______________________________________No filtering element 28 11Filter No. l 3Filter No. 2 0Filter No. 3 0______________________________________
As is apparent from Table 3. making the diameter d min of the pores of the filtering element 28 smaller than the gap width D min and positioning the filter 27 immediately before the coating head can greatly reduce the possibility of forming s scratches on the coated surface and prevents the coated surface from being damaged during coating. | A coating method and apparatus employing an extrusion-type coating head in which the probability of damaging the surface of the layer being formed on a support is remarkably decreased. Coating solution, such as a magnetic solution for forming a magnetic recording tape or the like, is supplied by a pump through a pipe line and thence a filtering element to the extrusion-type coating head, which applies the coating solution onto a support being run directly or through a coating roll. The filtering element, which is disposed at or near the coating solution supplying inlet of the extrusion-type coating head, has openings whose diameter is smaller than a coating clearance between a doctor edge of the extrusion-type coating head and the support or coating roll. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an inflator for inflating articles such as personal floatation devices, rafts, buoys, and emergency signaling equipment. More particularly, this invention relates to inflators whose housings may be directly heat-sealed to the inflatable article while assuring that the inflatable article remains inflated even when the gas cartridge of the inflator is removed.
2. Description of the Background Art
Presently, there exist many types of inflators designed to inflate inflatable articles such as personal floatation devices (life vests, rings and horseshoes), life rafts, buoys and emergency signaling equipment. Inflators typically comprise a body for receiving the neck of a cartridge of compressed gas such as carbon dioxide. A reciprocating pierce pin is disposed within the body of the inflator for piercing frangible seal of the cartridge to permit compressed gas therein to flow into a manifold assembly of the inflator and then into the article to be inflated. Typically, a manually movable firing lever is operatively connected to the piercing pin such that the piercing pin pierces the frangible seal of the cartridge upon jerking of a ball lanyard. U.S. Pat. No. 3,809,288, the disclosure of which is hereby incorporated by reference herein, illustrates one particular embodiment of a manual inflator.
Water-activated actuators have been incorporated into manual inflators so that in an emergency situation such as downed aviator, injured person or a man overboard, the inflator is automatically actuated to inflate the inflatable article to which it is connected. Representative automatic actuators for inflators are disclosed in U.S. Pat. Nos. 3,059,814, 3,091,782, 3,426,942, 3,579,964, 3,702,014, 3,757,371, 3,910,457, 3,997,079, 4,223,805, 4,267,944, 4,260,075, 4,382,231, 4,436,159, 4,513,248, 4,627,823, and 5,076,468, the disclosures of which are hereby incorporated by reference herein.
As disclosed in the above-referenced patents, inflators, whether manually or water-activated, are typically connected to the inflatable article by means of the manifold assembly that consists of a metal manifold having a lower flange which is molded in situ with a rubber flange to establish a flow path between the flange and the metal manifold. A one-way valve, such as a schraeder valve, is installed in the manifold. During installation, a hole is formed in the inflatable article and the manifold is positioned therethrough. The flange of the manifold assembly is then heat-sealed to the wall of the inflatable article. Notably, the one-way valve in the manifold permits inflation of the inflatable article while precluding deflation once inflated. Representative patents relating to manifold assemblies are U.S. Pat. Nos. 5,080,402, 5,058,933, 5,058,932, 4,216,182, 3,809,288 and 3,754,731, the disclosures of which are hereby incorporated by reference herein.
Correspondingly, typical inflators comprise a manifold hole which is configured and dimensioned to receive the manifold of the manifold assembly. A locking nut is threaded onto the end of the manifold to secure the inflator. An O-ring seal is provided to prevent leakage between the manifold and the inflator.
During use, upon firing of the inflator, either manually or automatically, gas from the compressed gas cartridge flows into the manifold hole of the inflator and then into the manifold. The gas then flows past the one-way valve in the manifold and into the inflatable article. Since the one-way valve of the manifold assembly precludes deflation of the inflatable article, the gas cartridge may be removed from the inflator and the inflatable article will remain inflated.
While manifold assemblies have been in extensive use in the industry for many years, they are relatively expensive to manufacture and require additional assembly operations. Accordingly, there existed a need in the inflator industry for an inflator which may be heat-sealed directly to the inflatable article thereby obviating the need for manifold assemblies and the like.
U.S. Pat. No. 4,894,036, the disclosure of which is hereby. incorporated by reference herein, discloses an inflator which may be heat-sealed directly to an inflatable article thereby obviating the need for manifold assemblies and the like. The heat-sealable inflator as shown in such patent includes a mounting flange integrally formed about the housing of the inflator. The housing together with the integral mounting flange are composed of a plastic or similar material which may be heat-sealed to inflatable articles composed of conventional plastic or other materials. The housing includes a reciprocal pierce pin and a firing lever. A pair of compression springs are provided at opposing ends of the pierce pin to exert forces thereon in opposite directions. A pair of O-rings is also provided at opposing ends of the pierce pin. During firing upon jerking of the manual firing lever, the cammed end thereof exerts a force on the rearward (stronger) spring and causes the pierce pin to move forwardly and pierce the gas cartridge. The cammed end of the manual firing lever is configured such that upon further movement of the lever, the pierce pin may be blown-back fully rearwardly by means of the forward (weaker) compression spring combined with the pressure exerted by the gas from the gas cartridge. The bore of the housing in which the pierce pin is reciprocatably positioned is configured in such a manner that when the pierce pin is blown-back fully rearwardly, the gas may flow through a port into the inflatable article. However, once the gas has escaped from the gas cartridge into the inflatable article, the lost pressure allows the rearward (stronger) spring to return the pierce pin assembly to its rest position. The bore of the housing is configured so that when the pierce pin is in its rest position, the O-rings seal the port both forwardly and rearwardly in the bore thereby precluding the gas from the inflatable article from escaping.
Unfortunately, the specific design of the heat-sealable inflator as shown in U.S. Pat. No. 4,894,036 is expensive to manufacture due to the necessity of dual springs and its other components. Moreover, it appears that the specific design could undesirably prevent inflation if the firing lever was only moved partially through its path of travel (see FIG. 5 thereof).
U.S. Pat. No. 5,564,478, the disclosure of which is hereby incorporated by reference herein discloses an improved heat sealable inflator having a design that is significantly easier to manufacture and less costly. The heat sealable inflator as disclosed in U.S. Pat. No. 5,564,478 comprises a housing with an integrally formed mounting flange that is injected molded. A pierce pin assembly is then assembled within a bore in the housing. A firing lever is then pivotally connected to the pierce pin assembly such that upon actuation of the firing lever, the pierce pin assembly is actuated to pierce the frangible seal of a gas cartridge threaded therein, thereby allowing inflation of the article to which the inflator is heat sealed. Unfortunately, however, the inflator of U.S. Pat. No. 5,564,478 requires thick wall sections for a metal thread insert that threadably receives the gas cartridge, thereby increasing cycle times and costs during injection molding. Moreover, the escaping gas contacts the heat sealable material along with the metal components of the pierce pin assembly, which could lead to leaks to the outside if adequate sealing adhesion is not attained between such components. Moreover, the pivot pin on which the firing lever pivots is installed through a hole that must be drilled through the housing. Since the main bore core pin, during injection, has water running through it, thereby precluding the possibility of positioning a pin for the pivot hole through the core pin. It is noted that the running water through the main bore core pin is required to maintain the type of tolerances required by the O-ring that seals the bore in the assembly. Accordingly, there presently exists a need for a more easily manufacturable and assemblable heat sealable inflator that allows thinner wall sections and obviates the need for manual drilling of the hole for the pivot pin of the firing lever.
Therefore, it is an object of this invention to provide an improvement which overcomes the aforementioned inadequacies of the prior art devices and provides an improvement which is a significant contribution to the advancement of the inflation art.
Another object of this invention is to provide a heat-sealable inflator for inflatable articles having a housing with a mounting flange integral thereto, the housing and the flange being composed of a material that is capable of being easily sealed to the type of materials that are typically utilized in the construction of inflatable articles.
Another object of this invention is to provide a heat-sealable inflator which utilizes a minimal number of components and is therefore economical to manufacture.
Another object of this invention is to provide a heat-sealable inflator having a design which precludes deflation of the inflatable article once inflated even if the gas cartridge threaded into the housing is removed.
Another object of this invention is to provide a heat-sealable inflator having a design which eliminates a condition of non-inflation even if the firing lever thereof does not move through its full path of travel.
The foregoing has outlined some of the pertinent objects of the invention. These objects should be construed to merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed invention in a different manner or modifying the invention within the scope of the disclosure. Accordingly, other objects and a fuller understanding of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
For the purpose of summarizing this invention, this invention comprises an inflator adapted to be heat-sealed directly to an inflatable article thereby obviating the need for inflation manifolds and the like. More particularly, the inflator of the invention comprises a housing having an integrally formed mounting flange. A pierce pin assembly is reciprocatably mounted within a central bore of the housing. Importantly, a sleeve is injection molded in-situ inside the housing in either an insert-molded or a two-shot molding process.
The utilization of a sleeve within the housing allows the wall thickness of the housing to be significantly reduced, thereby significantly minimizing cycle times and costs during the injection molding process. Moreover, the molding of the sleeve in-situ inside the housing assures that the escaping gas from the cylinder always contacts the housing material. The likelihood of leaks which may otherwise occur because of the lack of adequate sealing adhesion during molding between the housing material and the sleeve is essentially eliminated due to the escaping gas always contacting the housing material.
Another significant aspect of the heat sealable inflator of the invention is the incorporation of a blind hole for the pivot pin of the firing lever in the inflator body without the need for drilling the hole as is common in my prior patent, U.S. Pat. No. 5,564,478. More particularly, in this invention, the blind hole formed in the inflator housing is created by first injection molding the sleeve having a skirt extension formed with a socket defining the blind hole for receiving the end of the pivot pin. The blind hole of the socket is blocked-off during the molding of the housing around the cylinder in such a way that the plastic does not fill the hole. A more complete description of this molding process is described in our concurrently-filed patent application entitled “Two-Shot Injection Molding Manufacturing Apparatus and Method”, the disclosure of which is hereby incorporated by reference herein.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a front view of the inflator of the invention;
FIG. 2 is a rear view thereof;
FIG. 3 is a right side view thereof;
FIG. 4 is a left side view thereof;
FIG. 5 is bottom view thereof;
FIG. 6 is a top view thereof;
FIG. 7 is a perspective view thereof;
FIG. 8A is a perspective view of the firing lever incorporated into the inflator of the invention;
FIG. 8B is a front view thereof;
FIG. 8C is a right side view thereof;
FIG. 9A is a front view of the housing of the inflator of the invention with all other components removed;
FIG. 9B is a right side view thereof;
FIG. 9C is a left side view thereof;
FIG. 9D is a top view thereof;
FIG. 9E is a bottom view thereof;
FIG. 10A is a front view of the operative components of the inflator of the invention with the housing omitted;
FIG. 10B is a right side view thereof;
FIG. 10C is a left side view thereof;
FIG. 10D is a top view thereof;
FIG. 10E is a perspective view thereof;
FIG. 11A is a cross-sectional view of FIG. 10B along lines 11 A- 11 A with the firing lever removed for clarity;
FIG. 11B is a perspective view of FIG. 11A ;
FIG. 11C is a partial cross-sectional of the inflator of the invention employing an alternative embodiment of a check valve to prevent an inflated inflatable from deflating in the event the gas cartridge is removed;
FIG. 11D is a partial cross-sectional of the inflator of the invention employing another alternative embodiment of a check valve to prevent an inflated inflatable from deflating in the event the gas cartridge is removed;
FIG. 12A is a cross-sectional view of FIG. 10A along lines 12 A- 12 A; and
FIG. 12B is a perspective view thereof.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-7 , the heat sealable inflator 10 of the invention comprises a generally rectangular housing 12 having an integral peripheral flange 14 . The material constituting the housing 12 with its flange 14 is composed of a heat sealable material such as polyurethane that may be heat sealed to conventional inflatable articles such as personal floatation devices, life rafts, and the like (not shown). Characteristically, the material constituting the housing 12 and its integral flange 14 is of a generally softer material having a hardness in the range of 40 to 90 on the durometer scale Shore D and a tensile strength of about 5800 psi.
As best shown in FIG. 2 , formed in the rear surface 16 of the inflator housing 12 is an exhaust port 18 which provides fluid communication from the inflator 10 into the inflatable article (not shown).
As best shown in FIG. 7 , the inflator 10 is adapted to receive the threaded neck of a gas cylinder (shown in phantom as numeral 20 ) such that upon release of the gas therefrom, the gas may flow through the inflator 10 and then out the exhaust port 18 (see FIG. 2 ) into the inflatable article (not shown).
As shown in FIG. 7 , the inflator 10 comprises a firing lever 22 to which is tethered a jerk handle 24 by means of a braided lanyard 26 . A removable safety clip 28 is provided for retaining the firing lever 22 into its normal unfired position substantially flush with the left side 30 of the inflator (see FIGS. 5 and 6 ) such that the firing lever 22 does not protrude therefrom and otherwise be inadvertently caught or snagged.
The firing lever 22 is shown in FIGS. 8A , 8 B and 8 C and generally comprises an L-shaped configuration having an upstanding arm 32 to which the lanyard 26 is inserted into and tightly and permanently secured such as by staking. The lower leg portion 34 of the firing lever 22 comprises a pivot hole 36 through which a pivot pin 38 is inserted and a cammed surface 40 which is operatively designed to cam against the actuator pin 42 of the pierce pin assembly 44 described hereinafter in more detail. To reduce friction, the pivot hole may be a plurality of upstanding protrusions 36 A encircling the pivot hole 36 .
FIGS. 9A-9E illustrate the housing 12 of the invention with all of the other components removed. Correspondingly, FIGS. 10A-10E illustrate the other components that are assembled within the housing 12 of FIG. 9 . These other components shown in FIG. 10 include the firing lever 22 and the safety clip 28 as previously described above and a safety flag 48 , preferably colored red, that is snap-fitted between ridges 50 formed in the housing 12 . The safety flag 48 is hidden behind the firing lever 22 when the firing lever 22 is in its unactuated/unfired condition. Conversely, the flag 48 is exposed when the firing lever 22 is actuated, thereby indicating a fired condition.
As best shown in FIGS. 11A and 11B and 12 A and 12 B, a generally cylindrical sleeve 52 is molded in-situ with the housing 12 . The cylindrical sleeve 52 comprises at its upper portion 42 a threaded bore 56 for receiving the threaded neck of the gas cylinder 20 .
As best shown in FIGS. 11A and 11B and 12 A and 12 B, the pierce pin assembly 44 is reciprocatably positioned within a longitudinal bore 60 of the housing 12 . The pierce pin assembly 44 comprises an actuator pin 42 with a firing pin 54 staked therein for piercing the frangible seal of the gas cartridge 20 when actuated. The actuator pin 42 comprises an O-ring groove 62 at its lower end for receiving a conventional O-ring 64 . The O-ring 64 prevents air flowing from the gas cartridge 20 from escaping from the longitudinal bore 60 such that it is directed to exit the housing 12 via exhaust port 18 to flow into and inflate the inflatable.
It is noted that once the gas cartridge 20 is removed, an air may simply escape from inflated inflatable path in the reverse direction. In order to prevent deflation of the inflatable once the gas cartridge 20 is removed, a check valve is employed. The preferred embodiment of the check valve best illustrated in FIGS. 11A and 11B comprises a seat assembly 66 that is reciprocally and sealingly positioned over the actuator pin 42 . The seat assembly 66 comprises an annular seal 68 positioned within a retainer clip 70 for support. The annular seal 68 functions to seal against the opening 72 in the bore 60 leading into the threaded bore 56 and against the outer cylindrical surface of the actuator pin 42 . A spring 74 is positioned between the seat assembly 66 and the O-ring groove 62 to urge the seal 68 into sealing engagement with the opening 72 and to allow the seat assembly 66 to blow back by the force of the escaping gas from the cartridge 20 upon firing. The spring 74 also functions to return the seat assembly 66 to its sealing engagement with the opening 72 after the gas has escaped, thereby preventing leakage of the inflated inflatable in the event the gas cartridge 20 is removed.
Another embodiment of the check valve is illustrated in FIG. 11C and comprises a flapper valve 68 A that secured over the exhaust port 18 by a fastener 69 . The flapper valve is composed of a sealing material that forms a seal with the exhaust port 18 when the inflatable is inflated, thereby allowing the gas cartridge 20 to be removed without deflation of the inflatable.
Still another embodiment of the check valve is illustrated in FIG. 11D and comprises an annular seal 68 B centered within a retainer ring 70 A for support. The annular seal 68 B functions to seal against the exhaust port 18 . A spring 74 B is positioned between the retainer ring 70 A and an annular mounting ring 70 A secured to the housing 12 to urge annular seal 68 B into sealing engagement with the exhaust port 18 and to allow annular seal 68 B to blow back by the force of the escaping gas from the cartridge 20 upon firing. The spring 74 B also functions to return the annular seal 68 B to its sealing engagement with the exhaust port 18 after the gas has escaped, thereby preventing leakage of the inflated inflatable in the event the gas cartridge 20 is removed.
It is noted that as shown in FIGS. 11C and 11D , the pierce pin 54 may comprise a central passageway that allows the flow of gas through the pierce pin 54 and the actuator pin 42 to exit therefrom proximate to the exhaust port 18 . However, when using the pierce pin assembly 44 of the preferred embodiment, the pierce pin 54 may simply be fluted as shown in the other figures whereupon the escaping gas simply flows through the flute on the pierce pin 54 to blow back the seat assembly 66 , then around the actuator pin 42 to exit the exhaust port 18 .
An important feature of the present invention is the use of the cylindrical sleeve 52 of FIG. 10 in combination with the housing of FIG. 9 . Specifically, as noted above, the material constituting the housing 12 should be of a softer material that is heat sealable with conventional articles to be inflated. In contrast, the material constituting the cylindrical sleeve 52 may be of a significantly harder, high-strength, material such as glass-filled nylon and having a tensile strength of about 30,000 psi. According to the invention, the cylindrical sleeve 52 is injection molded in a first step and then the housing 12 is injection molded about the sleeve 52 in a second injection molding step. These two steps may occur with the cylindrical sleeve 52 being insert-molded or with the cylindrical sleeve 52 being formed in-situ in a two-step molding process as more particularly set forth in our concurrently-filed patent application directed to the same and incorporated by reference herein.
Since the material constituting the cylindrical sleeve 52 is composed of a much stronger material than that of the housing 12 , it should be appreciated that it can better withstand the significant pressures that occur immediately upon actuation when gas is rapidly flowing from the gas cartridge 20 through the housing 12 into the inflatable article. Indeed, the use of the cylindrical sleeve 52 in the structure provides the needed strength to withstand the force of the rapidly-flowing gas from the cartridge. Yet, the gas contacts only the housing 12 and no portion of the sleeve 52 . The likelihood of separation between the materials is therefore essentially eliminated since the gas flows directly into the article being inflated without contacting the bond formed between the materials constituting the sleeve 52 and the housing 12 .
Another significant advantage achieved by utilizing the cylindrical sleeve 52 as described above is the ability to incorporate a depending skirt portion 76 therefrom which forms a socket 78 with a blind hole for receiving the pivot pin 38 . Specifically, the socket 78 depending from the skirt 76 is embedded within the housing 12 during the two-step injection process. Consequently, during assembly, the pivot pin 38 may be easily inserted therein without having to pre-drill a hole as in the case of my prior patent, U.S. Pat. No. 5,564,478. The elimination of any need for pre-drilling significantly reduces manufacturing and assembly costs. A more detailed description of the manufacturing apparatus and method for forming the blind hole is set forth in our concurrently-filed application noted above that is hereby incorporated by reference herein.
The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention.
Now that the invention has been described, | An inflator comprising a housing having an integrally formed mounting flange adapted to be heat-sealed directly to an inflatable article. A sleeve is injection molded in-situ inside the housing in which a pierce pin assembly is reciprocatably mounted within a central bore thereof. The sleeve within the housing allows the wall thickness of the housing to be significantly reduced and assures that the escaping gas from the cylinder always contacts the housing material. The sleeve includes a skirt extension with a socket defining the blind hole for receiving the end of the pivot pin of the firing lever to allow the injection-molding of a blind hole for the pivot pin without the need for subsequent drilling of the hole. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to cooling devices, and more particularly to a cooling device with an aerosol capable of nebulizing water, and the nebulized water drops will be ejected outward by a fan and fall on a heat exchanger, whereby they may get boiled or vaporized and absorb heat efficiently, and whereby large amounts of electricity and water will be saved. Further, since the temperature of the heat exchanger is low, the cooling effect of an air conditioner or a cooler for a heat generating device can be enhanced. Further, if either the water quality or the air quality of the environment is bad, a pre-treatment of the water to be used by the aerosol is needed so as to prolong the life of the device.
BACKGROUND OF THE INVENTION
[0002] The tonnage of the conventional gas-cooling air conditioners and coolers is selected according to the area of a space to be cooled. However, the cooling efficiency of the conventional air conditioners and coolers is low, and therefore they cannot attain the goal of saving energy, leading to high electricity cost. It is an alternative that air conditioners and coolers may use a cooling water tower or a water aerosol for the desired cooling effect. This method is disadvantageous in significant consumption of water, which is a waste of water resource and may pollute the environment after being used for an extended period of time. It is another disadvantage that this type of water-cooling devices will inevitably produce condensed water, which needs extra treatment to prevent water leakage that may cause environmental pollution and waste of water.
[0003] On the other hand, conventional cooling devices for engines can be categorized into two types. The first type utilizes a fan to send a wind to the unit to be cooled. However, the cooling effect is not good enough, especially when the air temperature is high. The second type utilizes a water cooling tower to spray water drops, which is more efficient but wastes a large mount of water. Moreover, the second type may pollute the environment for a long time of usage. Finally, it is very significant to invent a cooling device that is energy-economical, given that the energy price has been growing recently.
SUMMARY OF THE INVENTION
[0004] Accordingly, the primary objective of the present invention is to provide a cooling device of high cooling efficiency that solves the above-mentioned disadvantages.
[0005] The present invention mainly comprises a fan, a heat exchanger and an aerosol, whereby the forced convection of the air driven by the fan will blow the heat exchanger, so that the water drops produced can be easily boiled or vaporized and absorb heat efficiently. This mechanism will save water and electricity significantly and at the same time reduce the temperature of the heat exchanger, therefore enhancing the cooling efficiency of the device. Further, if either the water quality or the air quality of the environment is bad, a pre-treatment of the water to be used by the aerosol may be needed so as to lengthen the life of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a preferred embodiment of the first type of aerosols of the present invention.
[0007] FIG. 2 is a perspective view of a second preferred embodiment of the first type of aerosols of the present invention.
[0008] FIG. 3 is a perspective view of a third preferred embodiment of the first type of aerosols of the present invention.
[0009] FIGS. 4 and 6 are perspective views of a preferred embodiment of the first type of aerosols of the present invention, wherein the aerosol is located within the cooling device.
[0010] FIGS. 5 and 7 are perspective views of a preferred embodiment of the first type of aerosols of the present invention, wherein the aerosol is located outside the cooling device.
[0011] FIG. 8 is a perspective view of a preferred embodiment of the second type of aerosols of the present invention. FIG. 9 is a perspective view of a preferred embodiment of the third type of aerosols of the present invention, wherein the nebulization is caused by water being cut directly by the fan blades.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawings.
[0013] Referring a according to the present invention comprises a fan 1 , an aerosol 2 and a heat exchanger 3 , whereby the heat generated by a compressor or an engine will be transferred to the heat exchanger 3 by a coolant, such as water, and raise the temperature of the exchanger 3 . The aerosol 2 will nebulize water into fine droplets and be blown away by forced convection of the air produced by the fan and then ejected onto the heat exchanger 3 . The water droplets can be easily boiled or vaporized and absorb heat efficiently. Meanwhile, this mechanism will reduce the temperature of the heat exchanger, therefore enhancing the cooling efficiency of the device. The capacity of an air conditioner or a cooler installed with the device is therefore enhanced. Further, the problem of water leakage can be solved.
[0014] Three types of aerosols suitable for the invention will be illustrated as follows.
[0015] Referring to FIGS. 1 to 7 , the first type of aerosols has the aerosol including at least one set of sprinkle-nozzle and pressurizing unit. The pressurizing unit is powered by a pump for transporting pressurized water. The water flows through the sprinkle-nozzle of the pressurizing unit and is ejected onto the fan and then is blown away in the down-stream, up-stream or lateral direction as nebulized droplets, which is then blown onto the heat exchanger, whereby the water droplets can easily boil or vaporize and absorb heat efficiently.
[0016] Referring to FIG. 8 and as the second type of aerosols, the pressurizing unit of this type can use a water tank storing pressurized water or a water tank higher than the sprinkle-nozzle, whereby the water can be ejected through the sprinkle-nozzle by the intrinsic water pressure or hydrostatic pressure onto the fan. The water is then blown away by the fan in the down-stream, up-stream or lateral direction as nebulized droplets, which is then blown onto the heat exchanger, whereby the water droplets can be easily boiled or vaporized and absorb heat efficiently.
[0017] Referring to FIG. 9 , as the third type of aerosols, the pressurizing unit of this type can use wind pressure produced by the fast rotation of the blades of the fan, whereby water will be cut by the blades and get mixed up with the air to become nebulized. The nebulized water is then blown away by the fan onto the heat exchanger, whereby the water droplets can be easily boiled or vaporized and absorb heat efficiently.
[0018] Further, the water collected in a water collector can be reused and ejected toward the fan, whereby the water will be cut and get mixed up with the air by the fan blades to form nebulized water droplets, which will be in turn blown onto the heat exchanger by the forced convention induced by the fan. Thereby, the water droplets can be easily boiled or vaporized and absorb heat efficiently.
[0019] The above-mentioned types of aerosols will be described in details with the figures.
[0020] Referring to FIG. 2 , the first preferred embodiment of the first type aerosols of the present invention includes a pump 231 capable of draining the water left in a water collector 232 and transporting it to the aerosol 2 via a water tube 234 . The water was condensed from the cooling water or deicing water in a vaporizer, which is not shown in the figure. The water from the water tube 234 is then ejected through the sprinkle-nozzle 21 toward the fan 1 in a direction countering the wind. The water is thereby nebulized and then blown onto the heat exchanger 3 by a forced convention induced by the fan 1 , whereby the water droplets can be easily boiled or vaporized and absorb heat efficiently.
[0021] Referring to FIG. 3 and as another preferred embodiment of the first type of aerosols, the cooling device has the aerosol 2 disposed between the fan 1 and the heat exchanger 3 . Further the aerosol 2 can be installed right in front of the heat exchanger 3 , whereby the water droplets from the aerosol 2 can be drawn onto the heat exchanger 3 by the fan 1 directly.
[0022] Further, referring to FIGS. 4-7 and as other preferred embodiments of the first type, the aerosol 2 thereof is disposed within the cooling device (as shown in FIGS. 4 and 6 ) or on a sidewall, the top surface or the bottom surface of the outer case (as shown in FIGS. 5 and 7 ). Thereby, when the cooling water is nebulized by the aerosol 2 , the fan 1 will blow it onto the heat exchanger 3 directly.
[0023] Referring to FIG. 8 , a preferred embodiment of the second type of aerosols includes a pressurizing unit in the aerosol powered by either the pump 231 or a water tank 233 located at a predetermined height above the sprinkle-nozzle 21 . In the latter pressuring means, the water flown from the water tank 233 through the water tube 234 to the sprinkle-nozzle 21 is pressurized and can be sufficiently nebulized. The nebulized water is then transported to the heat exchanger 3 by a forced convection induced by the fan 1 , whereby the water droplets can be easily boiled or vaporized and absorb heat efficiently.
[0024] Referring to FIG. 9 , the a preferred embodiment of the third type of aerosols has the aerosol using wind pressure produced by the fast rotation of the blades of the fan, whereby water will be cut by the blades 12 and get mixed up with the air to become nebulized. The nebulized water is then blown away by the fan 1 onto the heat exchanger 3 , whereby the water droplets can be easily boiled or vaporized and absorb heat efficiently.
[0025] Referring to FIG. 9 , the aerosol of the cooling device of the present invention takes water from a first water collector 41 under the fan 1 . One side of the set of the blades 12 is immersed into a second water collector 232 . When the cooling water or deicing water condensed from a vaporizer of an air conditioner and flows into the second water collector 232 or an external water supplying collector 232 , the portion of the blades 12 immersed in the water will rotate quickly, whereby the water will be cut by the blades 12 and get mixed up with the air to become nebulized. The nebulization can also be done by draining water from the second water collector 232 and then injecting onto the blades 12 of the fan 1 , whereby the water will be cut by the blades 12 and get mixed up with the air by the forced convection to become nebulized. The forced convection induced by the fan 1 will blow the nebulized water onto the heat exchanger 3 , whereby the water droplets can be easily boiled or vaporized and absorb heat efficiently. Further, the fan 1 of the cooling device can be added as an external unit, and the second water collector 232 can have a sloppy bottom and include a cleansing outlet at the lowest place on the bottom.
[0026] The water source for the aerosol can be selected from regularly processed water, purified cooling water and purified deiced water by a water treatment means. The mixture of the above mentioned types of water can also be used.
[0027] When the water quality or the air quality is low, the cooling water used by the aerosol can be added with chemicals or go through a water treatment means, such as magnetic, nano-particle or quantum methods, whereby the water can be purified. This will lengthen the durability of the heat exchanger 3 .
[0028] The aerosol may be further equipped with a control unit to activate the aerosol in accordance with the setting of the cooling temperature, so as to enhance the efficiency of the aerosol.
[0029] The above mentioned twisted tube can be installed vertically or horizontally into the heat exchanger. The outer surface of the twisted tube can have fins, added or intrinsically formed, or a screw thread for better heat exchange. The twisted tube can be made of materials of high thermal conductivity.
[0030] The aluminum fins attached onto the copper tube can be treated by surface treatment means for lengthening their durability.
[0031] The present invention is thus described, and it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A cooling device comprises a fan, a heat exchanger and an aerosol, whereby water will be nebulized and then ejected by the fan onto the heat exchanger, so that the water drops produced can be easily boiled or vaporized and absorb heat efficiently. This mechanism will save water and electricity significantly and at the same time reduce the temperature of the heat exchanger, therefore enhancing the cooling efficiency of the device. Further, if either the water quality or the air quality of the environment is bad, a pre-treatment of the water to be used by the aerosol is needed so as to prolong the life of the device. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel sulfide, polysulfide, selenide and polyselenide compositions useful as solid electrolytes. More particularly, this invention relates to the sulfide, polysulfide, selenide and polyselenide compositions useful as ionic conducting solid electrolytes and electrical energy storage devices utilizing such electrolytes.
2. Description of Art:
Significant research is presently being conducted to develop new types of energy storage devices. One area of research receiving considerable emphasis is a search for better solid cation conductors which can be utilized in energy storage systems. Solid electrolytes may provide distinct advantages as compared with liquid electrolytes in the manufacturing of solid state high-energy storage devices. For example, the solid electrolyte eliminates many of the problems found in manufacturing energy storage devices with corrosive electrolytes. Further, the ionic conducting solid electrolytes can replace current molten salt electrolytes and be utilized at room temperatures.
The article Ionic Conductivity of Solid Liquid LiAlCl 4 by W. Weppner et al. discloses the electrical conductivity of lithium chloroaluminate in a temperature range between room temperature and 180° C. The article Negative Oxidation States of the Chalcogens in Molten Salts. 1. Raman Spectroscoptic Studies on Aluminum Chlorosulfides Formed in Chloride and Chloroaluminate Melts and Some Related Solid and Dissolved Compounds by Rolf W. Berg et al. discloses Raman spectroscopic measurements on series of LiCl-CsCl and CsCl-AlCl 3 melts. Also disclosed therein is a novel sulfur-containing compound of the formula CsAlSCl 2 . However, the use of these compounds as electrolytes was not discussed in this article. Finally, the article Novel Materials for Advanced Batteries by B. C. H. Steele disclose at page 371 non-crystalline lithium ion conductors of the formula Li 2 S-P 2 S 5 -LiI and polymeric ethylene oxides and propylene oxides incorporating lithium salts.
SUMMARY OF THE INVENTION
The present invention provides a novel compound of the formula:
[AlYZ.sub.2 ].sub.n [A.sub.a Cs.sub.b ].sub.n (I)
wherein:
Y is selected from the group consisting of S and Se;
Z is selected from the group consisting of Cl, Br and I or combinations thereof;
A is selected from the group consisting of Li, Na or K or combinations thereof;
n is a positive integer;
a is a number greater than 0.1,
b is a number greater than 0.01 and the sum of a+b equals 1.
This invention also provides for the use of the composition of formula I as an ionic conducting solid electrolyte.
Electrical energy storage devices are also provided comprising:
(a) a housing;
(b) at least two electrodes, including a positive electrode and a negative electrode, positioned within said housing; and,
(c) an ionic conducting solid electrolyte disposed between and electrically contacting said electrodes wherein said ionic conducting solid electrolytes comprises a composition of the formula:
[AlYZ.sub.2 ].sub.n [A.sub.a Cs.sub.b ].sub.n (I)
wherein:
Y is selected from the group consisting of S and Se;
Z is selected from the group consisting of Cl, Br and I or combinations thereof;
A is selected from the group consisting of Li, Na or K or combinations thereof;
n is a positive integer;
a is a number greater than 0.1,
b is a number greater than 0.01 and the sum of a+b equals 1.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the present invention are amorphous solid conductors of cations containing alkali cations selected from the group Li + , Na + and K + or combinations thereof in combination with Cs + coordinated within a polymeric anionic structure. The polymeric anionic structure comprises (a) aluminum, (b) sulfur or selenium and (c) a halide selected from chloride, bromide or iodide or combinations thereof. Preferably, the polymeric anionic structure is composed of (a) aluminum, (b) sulfur and (c) chloride or bromide, with chloride being most preferred.
Although the exact structure of the amorphous or glass compounds have not been specifically identified, it is believed that the polymeric anionic structure is a ionic polymer represented by the repeating unit: ##STR1## wherein Y and Z are defined as in formula (I) with the structure in chains or rings. The alkali cations are believed to individually and independently orient themselves about the units and counterbalance the negative charge of the anionic structure such that the compositions exhibit no net charge. The alkali cations are not believed to be in a bound form with other alkali cations.
The alkali cations used in the present invention are characterized by their atomic size and charge as compared to the cesium cation. Although the charge of the cations should be equal to the cesium cation, the size of the cations as defined by its ionic radius are preferably smaller than the cesium cation. Because of its small cationic size, lithium is most preferred. Although not intending to be bound to theory, it is believed that the smaller cations have greater mobility within the polymeric anionic structure as compared to the cesium cations. This greater mobility results in high ionic conductivities when subjected to potential differences across the compositions. Further, it is believed that the conduction of charged species is practically purely ionic and is attributed predominantly to the transport of cations.
The amorphous compositions of the present invention are prepared by mixing the elements or compounds containing the components of formula I at elevated temperatures. The components can be added in various forms including but not limited to metals, metal halides, alkali halides, elemental chalcogens, elemental halides and the like. The individual components are added in molar ratios of about 0.8-1.2 cation/0.8-1.2 Al/0.8-1.2 S or Se/1.8-2.2 halide and preferably, will be in molar ratios of about 1/1/1/2.
It is believed that the presence of cesium cations is necessary to provide the amorphous structure which allows high mobility of the smaller cations. This may result from the fact that the larger cesium cations contribute to the glass forming properties of these compositions. Generally, at least 1 percent of alkali cations utilized must be cesium in order to obtain the proper amorphous struction. Preferably, at least 10 percent of the alkali cations will be cesium.
The temperatures employed in preparing the amorphous compounds should be at least 550° C., preferably at least 650° C. and most preferably at least 750° C. The components are maintained at the elevated temperatures until a homogeneous viscous liquid is observed.
The pressure employed can vary widely. Typically, subatmospheric, atmospheric or superatmospheric pressures can be employed although subatmospheric pressures may be preferred when the compounds are prepared in sealed containers in order to avoid explosive pressures developing within the containers. Preferably, a vacuum is employed ranging from about 10 -3 to about 10 -6 atmospheres. Depending upon the apparatus employed, it may also be desirable to employ an inert atmosphere since the presence of oxygen and water is undesirable. Typically, the inert gases which may be employed include helium, argon, krypton, xenon, nitrogen and the like.
After heating the mixture until a homogeneous viscous liquid is formed, an amorphous compound is obtained by cooling the mixture to room temperature or below. Rapid cooling techniques such as those techniques used in the production of amorphous metals can also be employed. Further, it may be desirable to retain subatmospheric pressures and/or inert environments during cooling.
The amorphous compositions of this invention can be utilized as ionic conducting solid electrolytes in various electrical energy storage devices such as batteries, capacitors and the like. Typically, the solid electrolytes are employed in electrical energy storage devices containing at least two electrodes, a positive electrode and a negative electrode, with the solid electrolyte contactingly positioned between the electrodes. Typically, the energy storage devices will have a first current carrier electrically connected to the positive electrode and a second current carrier electrically connected to the negative electrode to provide for energy transfer to and from the device. Ideally, the solid electroyte need only be thick enough to separate the electrodes from contacting each other and therefore can be very thin such as between 0.1 to 0.001 inches (0.3 to 0.003 cm) thick or thinner.
Because the electrolyte is solid, the electrodes can be either solid or liquid. Solid electrodes include but are not limited to lithium, platinum, graphite, carbon, ruthenium, nickel, silver, gold, lead, mercury, zinc, cadium, aluminum, copper and the like. Liquid electrodes include but are not limited to liquid metals such as liquid lithium, liquid metal alloys such a lithium-mercury amalgams and the like.
An advantage of the present invention is that the amorphous compounds have a glass-like morphology and exhibit no grain boundries as compared to crystaline solids. Since no grain boundries exist in the composition of the present invention, mobile cations can move uninterrupted through the composition due to the homogenous morphology of the material.
Depending on the energy storage system and electrodes employed, various types of membranes may also be used between the solid electrolyte and the electrode. For example, conducting rubbers, polymers, celluloses and the like can be placed between the electrode and electrolyte to decrease the internal resistance exhibited at the electrode/electrolyte interface by increasing the surface connection.
SPECIFIC EMBODIMENTS
Example 1
A 12 mm outside diameter fused quartz tube was sealed at one end, cleaned and dried at 225° C. for 24 hours. The quartz tube was then transferred to a Vacuum Atmospheres glove box (with an N 2 atmosphere at about 1 atmosphere) to cool. Within the glove box, 0.57 g metallic aluminum spheres, 0.91 g elemental sulfur in powdered form, 1.29 g vacuum distilled AlCl 3 , 4.05 g CsCl and 0.20 g LiCl were added to the fused quartz cell. The final mixture had the molar ratio of 0.18Li/0.86Cs/1.1Al/1.0S/2.1Cl. The tube was stopped while in the glove box and then removed. The stopper was then removed with the tube being quickly placed on a vacuum line to evacuate the gases within the tube. This step was performed very quickly in order to minimize the possible exposure of the mixture to the air. After about 30 minutes on the vacuum line, the tube was fused shut, enclosing the mixture while still under vacuum. The sealed tube was then placed in a furnace at a temperature of about 500° C. for 48 hours. After 48 hours at 500° C. the tube was rotated at a rate of about 8-10 rpm at 500° C. for an additional 48 hours. Subsequently, the furnace temperature was raised to about 580° C. for approximately 8 hours increased to 610° C. for 24 hours, increased to 710° C. for 42 hours and finally to 780° C. for 48 hours. The tube was cooled to room temperature with the contents being examined visually while still in a sealed tube. The compound was brown in color and had a glass-like appearance.
It is to be understood that the subject invention is not to be limited by the example set forth herein since this has been provided merely to demonstrate operability. The selection of elemental components, compound formulations, component ratios and reaction conditions can be determined from the total specification disclosure provided without departing from the spirit of the invention herein disclosed and described. The scope of this invention includes equivalent embodiments, modifications and variations that fall within the scope of the attached claims. | Novel sulfide, polysulfide, selenide and polyselenide compositions are provided which are useful as ionic conducting solid electrolytes. Electrical energy storage devices utilizing such electrolytes are also provided. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This Patent Application claims priority from UK Patent Application No. GB1518483.1, filed the 19 Oct. 2015, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to flame detectors. In particular, the present invention relates to a flame detector, a method for flame detection and a further flame detector.
BACKGROUND OF THE INVENTION
[0003] Early detection of fires and flames is very important in the industrial and domestic environments. Domestic sensors tend to detect combustion bi-products which are, of course, produced after a fire has started, detection occurring once those by-products have reached the sensor—which can be some distance from the fire. Early detection of fires is essential in many environments where untold damage can occur very quickly and where there is a serious risk to safety. Flame detectors per se are known in the art and do provide early warning of the existence of fires, and such detectors are often located to monitor specific equipment, etc. where there is an increased risk of fire.
[0004] FIG. 2 (although it additionally shows aspects of the invention, it is here referred to so as to identify background information known to those skilled in the art and help set the scene) is an example of the approximate electromagnetic spectrum produced by burning petrol—line 20 represents the approximate relationship of energy vs wavelength. Line 20 may be sectioned into three approximate regions. A first region, identified with I, represents both the ultraviolet and visible regions of the spectrum; a second region, identified with II, represents the near-infrared and short-/mid-infrared, which includes a characteristic black body-type heat signature emitted by a flaming material; and the third region, identified by III, represents the mid-/long-infrared which includes the carbon dioxide (hereinafter CO 2 ) peak at 4.3 microns. Whilst it is not intended to be bound by theory, when a material becomes hot, for example during combustion, the amount of radiation (blackbody-type radiation) increases, together with a corresponding movement of the wavelength towards the shorter wavelengths. Hereinafter, ultraviolet may be designated ‘UV’ and infrared may be designated ‘IR’.
[0005] A predominance of known flame detectors look for the signal produced by hot gases, like CO 2 at 4.3 microns, as this is representative of the burning of many fuels. However, not all fuels contain carbon and, as such, when a fuel such as hydrogen burns, there is no CO 2 peak produced. In that situation, those known detectors cannot detect the presence of a flame or fire, as the sensors used therein are entirely blind to other parts of the spectrum produced by a flaming material. Further, such detectors cannot distinguish between a flame producing CO 2 and CO 2 produced by, for example, an engine. Additionally, real-world fires typically produce a large amount of dirt, soot and smoke. The presence of smoke, soot and other particulates makes fires very challenging to detect, as the smoke created by a ‘dirty’ flame can block the tell-tale 4.3 micron signal. A further particular disadvantage of narrowband detectors aimed at the 4.3 micron peak is that, in a situation that the fuel is burning in a confined space, carbon monoxide might be created rather than CO 2 , which would lead to a reduced 4.3 micron peak. This can significantly affect the speed of detection. A further disadvantage of these detectors is that, as known by those skilled in the art, 4.3 micron light is blocked by regular glass and, therefore, expensive sapphire windows must be used. Additionally, the 4.3 micron peak can be readily blocked by contaminants, such as water vapour, dirt, ice and snow. Accordingly, such known detectors are often heated and must be cleaned to ensure their correct functioning, which increases the overall cost of the unit and the running cost of the unit and associated infrastructure.
[0006] It is, therefore, understood by the Applicant that directing a flame detector to only around the 4.3 micron peak has clear disadvantages. As such, a more rounded and useful flame detector could be produced by increasing the range of wavelengths detected, which has led to a phrase coined by the Applicant: BROADSPECTRUM™.
[0007] There are many infrared sensors which exist in the marketplace, each having different characteristics of performance and cost. Generally speaking, the wider the effective range of detection of the sensor, the more expensive the sensor. Therefore, with respect to narrowband detection, this is not so much of an issue as the spectral peaks which they are intended to detect are themselves narrow; however, it becomes more of an issue when one is trying to detect wider peaks or significantly more of the spectrum emitted by a flame.
[0008] Infrared sensors come in a variety of different types, each based on a different semi-conductor metal salt. Each sensor has a different response to temperature and its relative degradation over time. As a result, detectors that rely upon interplay of various different sensors will give variable detection with temperature change and their performance will change over time as the sensors degrade at different rates. As such long-term detection of the unit can be compromised.
[0009] Further, there are a number of manufacturers who supply a range of flame detectors, each having its own detection characteristics and associated cost. Many manufacturers seem to believe that the inclusion of a plethora of sensors within the same detector provides for better detection, and sometimes this is true; however, as the sensor becomes more advanced and more numerous, the associated cost of the unit increases.
[0010] As such, there exists in the marketplace a need for a powerful (in that it is not narrowband) flame detector which, although economically produced, does not compromise on the accuracy of detection. The present invention is aimed at providing early detection of flames and fires but without the associated significant expense of various sensors on the market.
SUMMARY OF INVENTION
[0011] According to a first aspect, the present invention provides a flame detector comprising:
a fire sensor, capable of detecting a characteristic blackbody-type radiated heat signature emitted by a flaming material; and a guard sensor, for detecting an at least further part of the spectrum emitted by said material and which serves to assist in rejecting false alarms, in use during detection of a flame, the guard sensor is arranged to detect radiation of shorter wavelength than the fire sensor and detects an intensity of radiation G in a guard band range of wavelengths and the fire sensor detects an intensity of radiation F in a fire band range of wavelengths, wherein the guard band is narrower than the fire band and each band is distinct from the other, and positive detection of a flaming material depends upon the following criteria:
[0016] F>0;
[0017] G>0; and
[0018] F>G.
[0019] Preferably, by being distinct, a so-called sensory gap is provided between the fire band and the guard band, in which sensory gap no or practically no detection occurs.
[0020] Preferably, the guard sensor is arranged to detect the intensity of radiation G from a part of the spectrum associated with artificial light or sunlight.
[0021] Preferably, the fire sensor and/or guard sensor are arranged to operate in the wavelength region of less than about 4 μm, less than about 3.2 μm, less than about 3 μm, or less than about 2.55 μm. Most preferably, the fire sensor and/or guard sensor are arranged to operate in a wavelength region of from about 0.6 μm to about 3.2 μm, or from about 1 μm to about 3.2 μm, or from about 1 μm to about 2.2 μm.
[0022] Preferably, detection at the distinct guard band and fire band is arranged to be separated by a sensory gap of about 0.1 μm to about 1 μm, of about 0.2 μm to about 0.8 μm, of about 0.5 μm to about 0.7 μm, or of about 0.6 μm.
[0023] Most preferably, the guard band detects over a range of about 0.2 μm and the fire band detects over a range of about 0.4 μm.
[0024] Preferably, the fire sensor is arranged to detect radiation having a wavelength range of: from about 1.6 μm to about 2.4 μm; from about 1.7 μm to about 2.3 μm; or from about 1.8 μm to about 2.2 μm; or other distinct ranges within any of those extremes.
[0025] Preferably, the guard sensor is arranged to detect radiation having a wavelength range of: from about 0.6 μm to about 1.4 μm; from about 0.7 μm to about 1.3 μm; from about 0.8 μm to about 1.2 μm; or from about 1 μm to about 1.2 μm; or other distinct ranges within any of those extremes.
[0026] Preferably, the detector is arranged to reject or filter-out radiation of regular modulation.
[0027] Most preferably, the detector is arranged to react only upon detecting radiation of irregular modulation at about 1 Hz to about 30 Hz or about 1 Hz to about 25 Hz.
[0028] Preferably, the fire sensor and the guard sensor comprise a common sensor comprising PbS or InGaAs. Most preferably, the sensors are arranged to have different optical filters.
[0029] Preferably, the fire sensor and the guard sensor are different sensors; however, they could be the same sensor arranged to act firstly as a fire sensor and secondly as a guard sensor or vice versa.
[0030] According to a second aspect, the present invention also provides a method for flame detection comprising:
detecting an intensity of radiation F in a fire band range of wavelengths from a characteristic blackbody-type radiated heat signature emitted by a flaming material; and detecting an intensity of radiation G in a guard band range of wavelengths from an at least further part of the spectrum emitted by said material which serves in assisting rejection of false alarms, wherein, the guard band wavelengths are shorter than the fire band wavelengths, and the guard band is narrower than the fire band and each band distinct from the other, and detecting a flame if:
[0034] F>0;
[0035] G>0; and
[0036] F>G.
[0037] Preferably, detecting an intensity of radiation G from a flame in a region of the spectrum associated with artificial light or sunlight.
[0038] Preferably, the method comprising detecting in a wavelength region of the spectrum of less than about 4 μm, less than about 3.2 μm, less than about 3 μm or less than about 2.55 μm.
[0039] Preferably, the method comprising detecting in a wavelength region of from about 0.6 μm to about 3.2 μm, from about 1 μm to about 3.2 μm, or from about 1 μm to about 2.2 μm.
[0040] Preferably, the method comprising arranging the guard band and fire band to be separated by a sensory gap of about 0.1 μm to about 1 μm, of about 0.2 μm to about 0.8 μm, of about 0.5 μm to about 0.7 μm, of about 0.6 μm.
[0041] Preferably, detecting the guard band within a range of about 0.2 μm and detecting the fire band within a range of about 0.4 μm.
[0042] Preferably, detecting fire band radiation having a wavelength range of: from about 1.6 μm to about 2.4 μm; from about 1.7 μm to about 2.3 μm; or from about 1.8 μm to about 2.2 μm.
[0043] Preferably, detecting guard band radiation having a wavelength range of: from about 0.6 μm to about 1.4 μm; from about 0.7 μm to about 1.3 μm; from about 0.8 μm to about 1.2 μm; or from about 1 μm to about 1.2 μm.
[0044] Preferably, rejecting or filtering-out radiation of regular modulation.
[0045] Most preferably, detecting a flame only upon detecting radiation of irregular modulation at about 1 Hz to about 30 Hz or about 1 Hz to about 25 Hz.
[0046] Preferably, detecting radiation F and G using a different but common sensor comprising PbS or InGaAs. Most preferably, arranging the two sensors with different optical filters.
[0047] According to a third aspect of the present invention, there is provided a flame detector as defined in the first aspect, in which the fire sensor and the guard sensor (hereinafter referred to as a first guard sensor) are arranged to act in the infrared regions of the spectrum and in which the first guard sensor is arranged to detect radiation of shorter wavelength than the fire sensor; the flame detector additionally comprising a second guard sensor arranged to act in the infrared regions of the spectrum;
[0000] in use, during detection of a flame, the first guard sensor detects an intensity of radiation G 1 in a first guard band range of wavelengths, the fire sensor detects an intensity of radiation F in a fire band range of wavelengths, wherein the first guard band is narrower than the fire band and each band is distinct from the other, and the second guard sensor detects an intensity of radiation G 2 in a second guard band, and positive detection of a flaming material depends upon the following criteria:
[0048] F>0;
[0049] G 1 >0;
[0050] G 2 >0;
[0051] F>G 1 ; and
[0052] F>G 2 .
[0053] According to a further aspect, the present invention provides a flame detector comprising:
a first sensor, for detecting a characteristic blackbody-type radiated heat signature emitted by a flaming material, being arranged to detect radiation having a wavelength range of: from 1.6 μm to 2.4 μm; from 1.7 μm to 2.3 μm; or from 1.8 μm to 2.2 μm; and a second sensor, for detecting an at least further part of the spectrum emitted by said material and which serves to assist in rejecting false alarms, being arranged to detect radiation having a wavelength range of: from 0.6 μm to 1.4 μm; from 0.7 μm to 1.3 μm; from 0.8 μm to 1.2 μm; or from 1 μm to 1.2 μm, wherein each sensor comprises a detection zone manufactured from a material comprising lead sulphide (PbS) or indium gallium arsenide (InGaAs).
[0057] Preferably, additionally comprising a third sensor manufactured from lead sulphide (PbS) or indium gallium arsenide (InGaAs).
[0058] Preferably, wherein each of the first, second and third sensors are capable of detecting infrared, or the first and second sensors are capable of detecting infrared and the third sensor is capable of detecting ultra violet.
[0059] Preferably, the second sensor is arranged to detect a part of the radiation of a flame associated with artificial light or sunlight.
[0060] Preferably, the first sensor and/or second sensor are arranged to operate in the wavelength region of less than about 4 μm, less than about 3.2 μm, less than about 3 μm, or less than about 2.55 μm. Most preferably, the first sensor and/or second sensor are arranged to operate in a wavelength region of from about 0.6 μm to about 3.2 μm, or from about 1 μm to about 3.2 μm, or from 1 μm to 2.2 μm.
[0061] Preferably, detection at the second sensor and the first sensor is arranged to be separated by 0.1 μm to 1 μm, or by 0.2 μm to 0.8 μm, by 0.5 μm to 0.7 μm, or by 0.6 μm.
[0062] Most preferably, the second sensor detects over a range of about 0.2 μm and the first sensor detects over a range of about 0.4 μm.
[0063] Preferably, the detector is arranged to reject or filter-out radiation of regular modulation.
[0064] Most preferably, the detector is arranged to react only upon detecting radiation of irregular modulation at about 1 Hz to about 30 Hz or about 1 Hz to about 25 Hz.
[0065] Advantageously, the present invention typically relates to detection through defining a distinct guard band and a distinct fire band, with a sensory gap therebetween, at or around the expected maximum radiated heat energy portion of the spectrum. In particular, this detection is at wavelengths well below the 4.3 micron peak for CO 2 .
[0066] Advantageously, by acting upon the specific heat signature of a flame across the spectrum, these flame detectors and associated methods are more capable of detecting fires from practically all fuels, whilst rejecting false alarms.
[0067] Advantageously, a ‘dirty’ flame does not block the heat signature produced by the flaming material and, therefore, does not prejudice detection.
[0068] Advantageously, by being distinct, a so-called sensory gap is provided between the guard band and fire band. The effects of the sensory gap are that it:
1) allows a single flame detector to clearly distinguish the fire band and guard band signals, which improves resolution and creates the ability to better distinguish between a light source (whether natural or synthetic) and a fire source—the light source being, typically, a source of false alarms; 2) by contrast, if the fire and guard bands are adjacent, then bleeding of signal from one band into the other band would occur and affect detection—making this an additional source of false alarms; and 3) it is easier for signal processing to process signals from distinctively separate bands.
[0072] Advantageously, the effects of the guard band being narrower than the fire band are as follows.
1) Owing to Wien's displacement law, the shoulder of peak wavelength is displaced with temperature. The effect of this is that synthetic light or sunlight gives a greater signal in the visible light spectra—such that, in the guard band, an equivalent signal intensity to the fire band is provided by a relatively narrower region of guard band. As such, greater specificity of rejection of false alarms is provided by having a narrower guard band. 2) Wide-band spectra analysis improves the types of sources which can be detected by the flame detector. Wider integrating areas minimise the impact of chemical emission bands (which bands are specific to particular gas species), which provides a more reliable black-body signal for fire detection. This provides greater coverage of sources of fires, for example cooler burning fires such as those created by hydrogen. Conversely, if the guard band is made wider, overall flame detection is reduced as less of the spectrum falls in the fire band. 3) A narrow guard band operates effectively to reduce false alarms whilst not affecting overall detection in the fire band.
[0076] Advantageously, by maintaining the same detector material within all sensors, degradation in unit performance over time and with variance in temperature is minimised, through pegging of the sensors to one another. Lead sulphide offers a relatively wide absorption band. Advantageously, lead sulphide sensors are amongst the least expensive infrared sensors on the market but can be appropriately adapted so as to provide very effective detectors. Beyond the simplification of supply chains and production, the main advantage to using a single sensor type for both sensors is the uniformity of response from each sensor. Through time, the environment can change or degrade the sensors and different sensors will behave differently according to those conditions. However, if the sensors are the same type of sensor, then it is fair to expect both sensors to degrade or change in either the same or a similar way over time. Accordingly, the sensors are effectively pegged to one another. A further consideration is the fact that the sensitivity of many sensors is affected by the temperature of the sensor, and lead sulphide is no exception. With the present invention, any changes in temperature are equally felt by both sensors, which again pegs their performance. Owing to the use of two optical filters (in the case of an IR 2 detector), each with a different transmission window, a detector operates as if it had two very different sensor substrates, whilst still keeping the benefits of a single sensor type. The addition of a third or subsequent sensor of the same type, potentially having its own optical filter, maintains this advantage.
[0077] An additional sensor adds another basic input into the fire decision, increasing reliability and rejection of false alarms. False alarm rejection can be further enhanced by considering the flame flicker produced during the burning of a material.
[0078] Advantageously, the present detectors are capable of being used behind standard glass, such as to separate them from dirty environments, whilst still maintaining their function. As such, this provides both practicality and an economic advantage over narrowband CO 2 detectors. Further, no heating of the detector unit is required. The present flame detectors can operate in difficult conditions without heaters and other accessories.
[0079] The present invention leads to significant false alarm rejection, universal fuel detection and all in an inexpensive detector.
[0080] As used herein, the term ‘material’ is intended to have its customary meaning of something which can be a solid, a liquid or a gas, or mixtures thereof.
BRIEF DESCRIPTION OF FIGURES
[0081] The invention will now be disclosed, by way of example only, with reference to the following drawings, in which:
[0082] FIG. 1 is a schematic diagram of sensors and associated apparatus of a flame detector;
[0083] FIG. 2 is graphical representation of part of the spectrum emitted by a flaming material;
[0084] FIG. 3 is a schematic diagram of a second arrangement of sensors and associated apparatus of a flame detector.
DETAILED DESCRIPTION
[0085] FIG. 1 shows aspects of a flame detector, identified generally by reference 1 , specifically its sensors and their associated apparatus. The detector 1 includes a pair of infrared sensors 2 a and 2 b , a pair of optical filters 3 a and 3 b , a pair of spacers 4 a and 4 b and a visible filter 5 . This type of detector 1 having two infrared sensors is often referred to as an IR 2 .
[0086] The infrared sensors 2 a ; 2 b are of the type commonly available in the marketplace, and in this example they are lead sulphide photoconductive sensors as manufactured by HAMAMATSU®. Each of the sensors 2 a ; 2 b is associated with a corresponding optical filter 3 a or 3 b , respectively, and a quartz spacer 4 a ; 4 b , respectively. The visible filter 5 is of the type found in remote control apparatus and is opaque to visible light, preventing substantially all light below 0.8 microns from reaching the sensors 2 a ; 2 b . Specifically, as both sensors 2 a ; 2 b are of the same type and have corresponding sensor characteristics, their respective performances will be pegged.
[0087] Optical filters 3 a and 3 b are both crystalline materials but have different optical characteristics in that they each only allow radiation of a particular range of wavelengths through, providing a first sensor 2 a having a wavelength region of 0.6 to 1.4 microns and a second sensor 2 b having a wavelength region of about 1.6 to 2.4 microns. The wavelength region of 0.6 to 1.4 microns defines a ‘guard band’ and sensor 2 a together with its filter 3 a can be considered a guard sensor, and the wavelength region of 1.6 to 2.4 microns defines a ‘fire band’ and sensor 2 b together with its filter 3 b can be considered a fire sensor.
[0088] As those skilled in the art will realise, the sensors and associated apparatus described above are just part of a flame detector 1 , which detector 1 will additionally include various circuitry for comparing and analysing the signals received from the sensors 2 a ; 2 b . The following is not shown in the Figures, but is present in a flame detector of this type. The detector 1 includes processing circuitry, analysis software and various outputs, for example light emitting diodes (LEDs) and/or relays for connecting to a fire panel.
[0089] In use, and as shown generally in FIG. 1 , electromagnetic radiation emitted from a flaming material, identified as the arrow bearing reference 10 , is incident upon the detector 1 and first passes through the visible filter 5 , before passing through respective spacers 4 a and 4 b , then respective optical filters 3 a and 3 b , and, finally, falls upon respective sensors 2 a and 2 b . Owing to the optical filtering (optical filters 2 a ; 2 b and the visible filter 5 ), radiation which is outside of the desired transmission wavelengths is substantially hindered and prevented from being transmitted to the sensors 2 a ; 2 b . At the sensors 2 a ; 2 b , the intensity of radiation signals in the desired wavelength ranges can be easily detected. Such signals detected by the sensors 2 a ; 2 b are processed by the processing circuitry and analysed by the software, where the characteristics of the detected signals are compared with that of a flame, for example the signal amplitude, modulation regularity and proportional differences at specific wavelengths which are considered intrinsic to practically all flame types. The detector 1 will signal a ‘fire’ if there is a match in various characteristics and if pre-set thresholds are achieved, and activate a corresponding LED and switching relay in the fire monitoring control equipment. Additionally, signal (non-optical) filtering may occur, in combination or separately to analysis of the frequency of modulation of the source of radiation and/or analysis of the ratios of wavelengths being detected. In particular, for a ‘fire’ to be signalled, an intensity of radiation F detected in the ‘fire band’—by sensor 2 b —must be greater than an intensity of radiation G detected in the ‘guard band’—by sensor 2 a —and both sensors 2 a and 2 b must each be receiving a signal (F>0 and G>0). In order to improve performance with respect to false alarms, flame flicker analysis can be included during processing, which has the effect of discounting regularly modulated radiation which is typically emitted by simple hot objects, as compared to a flaming material. False alarm rejection can be further enhanced by considering the flame flicker produced during the burning of a material. For example, a natural fire will always have some turbulence created by differences within the fuel and airflows. Through looking at these phenomena, it is possible to create a detector which rejects virtually all false alarms. In particular, this is partly achieved through considering only those signals having a frequency of between, say, 1 and 25 Hertz (Hz). By way of an alternative, the infrared sensors could be of the indium gallium arsenide photodiode-type, as manufactured by HAMAMATSU®.
[0090] The present invention looks at a broad range of radiation produced by a flaming material and then separates the signal of the fire from that of background light. This can be achieved using the approximately short-wave infrared region (with respect to the embodiment of FIG. 1 ) and the ultraviolet region (with respect to the alternative embodiment of FIG. 3 ). With respect to the embodiment of FIG. 1 , detection is achieved by splitting the spectrum in or around the short-/mid-infrared (region II of FIG. 2 ) into a fire band and a guard band. The fire band is conveniently located in a region at which one would expect to detect a characteristic black body-type heat signature emitted by a flaming material. The guard band is located to detect radiation of shorter wavelength, although still within the short-/mid-infrared.
[0091] An example of this can be gleaned from FIG. 2 , as FIG. 2 shows the approximate electromagnetic spectrum produced by burning petrol, as previously introduced. Those skilled in the art will understand that the peak in the short-/mid infrared region is the type of peak which is characteristic of black body-type radiated heat emitted by a flaming material. As such, by setting a fire band at around 1.6 microns to about 2.4 microns (or other distinct range within those extremes) and a guard band at around 0.6 microns to about 1.4 microns (or other distinct range within those extremes), a detector with two identical sensors can accurately monitor and detect the specific heat signature of a flame and reduce the occurrences of false alarms by comparing the fire band intensity with a corresponding intensity from the guard band which, in the case of a flame, will always be less.
[0092] FIG. 2 also shows the approximate location and range of wavelengths of a fire band 21 , which is the right-most rectangular box, and the approximate location and range of wavelengths of a guard band 22 , which is the middle rectangular box. FIG. 2 also shows the approximate location and range of wavelengths of a further sensor band 23 , which is the left-most rectangular box, and which is located in the ultraviolet region. The locations are approximate—although in the cases of the fire band 21 and guard band 22 , they are shown as being in the correct region of short-/mid-infrared where the characteristic black body-type heat signature emitted by a flaming material is expected—because the exact optimum location and ranges can alter, depending upon what material is flaming. By detecting a range of wavelengths at the guard band and fire band, this increases the potential for the detector to detect a flame, no matter which material is flaming. Accordingly, these detectors are appropriate for detecting flames from practically all fuels. Most preferably, the guard band 22 range of wavelengths detects over a range of 0.2 μm and the fire band 21 detects over a range of 0.4 μm. A sensory gap 24 is defined between the guard band 22 and fire band 21 .
[0093] FIG. 3 shows a second form of detector, indicated generally by reference 1 ′, which is based upon the detector of FIG. 1 ; however, which includes an additional sensor and associated apparatus. This type of detector 1 ′ having three infrared sensors is often referred to as an IR 3 . The detector 1 ′ has various features in common with the detector 1 of FIG. 1 which will not be described further in detail, and only the differences will be discussed.
[0094] Detector 1 ′ includes a third sensor 2 c, with a corresponding optical filter 3 c, and corresponding quartz spacer 4 c. Sensor 2 c is an additional infrared sensor of the same type as described in relation to FIG. 1 . Corresponding optical filter 3 c will, typically, not have exactly the same optical characteristics as optical filter 3 a ; however, the sensor 2 c and filter 3 c are directed to the same function as they are intended to be a further guard sensor. As such, for a ‘fire’ signal to be initiated, an intensity of radiation F detected in the ‘fire band’ must be greater than an intensity of radiation G 1 detected in the first ‘guard band’, and also greater than an intensity of radiation G 2 detected in the second ‘guard band’, and all three sensors 2 a ; 2 b ; 2 c must each be receiving a signal (F>0; G 1 >0; G 2 >0). The effect of this is to reduce false alarms caused by sunlight, etc. striking the face of the detector, as the detector must cross-check its fire signal with an additional guard signal before indicating a fire.
[0095] An additional sensor adds another basic input into the fire decision, increasing the reliability of the system and, as phenomena such as sunlight tends to move slowly across the face of the detector, this will tend to hit one sensor and then another. In the case of an IR 2 , this may cause a fire activation if the light is modulated externally by, for example, a tree moving in the wind, however, in the case of an IR 3 , the extra sensor and the way the signals are compared reduces this occurrence of false alarms. In particular, in terms of the decision making as to whether to indicate a fire, there are two decisions made with the IR 3 detector—a comparison between the first guard band and the fire band, and a comparison between the second guard band and the fire band.
[0096] Although in the above sensor 2 c is described as an additional guard sensor in the infrared region, it could be an ultraviolet sensor, with very little revision to the hardware/software. The UV sensor would not be a guard sensor as such, as it would be intended to detect parts of the UV spectrum emitted by a flaming material. In particular, a UV/IR 2 unit is more sophisticated as it encompasses more of the spectrum, allowing the unit to make a better informed fire decision with fewer false alarms. Even though a flame produces only small amounts of UV radiation these can still be detected using the right type of sensor. An example of this is a UVtron from HAMAMATSU®. If using a UV sensor, filter 3 c may be dispensed with; however, a UV quartz spacer 4 c may be required. | A flame detector ( 1 ) including: a fire sensor ( 2 a ), capable of detecting a characteristic blackbody-type radiated heat signature emitted by a flaming material; and a guard sensor ( 2 b ), for detecting an at least further part of the spectrum emitted by the material and which serves to assist in rejecting false alarms, wherein, in use during detection of a flame, the guard sensor ( 2 b ) detects an amount of radiation G and the fire sensor ( 2 a ) detects an amount of radiation F, and positive detection of a flaming material depends upon the following criteria: F>0; G>0; and F>G. | 6 |
This is a continuation-in-part application claiming priority based on U.S. patent application Ser. No. 09/257,753 filed Feb. 25, 1999, now abandoned.
FIELD OF THE INVENTION
The present invention is directed to a process for purifying nitric oxide, and more particularly to a process for adsorbing nitrous oxide, nitrogen dioxide, nitrous acid, carbon dioxide, sulfur dioxide, carbonyl sulfide and moisture from a nitric oxide stream by adsorption.
BACKGROUND OF THE INVENTION
Nitric oxide plays an important role in medicine and electronic component manufacture. For example, in the medical field, inhaled nitric oxide helps maintain blood pressure by dilating blood vessels, and kills foreign invaders in the body's immune system. It can be appreciated that it is imperative that the nitric oxide used in such medical applications be of medical grade, i.e., it must not contain more than 5 parts per million by volume (ppm) nitrogen dioxide, and must be substantially free of all other impurities that are harmful to humans, such as slfur dioxide. In electronic applications, nitric oxide is used for nitriding gate oxides in the manufacture of silicon semiconductor devices. The purity requirements for electronic grade nitric oxide are likewise stringent. For example, electronic grade nitric oxide must contain less than about 30 ppm nitrogen dioxide and nitrous oxide. Nitric oxide can be produced by a variety of methods. U.S. Pat. No. 5,670,127, incorporated herein by reference, discloses a particularly desirable nitric oxide manufacturing method which involves the reaction of nitric acid with sulfur dioxide. According to this process aqueous nitric acid is introduced into the top of a trickle bed reactor while sulfur dioxide, introduced into the bottom of the reactor, passes upwardly through the bed. Nitric oxide, produced by reaction of the nitric acid and sulfur dioxide, passes out through the top of the reactor. Water vapor and any sulfur dioxide not consumed in the reaction also pass out of the reactor with the nitric oxide, and thus become impurities in the nitric oxide product gas. Additionally, nitrous oxide and nitrogen dioxide are also impurity byproducts of the process. Many of the above impurities are produced in most other nitric oxide production processes.
Various techniques are employed to remove nitrogen dioxide and sulfur dioxide from the nitric oxide. U.S. Pat. No. 3,489,515 discloses the purification of nitric oxide by washing the nitric oxide with a dilute aqueous solution of nitric acid. The water reacts with the nitrogen dioxide to produce nitric and nitrous acids, which can be washed from the gaseous product stream by washing the stream with water. This method is not satisfactory for producing electronic grade nitric oxide because it does not adequately reduce the concentration of nitrogen dioxide in the product gas stream. Nitrogen dioxide can also be removed from nitric oxide by cryogenic distillation. This method likewise leaves a lot to be desired because of the high capital cost of distillation equipment and because not all of the valuable nitric oxide is recovered during the distillation. Furthermore, liquid nitric oxide is known to be shock-sensitive and has been observed to detonate under certain conditions.
Another nitric oxide purification technique that has been reported is adsorption using various adsorbents. For example, U.S. Pat. No. 5,417,950 discloses the adsorptive removal of nitrogen dioxide and sulfur dioxide from nitric oxide using alumina-deficient type Y zeolite of ZSM5 zeolite as adsorbents; U.S. Pat. No. 5,514,204 discloses the adsorptive separation of nitrogen dioxide and moisture from nitric oxide using metal cation-free silica gel, alumina, or various zeolites, such as types A, X and Y zeolites; and U.S. Pat. No. 5,670,125 discloses the purification of nitric oxide by adsorbing nitrogen dioxide and sulfur dioxide from the nitric oxide using zeolites having a silica to alumina ratio not greater than about 200.
In addition to the above nitric oxide purification methods, adsorption has been used to remove nitrogen oxides (including nitric oxide) and sulfur dioxide from gas streams. U.S. Pat. Nos. 2,568,396 and 4,149,858 disclose the separation of sulfur and nitrogen oxides from use of activated coke or activated charcoal; and U.S. Pat. Nos. 3,674,429 and 4,153,429 disclose the removal of nitrogen oxides from gas streams using zeolites. Oxygen present in or added to the gas streams effects the oxidation of nitric oxide to nitrogen dioxide, and the nitrogen dioxide is adsorbed by the zeolite. The disadvantage of using most of the above adsorbents for the purification of nitric oxide is that they tend to promote the disproportionation of nitric oxide to nitrogen dioxide and nitrogen and/or nitrous oxide, and the oxidation of nitric oxide to nitrogen dioxide.
Because of the importance of producing nitric oxide that is substantially free of nitrogen dioxide, sulfur dioxide and other impurities for medical and electronic applications, highly effective methods for purifying nitric oxide are continuously sought. The present invention provides a simple and efficient method of achieving this objective.
SUMMARY OF THE INVENTION
According to the invention, gaseous impurities are adsorbed from nitric oxide gas using as the adsorbent a porous polymer.
According to a broad embodiment, the invention comprises a method for purifying a nitric oxide gas stream containing one or more gaseous impurities, comprising an adsorption step comprising passing the gas stream through at least one adsorption zone containing a porous, metal-free polymeric adsorbent that is selective for the one or more impurities, thereby adsorbing the one or more impurities from the nitric oxide gas stream and producing purified nitric oxide.
The porous, metal-free polymeric adsorbent that is selective for one or more impurities in the nitric oxide does not promote the disproportionation of nitric oxide to nitrogen dioxide and nitrogen or nitrous oxide, or by promoting the oxidation of nitric oxide to nitrogen dioxide.
The method preferably further comprises an adsorbent regeneration step comprising desorbing the one or more impurities from the adsorbent. More preferably, the adsorption step and the adsorbent regeneration step are steps of cyclic adsorption process. Most preferably, the cyclic adsorption process is pressure swing adsorption, temperature swing adsorption or a combination of these.
The polymeric adsorbent preferably comprises aromatic polymers, heterocyclic polymers, acrylic polymers, acrylic ester polymers, imine polymers, fluorocarbon polymers and combinations thereof.
Generally, the adsorption step of the method is carried out at a temperature in the range of about −200 to about 200° C. and a pressure in the range of about 0.5 to about 50 bara.
According to one preferred embodiment of the invention, the cyclic adsorption process is pressure swing adsorption and the adsorbent regeneration step is carried out at a pressure in the range of about 0.5 to about 5 bar. In this preferred embodiment, the polymeric adsorbent preferably comprises divinylbenzene polymers, styrene polymers, acrylic polymers or combinations thereof. Likewise, in this preferred embodiment, it is preferred that the adsorption step be carried out at a temperature in the range of about −150 to about 100° C. and a pressure in the range of about 1 to about 20 bara. It is also preferred in this preferred embodiment, that the adsorbent regeneration step be carried out at a pressure in the range of about 0.1 to about 2 bara.
According to another preferred embodiment of the invention, the cyclic adsorption process is temperature swing adsorption and the adsorbent is regenerated at a temperature in the range of about −150 to about 300° C. In this preferred embodiment, the polymeric adsorbent preferably comprises divinylbenzene polymers, styrene polymers, acrylic polymers or combinations thereof. Likewise, in this preferred embodiment, it is preferred that the adsorption step be carried out at a temperature in the range of about −150 to about 100° C. and a pressure in the range of about 1 to about 20 bara. It is also preferred in this preferred embodiment, that the adsorbent regeneration step be carried out at a temperature in the range of
In a more preferred embodiment of the invention, the polymeric adsorbent is a divinylbenzene polymer comprising polydivinylbenzene, divinylbenzene-styrene copolymer, divinylbenzene-ethylvinylbenzene copolymer, divinylbenzene-acrylonitrile copolymer, divinylbenzene-ethyleneglycol dimethacrylate copolymer, divinylbenzene-4-vinyl-pyridine copolymer, divinylbenzene-polyethyleneimine copolymer, divinylbenzene-N-vinyl-2-pyrrolidinone copolymer, or combinations thereof Likewise, in this more preferred embodiment it is preferred that the adsorption step be carried out at a temperature in the range of about −120 to about 0° C. and a pressure in the range of about 1.5 to about 10 bare. In this preferred embodiment, when the cyclic adsorption process is pressure swing adsorption, it is preferred that the adsorbent regeneration step be carried out at a pressure in the range of about 0.2 to about 1 bara, and when the cyclic adsorption process is temperature swing adsorption, it is preferred that the adsorbent regeneration step be carried out at a temperature in the range of about −50 to about 150° C.
In any of the above embodiments, the adsorbent regeneration step can be at least partly carried out by purging the adsorbent with the purified nitric oxide.
In a first specific embodiment, the invention comprises a method of purifying a substantially oxygen-free nitric oxide gas stream containing at least one gaseous impurity by repeatedly performing the steps:
(a) cocurrently passing the gas stream through at least one adsorption zone containing a porous, metal-free polymeric adsorbent selective for the at least one gaseous impurity at a temperature in the range of about −120 to about 0° C. and a pressure in the range of about 1 to about 20 bara, thereby adsorbing the at least one gaseous impurity and producing impurity-depleted nitric oxide; and
(b) countercurrently depressurizing the at least one adsorption zone to a pressure in the range of about 0.05 to about 2 bara, thereby desorbing the at least one gaseous impurity from the adsorbent.
In a preferred aspect of the first specific embodiment, the method further comprises countercurrently purging the at least one adsorption zone with the impurity-depleted nitric oxide. In another preferred aspect of the first specific embodiment, the method further comprises at least partly repressurizing the at least one adsorption zone by countercurrently introducing the impurity-depleted nitric oxide thereinto.
In another preferred aspect of the first specific embodiment, step (b) is at least partly carried out by purging the at least one adsorption zone with heated nonadsorbable gas, and another preferred aspect of this embodiment comprises purging the nonadsorbable gas from the at least one adsorption zone with the impurity-depleted nitric oxide.
In a second specific embodiment, the invention comprises a method of purifying a substantially oxygen-free nitric oxide gas stream containing at least one gaseous impurity by repeatedly performing the steps:
(a) passing the gas stream through at least one adsorption zone containing a porous, metal-free polymeric adsorbent selective for the at least one gaseous impurity at a temperature in the range of about −120 to about 0° C. and a pressure in the range of about 1 to about 20 bara, thereby adsorbing the at least one gaseous impurity and producing impurity-depleted nitric oxide; and
(b) desorbing the at least one gaseous impurity from the adsorbent at a temperature in the range of about −50 to about 150° C., thereby regenerating said adsorbent.
In a preferred aspect of the second specific embodiment, step (a) is carried out by cocurrently passing the gas stream through the at least one adsorption zone, and in another preferred aspect of the second specific embodiment, step (b) is at least partly carried out by at least partially purging, preferably countercurrently, the at least one adsorption zone with heated nonadsorbable gas. The second specific embodiment of the invention preferably further comprises purging the nonadsorbable gas from the at least one adsorption zone with the impurity-depleted nitric oxide.
In a preferred aspect of the first and second specific embodiments, the polymeric adsorbent comprises aromatic polymers, heterocyclic polymers, acrylic polymers, acrylic ester polymers, imine polymers, fluorocarbon polymers or combinations thereof
Preferably, in either of the above specific embodiments, the method is practiced such that the impurity-depleted nitric oxide contains not more than about 30 ppm each of nitrogen dioxide and sulfur dioxide, and not more than about 1 ppm each of water vapor and carbon dioxide.
The method of the invention is especially useful for removing gaseous impurities selected from nitrous oxide, nitrogen dioxide, nitrous acid, sulfur dioxide, carbonyl sulfide, water vapor, carbon dioxide or mixtures thereof from a nitric oxide gas stream. In preferred embodiments of the invention, it is preferred that the nitric oxide gas stream being purified be substantially oxygen-free.
In another preferred embodiment of the invention, the adsorption method is carried out in a battery of two or more adsorption beds arranged in parallel and operated out of phase, so that when the adsorption step is carried out in one or more adsorption zones, the adsorbent in one or more other adsorption zones is replaced or regenerated.
DETAILED DESCRIPTION OF THE INVENTION
The porous polymeric adsorbents used in the process of the invention for the nitric oxide purification are superior to adsorbents currently used for nitric oxide purification in that they do not cause disproportionation of nitric oxide to nitrous oxide and nitrogen dioxide, nor do they catalyze the oxidation of nitric oxide to nitrogen dioxide. It is not known with certainty why these polymeric materials have these advantages, but it is believed that the metal cations associated with zeolites and other currently used adsorbents promote one or both of these undesirable reactions. The polymeric adsorbents used in the invention are substantially metal-free; accordingly they do not significantly promote nitric oxide disproportionation or oxidation. The term “metal-free”, as used herein, means substantially free of metals or metal cations that adversely affect the purification process of the invention by, for example, promoting the disproportionation of nitric oxide to nitrogen dioxide and nitrogen and/or nitrous oxide, or by promoting the oxidation of nitric oxide to nitrogen dioxide.
The porous, metal-free adsorbents of the invention include aromatic polymers, such as styrene and divinylbenzene homopolyrners and copolymers, etc.; heterocyclic polymers, such as vinyl pyridine, vinyl pyrolidinone, etc.; acrylic polymers, including methacrylic polymers, such as acrylonitrile, ethyleneglycol dimethacrylate, etc.; polyimines, such as polyethyleneimine; fluorocarbon polymers, such as polytetrafluoroethylene; etc. Typically, these porous polymers have a surface area of about 50 m 2 /gram or more, and the most useful porous polymers are those having about 200 to about 800 or more m 2 /gram. Suitable porous polymers include those sold by Hayes Separation Inc. under the trademark series HayeSep®, those sold by Waters Corporation under the trademark series Porapak®, those sold by World Minerals Corp. under the Chromosorb® Century series trademark, those sold by Rohm and Haas under the trademark Amberlite®, and those sold by E. I. dupont de Nemours Company under the trademark Teflon®. Typical polymers suitable for use in the invention are porous polydivinylbenzene, divinylbenzene-styrene copolymer, divinylbenzene-ethylvinylbenzene copolymer, polystyrene, polyacrlic acid, divnylbenzene-acrylonitrile copolymer, divinylbenzene-ethyleneglycol dimethacrylate copolymer, divinylbenzene-4-vinyl-pyridine copolymer, divinylbenzene-polyethyleneimine copolymer, divinyl benzene-N-vinyl-2-pyrrolidinone copolymer, etc.
Preferred polymers are porous divinylbenzene polymers, such as polydivinylbenzene, divinylbenzene-styrene copolymer, divinylbenzene-ethylvinylbenzene copolymer, etc.
The process of the invention can be carried out in a single adsorption vessel or a battery of two or more adsorption vessels, preferably arranged in parallel and adapted to be operated out of phase. The adsorbent may be used once and disposed of, or it may be regenerated and reused. A preferred method of carrying out the invention is a cyclic process comprising adsorption and adsorbent regeneration or adsorbent replacement. It is preferred that the process be carried out in a system comprising two or more adsorption vessels arranged in parallel and operated out of phase, such that one or more adsorption vessels of the system are undergoing adsorption while the adsorbent in one or more other vessels is undergoing regeneration or being replaced. Such an arrangement provides a pseudo-continuous flow of purified gas from the adsorption system. Particularly preferred systems for practice of the invention comprise two adsorption vessels arranged in parallel and operated 180° out of phase.
Suitable cyclic processes for practice of the invention include pressure swing adsorption, PSA, (which includes vacuum swing adsorption (VSA), in which the adsorption step is conducted at atmospheric, superatmospheric or subatmospheric pressures, and the adsorbent regeneration step is carried out by reducing the pressure in the adsorption vessel or vessels that is or are in the regeneration mode to a pressure below the pressure at which the adsorption step is carried out; temperature swing adsorption (TSA), wherein the adsorption step is carried out at a selected temperature, preferably a low temperature, and adsorbent regeneration is carried out by heating the adsorbent in the vessel(s) undergoing adsorbent regeneration to a temperature above the temperature at which the adsorption step is carried out; purge swing adsorption, in which the adsorbent being regenerated is purged with a nonadsorbable or weakly adsorbable gas; and combinations of these.
When the nitric oxide being purified contains very small amounts of gaseous impurities, or when the impurities are very strongly adsorbed by the adsorbent, it may be preferred to use the adsorbent until it becomes saturated with impurities and then dispose of it. On the other hand, when the adsorbent is expensive and/or can be readily regenerated at reduced pressures or elevated temperatures, it is preferable to conduct the nitric oxide purification using PSA, TSA or combinations of these, with or without purging of the adsorbent. PSA is generally preferred when the gas being purified contains significant concentrations of impurities, and TSA is generally preferred when the concentration of impurities in the feed gas is relatively small.
The adsorption step is usually cared out at a temperature above about −200° C., but is preferably carried out at a temperature not lower than about −150° C., and more preferably is carried out at a temperature not lower than about −120° C. At the high end, it is usually carried out at temperatures not above about 200° C., is preferably carried out at a temperature not above about 100° C., and is more preferably carried out at a temperature below about 0° C. In some cases it is preferred that the adsorption step be carried out at or below −30° C.
The pressure at which the adsorption step is carried out can be as low as about 0.5 bara (bar absolute) or less, but it is usually not below about 1 bara, and it is often not below about 1.5 bara At the high end, the adsorption step is usually carried out at pressures not above about 50 bara, and is preferably carried out at pressures not above about 20 bara and is most preferably carried out at pressures not above about 10 bara.
The adsorbent regeneration temperature and pressure of the process of the invention depends upon the type of cyclic process that is practiced. When the adsorption process is PSA the regeneration step is generally carried out at a temperature in the neighborhood of the temperature at which the adsorption step is carried out, and at a pressure below the adsorption pressure. The pressure to which the adsorption vessels is reduced during the regeneration step of PSA cycles of the invention can be as low as 0.05 bara or lower, but is usually not below about 0.1 bara, and is often not below about 0.2 bara, and on the upper end, it is usually not above about 5 bara, and preferably not above about 2 bara and most preferably not above about 1 bara.
When the adsorption process is TSA, bed regeneration is usually carried out at a pressure in the neighborhood of the pressure at which the adsorption step is carried out, and at a temperature above the adsorption temperature. The temperature during the regeneration step of TSA cycles of the invention is usually not above about 300° C., and is preferably not above about 200° C., and is sometimes preferably not above about 150° C., and on the lower end, it is usually not below about −150° C., and preferably not below about −100° C., and most preferably not below about −50° C.
When a combination PSA/TSA process is employed, the temperature and pressure during the bed regeneration step are higher and lower, respectively, than they are during the adsorption step.
In starting a cyclical process according to the invention, the nitric oxide gas stream from which the impurities are to be removed is passed cocurrently (in the direction from the feed inlet end towards the nonadsorbed gas outlet) through the adsorption vessel(s) which are in the adsorption mode. The adsorption vessels are packed with the desired porous polymer adsorbent. As the gas passes through the bed of adsorbent in the adsorption vessel(s), the impurities are adsorbed, and an impurity-depleted nitric oxide product gas passes out of the adsorption vessel through the nonadsorbed gas outlet. As the adsorption step proceeds, impurity fronts of the various impurities contained in the feed gas form in the adsorbent bed and slowly move toward the nonadsorbed gas outlet end of the bed. When the most advanced impurity front reaches a predetermined point in the vessel(s), the adsorption process in the vessel(s) is terminated and these vessel(s) enter the regeneration mode. During regeneration, the impurity-loaded vessels are depressurized, if the adsorption cycle is pressure swing adsorption; heated, if a temperature swing adsorption cycle is employed; or both depressurized and heated, if a combination pressure swing-temperature swing process is used.
As noted above, the method of regeneration of the adsorption beds depends upon the type of adsorption process employed. In the case of pressure swing adsorption, the regeneration phase generally includes a countercurrent depressurization step during which the beds are vented countercurrently (in the direction opposite to the cocurrent direction) until they attain the desired lower pressure. If desired, the pressure in the adsorption vessel(s) can be reduced to subatmospheric pressure by means of a vacuum inducing device, such as a vacuum pump.
In some PSA cycles, in addition to the countercurrent depressurization step(s), it may be desirable to countercurrently purge the bed with a nonadsorbable gas, such as nitrogen, and/or with the purified nitric oxide product gas stream exiting the adsorbent bed(s). In these cases, the purge step is usually initiated towards the end of the countercurrent depressurization step, or subsequent thereto. During this purge step, the purge gas can be introduced into the adsorbent bed from an intermediate nitric oxide storage facility when the adsorption system comprises a single adsorber; or from another adsorber that is in the adsorption phase, when the adsorption system comprises multiple adsorbers arranged in parallel and operated out of phase.
When the adsorption process is TSA, adsorbent regeneration is carried out by heating the adsorbent to the desired regeneration temperature and maintaining it at the desired temperature until the desired degree of adsorbent regeneration is achieved. This can be accomplished by, for example, passing a heated purge gas through the adsorption vessel(s), preferably in the countercurrent direction. Alternatively, or additionally, the adsorption vessel(s) and/or the adsorbent contained therein can be heated using external or internal heating devices, such as heating jackets or heat-conducting immersion rods.
The adsorption cycle may contain steps other than the fundamental steps of adsorption and regeneration. For example, in PSA cycles, when the system comprises one or more pairs of adsorption vessels arranged in parallel and operated under conditions such that one vessel of a pair completes its adsorption step as the other vessel of the pair completes its adsorbent regeneration mode, it may be advantageous to include a bed pressure equalization step, wherein gas is passed from the bed completing its adsorption step to the bed completing its adsorbent regeneration step. Additionally or alternatively, it may be desirable to partially pressurize the vessel(s) completing adsorbent regeneration by passing purified nitric oxide product gas countercurrently thereinto.
It will be appreciated that it is within the scope of the present invention to utilize conventional equipment to monitor and automatically regulate the flow of gases within the system so that it can be fully automated to run continuously in an efficient manner.
The invention is further illustrated by the following examples in which, unless otherwise indicated, parts, percentages and ratios are on a volume basis.
EXAMPLE
A stainless steel cylinder, 24 inches long and 0.75 inches in diameter was packed with 20 ml of Amberlite-XAD-2 resin, a macroreticular styrene-divinylbenzene copolymer in nonionic bead form and having a mean surface area of 300 m 2 /gram. A one-half inch layer of quartz wool was inserted into the ends of the cylinder to hold the adsorbent in place, and to serve as a filter. The cylinder was then placed in a Dewar flask filled with n-propanol and cooled by liquid nitrogen. A test gas containing 99% NO and about 1000 ppm each of nitrogen dioxide, carbon dioxide and nitrous oxide was pre-cooled and purified by passing it through the packed cylinder. The test gas was introduced into the cylinder at a temperature of −100 degree C., a pressure of 30 psig and a flow rate of 350 cc/minute, and the purified gas was collected at an absolute pressure of 762 to 766 torr in a gas cell having an optical path length of 10 meters and a volume of about 1.6 liters. The gas cell was mounted on a Nicolet Magna 750 Fourier Transform Infrared (FTIR) spectrometer which recorded the infrared spectral measurements at a resolution of 0.5 cm−1. To obtain a high signal/noise ratio, 32 scans were used. After approximately 20 standard liters of test gas was passed through the packed cylinder, the purified nitric oxide gas exiting the system was found to contain less than 1 ppm each of nitrogen dioxide and carbon dioxide and less than 6 ppm nitrous oxide.
The above example shows that porous styrene-divinylbenzene copolymer is effective for significantly reducing the concentration of nitrogen dioxide, carbon dioxide, and nitrous oxide impurities present in a nitric oxide gas stream to very low levels.
Although the invention has been described with particular reference to a specific example, the example is merely representative of the invention, and variations are contemplated. For instance, mixtures of two or more adsorbents can be used in a single bed or two or more adsorbents can be used in tandem in the process of the invention. The scope of the invention is limited only by the breadth of the appended claims. | A gas mixture comprised of nitric oxide and one or more impurities selected from nitrous oxide, nitrogen dioxide, nitrous acid, sulfur dioxide, carbonyl sulfide, water vapor and carbon dioxide is purified by pressure swing adsorption or temperature swing adsorption using a porous, metal-free polymer adsorbent that does not promote the disproportionation of nitric oxide to nitrogen dioxide and nitrogen or nitrous oxide. The adsorption step is preferably carried out at tempereatures in the range of about −120 to about 0° C. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel method for reactive dyeing of leather and, more particularly, to a method for reactive dyeing of leather, which can enhance fastness and levelling property.
[0003] 2. Description of Related Art
[0004] During tanning, dyeing is an important process. In conventional methods for dyeing leather, leather is dyed mainly under acid dyeing condition, such that ionic bonds are formed between dyes and leather. However, ionic bonds between dyes and leather would be broken by alkaline solution, and thereby the dyed leather by acid dyeing methods cannot show excellent washing fastness and perspiration fastness.
[0005] US 2007/0033746 A1 discloses a dyeing method to dye wet blue. In the case of using wet blue to perform a reactive dyeing method, it can be found that leather cannot absorb tannin and fatliquor or leak tannin and fatliquor out, resulting in unleveling dyeing.
[0006] By conventional dyeing methods and the dyeing method disclosed by US 2007/0033746 A1, dyed leather with high washing fastness, perspiration fastness, migration fastness and levelling property cannot be achieved, and thereby the inventors of the present application have devoted themselves to development of a novel method which can enhance washing fastness, perspiration fastness, migration fastness and levelling property of dyed leather.
SUMMARY OF THE INVENTION
[0007] The object of the present invention is to provide a novel method for reactive dyeing of leather to obtain dyed leather with improved perspiration fastness, washing fastness, migration fastness, levelling property and colour strength.
[0008] To achieve the object, the present invention provides a method for reactive dyeing of leather, including: providing a reactive dye solution comprising at least one reactive dye and water, and making the reactive dye in the reactive dye solution to act on crust leather at a temperature from 25° C. to 70° C. to form covalent bonds between the reactive dye and the crust leather.
[0009] Accordingly, the dyeing method according to the present invention provides covalent bonds between the reactive dye and the crust leather so as to enhance perspiration fastness, washing fastness and migration fastness, and improve levelling property and feeling due to tannin and fatliquor being absorbed favorably during dyeing process. In comparison with conventional dyeing methods, the dyeing method according to the present invention can be performed at higher temperature, and the dyeing temperature may even be larger than 60° C. and reach 70° C. However, in conventional methods, the temperature is limited and cannot be larger than 60° C. (even 50° C.).
[0010] In the present invention, the reactive dye acts on crust leather preferably at a temperature from 25° C. to 70° C., and more preferably from 55° C. to 70° C.
[0011] In the present invention, the crust leather is not particularly limited in kind, and may be cow crust leather, pig crust leather or goat crust leather.
[0012] In the present invention, the reactive dye may be any conventional reactive dye, and may be a single dye or a mixture of various dyes. In particular, according to the novel dyeing method of the present invention, unleveling dyeing or inconsistent permeability would not occur, and thus various kinds of dyes can be used in a mixture to obtain various color tones. Herein, the reactive dye according to the present invention preferably contains a group of —SO 2 CH═CH 2 or —SO 2 CH 2 CH 2 W, W being a leaving group which is eliminable by a base, such as —Cl, —OSO 3 H,
[0000]
[0000] and R 1 , R 2 and R 3 each independently being C 1-4 alkyl.
[0013] The suitable reactive dyes according to the present invention include, but are not limited to: yellow dyes, such as
[0000]
[0000] and Everzol Yellow ED, Everzol Yellow NPN, Everzol Yellow LX, Everzol Yellow ED-R, Everzol Yellow GRB, Everzol Yellow PFG, Everzol Yellow 4GL, Everzol Yellow C-GL, Everzol Yellow 3GL, Everzol Yellow ED-2G, Everzol Yellow RNL, Everzol Yellow GSP, Everzol Yellow ED-S, Everzol Yellow GR and Everzol Yellow 3RS sold by Everlight Chemical Industrial Corporation; orange dyes, such as
[0000]
[0000] and Everzol Orange GR, Everzol Orange 2R, Everzol Orange 2GS, Everzol Orange ED-2R, Everzol Scarlet 3GF, Everzol Orange GSP, Everzol Orange ED, Everzol Orange 3R, Everzol Orange ED-G and Everzol Orange ED-R sold by Everlight Chemical Industrial Corporation; red dyes, such as
[0000]
[0000] and Everzol Red BS, Everzol Red ED-7B, Everzol Red LF-B, Everzol Red ED-2B, Everzol Red ED, Everzol Red F2B, Everzol Red 3BS, Everzol Red ED-S, Everzol Red BB, Everzol Red RBN, Everzol Rubine ED, Everzol Red ED-3R, Everzol Red ED-3B, Everzol Red LX, Everzol Red F3B, Everzol Red LF-2B, Everzol Red C-3B and Everzol Rubine ED-R sold by Everlight Chemical Industrial Corporation; blue dyes, such as
[0000]
[0000] and Everzol Navy Blue GG, Everzol Navy Blue BRF, Everzol Blue ED, Everzol Navy ED, Everzol Navy Blue FBN, Everzol Blue ED-G, Everzol Dark Blue LF, Everzol Blue LX, Everzol Blue R S/P, Everzol Turquoise Blue G, Everzol Navy LX, Everzol Navy Blue RGB H/C and Everzol Blue BB sold by Everlight Chemical Industrial Corporation; brown dyes, such as Everzol Brown LNS sold by Everlight Chemical Industrial Corporation; black dyes, such as
[0000]
[0000] and Everzol Black ED-G, Everzol Black GRN, Everzol Black GSP, Everzol Black GR, Everzol Black ED-2R, Everzol Black MW, Everzol Black B, Everzol Black C-RL, Everzol Black ED, Everzol Black ED-R, Everzol Black N, Everzol Black LNS and Everzol Black NR sold by Everlight Chemical Industrial Corporation. The above-mentioned dyes can be used in single or in mixture according to requirement. In particular, various color tones may be obtained by mixing dyes of various colors.
[0014] In the present invention, the reactive dye solution may further include a dispersant. Herein, the dispersant may be any dispersant favorable to level dyeing and desperation, and is preferably a dispersant containing naphthalene sulfonic acid condensate, such as Evertan PL sold by Everlight Chemical Industrial Corporation.
[0015] In the present invention, the reactive dye acts on the crust leather preferably under a pH from 9 to 11. Herein, any suitable alkaline substance or alkaline buffer system, such as sodium carbonate, sodium bicarbonate, sodium hydroxide, ammonia solution, may be used to control pH of the reactive dye solution.
[0016] In the present invention, the time of the reactive dye acting on the crust leather depends on the practical dyeing condition (such as pH and dyeing temperature), and preferably ranges from 100 minutes to 330 minutes.
[0017] In the present invention, the method may further include a step after the reactive dye acting on the crust leather: adding a fixing agent to make the fixing agent to act on the crust leather. Accordingly, the fixation of the reactive dye on the crust leather can be enhanced. Herein, the fixing agent may be any fixing agent capable of fixing dye, and preferably is a fixing agent containing polyamide, such as Evertan WF sold by Everlight Chemical Industrial Corporation.
[0018] In the present invention, the method may further include a step after the reactive dye acting on the crust leather: adding fatliquor to make the fatliquor to act on the crust leather. Herein, the fatliquor may be any fatliquor suitably used in a fatliquoring step, such as animal fats, plant fats, synthetic fats, waterproofing fats, to enhance feeling and full degree of leather. The step (i.e. fatliquoring step) may be performed after the step of adding the fixing agent.
[0019] In the present invention, the method may further include a step after the reactive dye acting on the crust leather: adding tanning agents to make the tanning agents to act on the crust leather. Herein, the tanning agents may be any known suitable tanning agents, and specifically is metal tannate, such as aluminum tannate, to enhance the fixation of dye on leather and full degree. The step for adding tanning agents may be performed after the fatliquoring step. In additional, a step after adding tanning agents may be further included: adding a fixing agent to make the fixing agent to act on the crust leather so as to enhance the fixation of the dye on the crust leather.
[0020] Accordingly, the dyeing method according to the present invention provides covalent bonds between the reactive dye and the crust leather so as to enhance perspiration fastness, washing fastness and migration fastness, and improve levelling property and feeling due to tannin and fatliquor being absorbed favorably during dyeing process. In comparison with conventional dyeing methods, the dyeing method according to the present invention can be performed at higher temperature, and the dyeing temperature may be even larger than 70° C. However, in conventional methods, the temperature is limited and cannot be larger than 60° C. (even 50° C.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] None.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] The following examples are used to illustrate the present invention, and many other possible modifications and variations can be made without departing from the spirit of the present invention according to various concepts and applications. The following examples are exemplified for a more concrete description, and the scope of the present invention should not be limited thereto. Without specific explanations, the unit of the parts and percentages used in the examples is calculated by weight, and the temperature is represented by Celsius degrees (° C.).
Example 1
[0023] Water of 600 parts, a dispersant (Evertan PL) of 2 parts and a reactive dye (Everzol Red ED) of 5 parts are added into a rotary drum, followed by maintaining the temperature at 60° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 8 parts with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 4 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 26° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0±0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1.5 parts with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a colorful red leather with high colour strength is obtained.
Example 2
[0024] Water of 200 parts, a dispersant (Evertan PL) of 2 parts and a reactive dye (Everzol Yellow ED) of 4 parts are added into a rotary drum, followed by maintaining the temperature at 50° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding water of 400 parts with drumming for 10 minutes and then sodium carbonate of 5 parts and sodium hydroxide of 1 part with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 3 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 30° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0+0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1 part with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a colorful yellow leather with high colour strength is obtained.
Example 3
[0025] Water of 600 parts and a reactive dye (Everzol Black ED-G) of 8 parts are added into a rotary drum, followed by maintaining the temperature at 70° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 8 parts with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 3 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 30° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0+0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1 part with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a black leather is obtained.
Example 4
[0026] Water of 600 parts, a dispersant (Evertan PL) of 2 parts and reactive dyes (Everzol Yellow ED of 2.6 parts, Everzol Red ED of 1.1 parts and Everzol Navy ED of 0.3 part) of 4 parts are added into a rotary drum, followed by maintaining the temperature at 60° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 8 parts with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 3 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 30° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0±0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1 part with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a brown leather with good levelling property and uniform permeability is obtained.
Example 5
[0027] Water of 600 parts, a dispersant (Evertan PL) of 2 parts and a reactive dye (Everzol Red ED) of 4 parts are added into a rotary drum, followed by maintaining the temperature at 30° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 8 parts with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 4 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 26° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0±0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1.5 parts with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a colorful red leather with common colour strength is obtained.
Example 6
[0028] Water of 600 parts and reactive dyes (Everzol Yellow ED of 1.8 parts, Everzol Red ED of 1.6 parts and Everzol Navy ED of 0.6 part) of 4 parts are added into a rotary drum, followed by maintaining the temperature at 50° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 8 parts with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 3 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 30° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0+0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1 part with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts with drumming for 10 minutes. Finally, the crust leather is dried and thus a navy brown leather with good levelling property and uniform permeability is obtained.
Example 7
[0029] Water of 600 parts, a dispersant (Evertan PL) of 2 parts and a reactive dye (Everzol Brown LNS) of 4 parts are added into a rotary drum, followed by maintaining the temperature at 60° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 5 parts with drumming for 30 minutes to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 3 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 30° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0±0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1 part with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a brown leather with good levelling property and uniform permeability is obtained.
Example 8
[0030] Water of 600 parts, a dispersant (Evertan PL) of 2 parts and a reactive dye (Everzol Navy ED) of 4 parts are added into a rotary drum, followed by maintaining the temperature at 60° C. and drumming for 10 minutes. Subsequently, a piece of retanned crust leather of 100 g (thickness: 1.2 to 1.4 mm) is positioned into the rotary drum and drummed for 30 minutes, followed by adding sodium carbonate of 4 parts twice with drumming for 15 minutes each to control pH in a range from 9 to 11. Then, a fixing agent (Evertan WF) of 3 parts is added therein and drummed for 30 minutes to fix the dye. Next, the crust leather is rinsed with water of 600 parts three times for 10 minutes each at 30° C., 40° C. and 50° C. Formic acid of 2 parts is added into water of 600 parts, followed by maintaining the temperature at 50° C. and drumming for 15 minutes. Then, fatliquor (silicon-containing waterproofing fatliquor) of 3 parts is added therein, drummed for 30 minutes and fixed with formic acid of 2.5 parts twice for 15 minutes each at pH 3.0+0.5. After washing with water, formic acid of 1 part is added into 40° C. water of 600 parts and drummed for 5 minutes, followed by adding aluminum tanning agents of 2 parts with drumming for 30 minutes, and then adding a fixing agent (Evertan WF) of 1 part with drumming for 30 minutes. Subsequently, the crust leather is rinsed with 26° C. water of 600 parts and drummed for 10 minutes. Finally, the crust leather is dried and thus a blue leather with good levelling property and colour strength is obtained.
Comparative Example 1
[0031] Water of 200 parts, a wetting agent of 0.3 part and a piece of wet blue leather of 100 g (its thickness: 1.2 to 1.4 mm) are added into a rotary drum, followed by maintaining the temperature at 40° C. and drumming for 60 minutes. After washing with water, water of 200 parts and chromium powder of 3 parts are added therein and the temperature is maintained at 25° C. with drumming for 60 minutes, followed by adding neutralizing tannin of 2 parts and formic acid of 2 parts with drumming for 20 minutes. Subsequently, soda (sodium bicarbonate) of 0.5 part is added therein with drumming for 50 minutes, and then the wet blue leather is rinsed with water. Water of 150 parts, acrylic tannin of 3 parts, resin tannin of 3 parts and polymer tannin of 3 parts are added therein with maintaining the temperature at 25° C. and drumming for 50 minutes, followed by washing with water. Water of 50 parts, and a leveling agent of 1 part and ammonia solution of 1 part are added therein with maintaining the temperature at 25° C. and drumming for 10 minutes. Subsequently, a reactive dye (Everzol Red ED) of 3 parts is added therein with drumming for 40 minutes, followed by adding fatliquor of 6 parts with drumming for 50 minutes and then water of 150 parts with maintaining the temperature at 50° C. and drumming for 10 minutes. Finally, formic acid of 1.5 parts is added twice with drumming for 20 minutes each, and then the wet blue leather is rinsed with water and dried.
Comparative Example 2
[0032] A piece of wet blue leather (its thickness after shaved: 1.1 mm) of 100 g is washed at 30° C. for 20 minutes in a rotary drum filled with water of 200 parts, followed by using water of 150 parts, a disperant (Evertan PL) of 2 parts and a reactive dye (Everzol Red ED) of 5 parts to dye the wet blue leather at pH 4.4 and 30° C. for 60 minutes. At 50° C., 15% sodium carbonate aqueous solution of 100 parts is added in batches to fix the dye in the course of 60 minutes of drumming at pH 10.0, followed by washing with water of 200 parts four times for 10 minutes each at 40° C. The pH value is adjusted to 4.7 by adding water of 200 parts and formic acid of 0.7 part. Next, the dyed leather is retanned in a freshly set float composed of water of 100 parts, a polymeric tanning material of 2 parts and a naturally based fatliquor of 2 parts at 35° C. for 30 minutes. The float is then admixed with a liquid synthetic tanning material of 15 parts, a polymeric tanning material of 6 parts and Tara vehetable tanning material of 10 parts and drummed for 20 minutes. The leather is subsequently fatliquored in the same float with a fishoil-based fatliquor of 8 parts and a lecithin-based fatliquor of 2 parts at 35° C. by drumming for 2 hours. Finally, the leather is acidified to pH 3.6 with concentrated formic acid of 2 parts and drummed twice for 10 minutes and once for 30 minutes. The dyed, retanned and fatliquored leather is additionally rinsed with cold water at 15° C. for 10 minutes and then dried.
Test Example
[0033] The dyed leathers prepared by Comparative Examples 1-2 and Examples 1-8 according to the present invention are compared in perspiration fastness, washing fastness, levelling property, feeling and colour strength, and the results are shown in Table 1. Herein, washing fastness is tested according to IUF 423, and perspiration fastness is tested according to the following method.
[0034] First, a saline solution (salt of 2 g being dissolved in distilled water of 100 mL) is prepared and positioned in a beaker of 250 mL, while another distilled water of 100 mL is positioned in another beaker of 250 mL. Subsequently, the dyed leather is cut into a specimen of 50.8×50.8 mm in size, and positioned between fiber fabrics (50.8×50.8 mm) to obtain two sandwich-like samples (i.e. a first sample and a second sample). Next, the first sample is immersed into the prepared saline solution until being wetted thoroughly and then squeezed to remove redundant liquid, followed by placing the first sample on a base plate of a perspiration tester. Then, the first sample is covered with clean plastic plates or glass plates. According to the above-mentioned steps, the second sample is immersed into the prepared distilled water and stacked on the plastic plates or the glass plates over the first sample. Subsequently, all plastic plates or glass plates are homed, and weights of 3.6 kg are placed on the perspiration tester with samples disposed thereon, followed by tightening screws of the perspiration tester to orientate the plate and then removing the weights. The perspiration tester is placed into a resealable plastic bag (33×38 cm), and disposed into an oven preheat to 38° C., therewith the bag being unsealed. Then, distilled water of 50 mL is placed into a beaker of 100 mL and disposed in the above-mentioned plastic bag, followed by sealing the bag and placing the sealed plastic bag into the oven for 24 hours or more. Then, the beaker is removed and the perspiration tester is taken out of the oven. The samples are taken from the plate of the perspiration tester and placed on a nonabsorbent material until the samples are thoroughly dry. During drying, the specimen cannot separate from the fiber fabrics. After drying, the distilled water and saline solution are observed for color bleeding to compare perspiration fastness of dyed leathers.
[0000]
TABLE 1
Kind of
perspiration
washing
levelling
colour
Entry
Color
leather
fastness
fastness
property
feeling
strength
Example 1
Red
cow grain
excellent
excellent
excellent
excellent
good
crust
leather
Example 2
Yellow
cow split
excellent
excellent
excellent
excellent
good
crust
leather
Example 3
Black
cow split
excellent
excellent
excellent
excellent
good
crust
leather
Example 4
Brown
cow split
excellent
excellent
excellent
excellent
good
crust
leather
Example 5
Red
cow split
excellent
excellent
excellent
excellent
common
crust
leather
Example 6
Brown
cow split
excellent
excellent
excellent
excellent
good
crust
leather
Example 7
Brown
cow split
excellent
excellent
excellent
excellent
good
crust
leather
Example 8
Blue
cow split
excellent
excellent
excellent
excellent
good
crust
leather
Comparative
Red
cow grain
bad
bad
good
excellent
common
Example 1
wet blue
leather
Comparative
Red
cow grain
good
good
bad
bad
excellent
Example 2
wet blue
leather
[0035] From the above-mentioned test examples, it can be found that the leathers prepared by Examples 1 to 8 of the present invention exhibit good permeability and levelling property, and excellent washing fastness and perspiration fastness. In comparison with the dyed leather according to Comparative Example 1, dyed leathers prepared by the dyeing method according to the present invent exhibit improved color tone, better stability of color strength, excellent washing fastness, perspiration fastness and levelling property. In addition, Comparative Example 2 uses wet blue leather to perform reactive dyeing, and the resultant dyed leather exhibits bad levelling property and feeling due to that leather cannot absorb tannin and fatliquor or leaks tannin and fatliquor out of it. On the contrary, Examples 1 to 8 according to the present invention use crust leather to perform a dyeing process, and thus the absorption of tennin can be improved and the leakage of fatliquor from the leather can be inhibited, resulting in dyed leathers with improved levelling property and feeling. Also, the dyed leathers prepared by Examples 1 to 8 of the present invention have better perspiration fastness and washing fastness than that prepared by Comparative Example 2.
[0036] Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed. | The present invention relates to a method for reactive dyeing of leather, which includes: providing a reactive dye solution including at least one reactive dye and water, and making the reactive dye in the reactive dye solution to act on crust leather at a temperature from 25° C. to 70° C. to form covalent bonds between the reactive dye and the crust leather. Accordingly, the method for reactive dyeing of leather according to the present invention can enhance fastness and levelling property. | 3 |
This is a divisional application of U.S. patent application Ser. No. 08/609,721, filed Mar. 1, 1996, now U.S. Pat. No. 5,786,495.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to fluorenyl compounds, to the corresponding bridged bis-fluorenyl metallocenes and to their use as catalyst components in processes for the polymerization of olefins.
2. Description of Related Art
Many metallocene compounds are known to be active as catalyst components in the olefin polymerization reactions. A particular class of these metallocenes is that of stereorigid metallocene compounds having two cyclopentadienyl ligands joined by means of a bridging group which gives stereo-rigidity to the molecule. These compounds, which are generally referred to as bridged metallocenes, can be prepared from the corresponding bridged ligands.
While compounds having two bridged ligands of the indenyl type are widely known, there are only a few disclosures of compounds having two bridged fluorenyl groups.
In Japanese Patent Application Publication No. 1 249 782, it is described the preparation of the potassium salt of the bis(fluorenyl)dimethylsilane to be used for preparing organo-lantanide hydrides. These compounds are useable as catalysts for the hydrogenation of olefins of every type and for the polymerization of ethylene.
A process for the preparation of bridged fluorenyl-containing compounds is disclosed in EP-A-512,554. With this process 1,2-bis(9-fluorenyl)ethane, 1,3-bis(9-fluorenyl)propane, bis(9-fluorenyl)methane, 1,2-bis(9-fluorenyl)-2-methyl-ethane and bis(9-fluorenyl)-dimethyl-silane were prepared.
Bridged bis-fluorenyl compounds are disclosed in EP-A-524,624. A number of ethylidene, propylidene, methylethylidene and, dimethyl-silyl-bridged bis-fluorenyl compounds were prepared.
EP-A-604,908 discloses a class of bis-fluorenyl compounds bridged with a one-atom-bridge. Only dimethyl-silyl-bridged bis-fluorenyl compounds are exemplified. These metallocenes are useful as catalyst components for the polymerization of olefins and, especially, for the preparation of high molecular weight atactic polypropylene.
Diphenyl-silyl and dimethyl-tin bridged bis-fluorenyl metallocenes are disclosed in EP-A-628,565. These compounds are used in the preparation of isotactic polypropylene.
SUMMARY OF THE INVENTION
New metallocenes having two bridged fluorenyl rings which can be advantageously used as catalytic components for the polymerization of olefins and, expecially, for the preparation of high molecular weight atactic polypropylene with improved yields, have been surprisingly found.
Therefore, in accordance with an aspect of the present invention, there are provided metallocene compounds having two fluorenyl ligands bridged with a single silicon or germanium atom, said atom having two substituent groups containing a total of at least four carbon atoms.
According to another aspect of the present invention there is provided a method for the preparation of the above described metallocene compounds.
Still further in accordance with the present invention, there are provided bis-fluorenyl ligands bridged with a single silicon or germanium atom, said atom having two substituent groups containing a total of at least four carbon atoms.
Furthermore, according to another aspect of the present invention, there are provided catalysts for the polymerization of olefins comprising the bis-fluorenyl metallocenes of the invention.
According to a still further aspect of the present invention there is provided a process for the polymerization of olefins comprising the polymerization reaction of at least an olefinic monomer in the presence of such catalysts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a computer generated diagram of a metallocene according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The metallocene compounds according to the present invention are those of the formula (I): ##STR1## wherein each R 1 , same or different, is an hydrogen atom, a C 1 -C 20 alkyl radical, a C 3 -C 20 cycloalkyl radical, a C 2 -C 20 alkenyl radical, a C 6 -C 20 aryl radical, a C 7 -C 20 alkylaryl radical, or a C 7 -C 20 arylalkyl radical, and optionally two adjacent R 1 substituents can form a cycle comprising from 5 to 8 carbon atoms and, furthermore, the R 1 substituents can contain Si or Ge atoms; the R 2 E-bridging group is selected from a >SiR 3 2 or >GeR 3 2 group, wherein each R 3 , same or different, is a C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 2 -C 20 alkenyl, C 6 -C 20 aryl, C 7 -C 20 alkylaryl or C 7 -C 20 arylalkyl radical, optionally containing heteroatoms, or the two R 3 substituents can be joined to form a cycle comprising up to 8 atoms, at least four total carbon atoms being contained in the two R 3 substituents;
M is an atom of a transition metal belonging to the group 3, 4 or 5 or to the Lanthanides or Actinides group of the Periodic Table of the Elements (new IUPAC version);
each X, same or different, is an halogen atom, an --OH, --SH, R 4 , --OR 4 , --SR 4 , --NR 4 2 or PR 4 2 group, wherein R 4 is defined as R 1 . Preferred substituents R 1 are hydrogen atoms, C 1 -C 10 , more preferably C 1 -C 3 , alkyl radicals; C 3 -C 10 , more preferably C 3 -C 6 , cycloalkyl radicals; C 2 -C 10 , more preferably C 2 -C 3 , alkenyl radicals, C 6 -C 10 aryl radicals, C 7 - 10 alkylaryl radicals or C 7 -C 10 arylalkyl radicals. Alkyl radicals can be linear or branched, in addition to cyclic.
In the E bridging group the R 3 substituents are preferably C 2 -C 10 , more preferably C 4 -C 8 , alkyl groups. Particularly preferred E bridging group are the >SiR 3 2 groups, such as the bis(n-butyl)silanediyl group.
The transition metal M is preferably selected from titanium, zirconium and hafnium, more preferably it is zirconium.
Substituents X are preferably halogen atoms or R 4 groups. More preferably, they are chlorine atoms or methyl radicals.
Non limitative examples of metallocenes of formula (I) according to the invention are:
diethylsilanediylbis(fluorenyl)titanium dichloride,
diethylsilanediylbis(fluorenyl)zirconium dichloride,
diethylsilanediylbis(fluorenyl)hafnium dichloride,
diethylsilanediylbis(fluorenyl)titanium dimethyl,
diethylsilanediylbis(fluorenyl)zirconium dimethyl,
diethylsilanediylbis(fluorenyl)hafnium dimethyl,
di(n-propyl)silanediylbis(fluorenyl)titanium dichloride,
di(n-propyl)silanediylbis(fluorenyl)zirconium dichloride,
di(n-propyl)silanediylbis(fluorenyl)hafnium dichloride,
di(n-propyl)silanediylbis(fluorenyl)titanium dimethyl,
di(n-propyl)silanediylbis(fluorenyl)zirconium dimethyl,
di(n-propyl)silanediylbis(fluorenyl)hafnium dimethyl,
di(n-butyl)silanediylbis(fluorenyl)titanium dichloride,
di(n-butyl)silanediylbis(fluorenyl)zirconium dichloride,
di(n-butyl)silanediylbis(fluorenyl)hafnium dichloride,
di(n-butyl)silanediylbis(fluorenyl)titanium dimethyl,
di(n-butyl)silanediylbis(fluorenyl)zirconium dimethyl,
di(n-butyl)silanediylbis(fluorenyl)hafnium dimethyl,
methyl(n-butyl)silanediylbis(fluorenyl)titanium dichloride,
methyl(n-butyl)silanediylbis(fluorenyl)zirconium dichloride,
methyl(n-butyl)silanediylbis(fluorenyl)hafnium dichloride,
methyl(n-butyl)silanediylbis(fluorenyl)titanium dimethyl,
methyl(n-butyl)silanediylbis(fluorenyl)zirconium dimethyl,
methyl(n-butyl)silanediylbis(fluorenyl)hafnium dimethyl,
methyl(n-hexyl)silanediylbis(fluorenyl)titanium dichloride,
methyl(n-hexyl)silanediylbis(fluorenyl)zirconium dichloride,
methyl(n-hexyl)silanediylbis(fluorenyl)hafnium dichloride,
methyl(n-octyl)silanediylbis(fluorenyl)titanium dichloride,
methyl(n-octyl)silanediylbis(fluorenyl)zirconium dichloride,
methyl(n-octyl)silanediylbis(fluorenyl)hafnium dichloride,
diethylgermandiylbis(fluorenyl)titanium dichloride,
diethylgermandiylbis(fluorenyl)zirconium dichloride,
diethylgermandiylbis(fluorenyl)hafnium dichloride,
diethylgermandiylbis(fluorenyl)titanium dimethyl,
diethylgermandiylbis(fluorenyl)zirconium dimethyl,
diethylgermandiylbis (fluorenyl) hafnium dimethyl,
diethylsilanediylbis(1-methylfluorenyl)titanium dichloride,
diethylsilanediylbis(1-methylfluorenyl)zirconium dichloride,
diethylsilanediylbis(1l-methylfluorenyl)hafnium dichloride,
diethylsilanediylbis(1-methylfluorenyl)titanium dimethyl,
diethylsilanediylbis(1-methylfluorenyl)zirconium dimethyl,
diethylsilanediylbis(1-methylfluorenyl)hafnium dimethyl,
The metallocene compounds of formula (I) can be prepared from the corresponding fluorenyl ligands with a process which comprises the following steps:
(a) the reaction of a compound of formula (II): ##STR2## wherein substituents R 1 , the same or different from each other, are defined as above, with a compound able to form the anion of formula (III): ##STR3## and thereafter with a compound of formula EX 2 , wherein R 2 is defined as above, and the substituents X, same or different from each other, are halogen atoms, thus obtaining a compound of formula (IV): ##STR4## (b) the subsequent reaction of the compound of formula (IV) obtained at point (a) with a compound able to form the dianion of formula (V): ##STR5## and thereafter with a compound of formula MX' 4 , wherein M is defined as above and the substituents X' are halogen atoms, thus obtaining the compound of formula (VI): ##STR6## and finally, (c) in the case at least one X in the metallocene of formula (I) to be prepared is different from halogen, the substitution of at least one substituent X' in the compound of formula (VI) with at least one X different from halogen. Non limitative examples of compounds able to form anionic compounds of formula (III) and (V) are methyllithium, n-butyllithium, potassium hydride, metallic sodium or potassium.
Non limitative examples of compounds of formula EX 2 are diethyldichlorosilane, di(n-propyl)dichlorosilane, di(n-butyl)dichlorosilane, methyl(n-butyl)dichlorosilane, methyl(n-hexyl)dichlorosilane, methyl(n-octyl)dichlorosilane,f methyl(2-bicycloheptyl)dichlorosilane, methyl(3,3,3-trifluoropropyl)dichlorosilane, diethyldichlorogermanium. Di(n-butyl)dichlorosilane is particularly interesting.
Non limitative examples of compounds of formula MX' 4 are titanium tetrachloride, zirconium tetrachloride, hafnium tetrachloride. Particularly interesting is zirconium tetrachloride.
The substitution reaction of substituents X' in the compound of formula (VI) with substituents X different from halogen is carried out by generally used methods. For example, when substituents X are alkyl groups, the compound of formula (VI) can be reacted with alkylmagnesium halides (Grignard reagents) or with lithioalkyl compounds.
According to an embodiment of the process according to the invention, the synthesis of the ligand of formula (IV) is suitably performed by adding a solution of an organic lithium compound in an aprotic solvent to a solution of the compound (II) in an aprotic solvent. Thus, a solution containing the compound (II) in the anionic form is obtained and this is added to a solution of the compound of formula EX 2 in an aprotic solvent.
From the solution obtained by working as above described, the ligand of formula (IV) is separated by common organic chemistry. The thus separed ligand is dissolved or suspended in an aprotic polar solvent, and to this solution a solution of an organic lithium compound in an aprotic solvent is added. The ligand (V) is thus obtained and is separated, dissolved or suspended in an aprotic polar solvent and thereafter added to a suspension of the compound MX' 4 in an apolar solvent. At the end of the reaction the solid product obtained is separated from the reaction mixture by generally used techniques.
During the whole process, the temperature is kept between -180 and 80° C. and, preferably, between 0 and 40° C.
As apolar solvents hydrocarbon solvents such as pentane, hexane, benzene and the like can be suitably used.
Non limitative examples of aprotic polar solvents are tetrahydrofurane, dimethoxyethane, diethylether, toluene, dichloromethane and the like.
The metallocene ligands according to the present invention are those of the formula (IV): ##STR7## wherein substituents R 1 and the E bridging group are defined as above, which are intermediate ligands that can be used for preparing metallocenes of formula (I).
Non limitative examples of compounds of formula (IV) according to the invention are diethylbis (fluorenyl) silane, di(n-propyl)bis(fluorenyl)silane, di(n-butyl)bis(fluorenyl)silane, methyl(n-hexyl)bis(fluorenyl)silane, methyl(n-octyl)bis(fluorenyl)silane, methyl(2-bicycloheptyl)bis-(fluorenyl)silane, methyl(3,3,3-trifluoropropyl)bis-(fluorenyl)silane, diethylbis(fluorenyl) germanium, diethylbis(1-methylfluorenyl)silane.
The present invention further relates to a catalyst for the polymerization of olefins, comprising the product of the reaction between:
(A) a metallocene compound of formula (I), optionally as reaction product with an aluminium organo-metallic compound of formula AlR 5 3 or Al 2 R 5 6 , wherein substituents R 5 , the same or different from each other, are defined as R 1 or are halogen atoms, and
(B) an alumoxane, optionally mixed with an aluminium organo-metallic compound of formula AlR 5 3 or Al 2 R 5 6 , wherein substituents R 5 , the same or different from each other, are defined as above, or one or more compounds able to give a metallocene alkyl cation.
The molar ratio between aluminium and the metal of the metallocene is comprised between about 10:1 and about 5000:1, and preferably between 100:1 and 4000:1.
The alumoxane used as component (B) can be obtained by reaction between water and an organometallic compound of aluminium of formula AlR 5 3 or Al 2 R 5 6 , wherein substituents R 5 , the same or different from each other, are defined as above, with the provision that at least one R 5 is different from halogen. In that case, these are reacted in molar ratios Al/water comprised between about 1:1 and 100:1.
Non limitative examples of aluminium compounds of formula AlR 5 3 or Al 2 R 5 6 are:
Al(Me) 3 , Al(Et) 3 , AlH(Et) 2 , Al(iBu) 3 ,
AlH(iBu) 2 , Al(iHex) 3 , Al(iOct) 3 , AlH(iOct) 2 ,
Al(C 6 H 5 ) 3 , Al(CH 2 C 6 H 5 ) 3 , Al(CH 2 CMe 3 ) 3 , Al(CH 2 SiMe 3 ) 3 ,
Al(Me) 2 iBu, Al(Me) 2 Et, AlMe(Et) 2 , AlMe(iBu) 2 ,
Al(Me) 2 iBu, Al(Me) 2 Cl, Al(Et) 2 Cl, AlEtCl 2 ,
Al 2 (Et) 3 Cl 3 ,
wherein Me=methyl, Et=ethyl, iBu=isobutyl, iHex=isohexyl, ioct=2,4,4-trimethyl-pentyl.
Among the above mentioned aluminium compounds, trimethylaluminium and triisobutylaluminium are preferred.
The alumoxane used in the catalyst according to the invention is believed to be a linear, branched or cyclic compound, containing at least one group of the type: ##STR8## wherein substituents R 6 , the same or different from each other, are R 5 or a group --O--Al(R 6 ) 2 .
Examples of alumoxanes suitable for use according to the present invention are methylalumoxane (MAO), isobutylalumoxane (TIBAO) and 2,4,4-trimethyl-pentylalumoxane (TIOAO), the methylalumoxane being preferred. Mixtures of differents alumoxanes are suitable as well.
Non limitative examples of compounds able to form a metallocene alkyl cation are compounds of formula Y + Z - , wherein Y + is a Bronsted acid, able to give a proton and to react irreversibly with a substituent X of the metallocene of formula (I), and Z - is a compatible anion, which does not coordinate, which is able to stabilize the active catalytic species which originates from the reaction of the two compounds and which is sufficiently labile to be able to be removed from an olefinic substrate. Preferably, the anion Z - comprises one or more boron atoms. More preferably, the anion Z - is an anion of the formula BAr( - ) 4 , wherein substituents Ar, the same or different from each other, are aryl radicals such as phenyl, pentafluorophenyl, bis(trifluoromethyl)phenyl. Particularly preferred is the tetrakis-pentafluorophenyl borate. Furthermore, compounds of formula BAr 3 can be suitably used.
Particularly suitable catalysts according to the invention are those comprising the product of the reaction between di(n-butyl)silandiylbis(fluorenyl)zirconium dichloride and a methylalumoxane.
The catalysts used in the process of the present invention can be also used on inert supports. This is obtained by depositing the metallocene (A), or the product of the reaction of the same with the component (B), or the component (B) and thereafter the metallocene (A), on inert supports such as for example silica, alumina, styrene-divinylbenzene copolymers, polyethylene or polypropylene.
The solid compound thus obtained, combined with a further addition of alkylaluminium compound either as such or prereacted with water, if necessary, is usefully used in the gas phase polymerization.
Catalysts of the present invention are useable in the polymerization reaction of olefins.
Still further the present invention relates to a process for the polymerization of olefins comprising the polymerization reaction of at least an olefinic monomer in the presence of a catalyst as above described.
In particular, catalysts according to the invention can be suitably used in the homopolymerization reaction of alpha-olefins such as ethylene, propylene or 1-butene. Another use of interest of the catalysts of the invention is in the copolymerization reactions of ethylene with alpha-olefins such as propylene and 1-butene.
A particularly interesting use of the catalysts of the invention is the polymerization of propylene. The propylene polymers obtainable with the present catalysts are endowed with an atactic structure and, therefore, they are substantially amorphous. Their melting enthalpy (ΔH f ) is generally not measurable.
The molecular weights of the aforementioned propylene polymers are generally of industrial interest. Their intrinsic viscosities is generally higher than 1.0 dl/g, preferably higher than 1.5, more preferably higher than 2.0 dl/g.
The molecular weights of the propylene polymers, in addition to being high, are distributed over relatively limited ranges. An index of molecular weight distribution is represented by the ratio M w /M n which is preferably less than 4, more preferably less than 3.
13 C-N.M.R. analysis gives information on the tacticity of the polymeric chain, that is the distribution of the relative configuration of the tertiary carbons.
The structure of the aforementioned propylene polymers is substantially atactic. It is observed that the syndiotactic diads (r) are more numerous than the isotactic diads (m). Generally, the value of the relation %r-%m is higher than 0, particularly higher than 5, more particularly higher than 10.
The Bernoullianity index (B), defined as:
B=4[mm][rr]/[mr].sup.2
has values near to the unit, generally comprised in the range 0.7-1.3, preferably comprised in the range 0.8-1.2.
The possibility of obtaining directly, as the only product of the polymerization reaction of propylene, a substantially amorphous polypropylene endowed with high molecular weight represents an advantage over the traditional processes.
The process of the polymerisation of olefins according to the invention may be carried out in liquid phase, optionally in the presence of an inert hydrocarbon solvent, or in gas phase. The hydrocarbon solvent may be aromatic such as toluene, or aliphatic, such as propane, hexane, heptane, isobutane, cyclohexane.
The polymerization temperature in processes for the ethylene or propylene homopolymerization is generally comprised between -50° C. and 250° C., in particular between 20° C. and 90° C.
The molecular weight of the polymers can be varied merely by varying the polymerization temperature, the type or the concentration of the catalytic components or by using molecular weight regulators.
The molecular weight distribution can be varied by using mixtures of different metallocenes, or carrying out the polymerization in more steps differing as to polymerization temperatures and/or concentrations of the molecular weight regulator.
Polymerization yields depend on the purity of the metallocene component of the catalyst. Therefore, in order to increase the yields of polymerization, metallocenes are generally used after a purification treatment. A major advantage of the metallocenes of the invention over those of the prior art is represented by their higher solubilities, allowing to obtain them in highly purified form and, consequently, to increase the polymerization yields to a significative extent.
The components of the catalyst can be contacted among them before the polymerization. The contact time is generally comprised between 1 minute and 24 hours. The precontacted components can be suitably brought to dryness and used in polymerization as a powder, optionally in admixture with suitable dispersing agents such as waxes or oils.
FIG. 1 reports a computer generated diagram of the metallocene prepared in Example 2 based on X-ray crystallography data.
The following examples are given to illustrate and not to limit the invention.
CHARACTERIZATIONS
The intrinsic viscosity [η] was measured in tetrahydro-naphtalene at 135° C.
The Differential Scanning Calorimetry (DSC) measurements were carried out on an apparatus DSC-7 of Perkin-Elmer Co. Ltd. according to the following procedure. About 10 mg of sample were heated at 200° C. with a scanning speed equal to 20° C./minute; the sample was kept at 200° C. for 5 minutes and thereafter was cooled with a scanning speed equal to 20° C./minute. Thereafter a second scanning equal to 20° C./min was carried out according to the same modalities of the first one. The values reported are those obtained in the second scanning.
The 1 H-N.M.R. analysis of the polymer have been carried out on a Bruker AC200 instrument at 200.133 MHz, using CDCl 3 as solvent at room temperature.
PREPARATIONS OF THE METALLOCENES
EXAMPLE 1
Synthesis of di(n-butyl)bis(9-fluorenyl)silane
Fluorene (23.27 g, 140 mmol) was dissolved in 100 mL diethyl ether and the solution was cooled to -78° C. Methyllithium (1.4M in diethyl ether, 140 mL) was added dropwise to the stirred solution while maintaining the temperature at -78° C. After the addition was complete, the solution was allowed to warm to room temperature. Stirring was continued overnight. In a separate flask, di-n-butyldichlorosilane (14.9 g, 70 mmol) was dissolved in 50 mL diethyl ether. The temperature was reduced to -78° C., and the solution (prepared above) containing the fluorene anion was added to this stirred solution, dropwise. After the addition was complete, the reaction was allowed to warm slowly to room temperature and stirred overnight. The reaction was then treated with a saturated solution of ammonium chloride, the organic layer was collected and dried over magnesium sulfate, and dried in vacuo. The material was further purified by washing with methanol and drying in vacuo. Yield: 23.39 g (70.7%, 97% purity by GCMS). 1 H-NMR (CD 2 Cl 2 ), d, ppm: 7.81 (d, 4H), 7.30 (m, 12H), 3.95(s, 2H), 1.05(m, 4H), 0.85(m, 10H), 0.5(m, 4H).
EXAMPLE 2
Synthesis of di(n-butyl)silanediylbis(9-fluorenyl)zirconium dichloride--Bu 2 SiFlu 2 ZrCl 2
Di(n-butyl)bis(9-fluorenyl)silane (4.72 g, 10 mmol) was dissolved in 100 mL of Et 2 O and the temperature was lowered to -78° C. Methyllithium (20 mmol, 1.4M in Et 2 O, 14.2 mL) was added dropwise to the stirred solution. After the addition was complete, the reaction was allowed to warm to room temperature and stirring was continued overnight.
In a separate flask ZrCl 4 (2.33 g, 10 mmol) was slurried in 70 mL of pentane and the temperature was then lowered to -78° C. The dianion prepared above was added in a dropwise fashion. After the addition was complete, the reaction was allowed to warm to room temperature and stirring was continued overnight. The solids were then collected by filtration, washed with fresh Et 2 O. The product was than repeatedly washed with CH 2 Cl 2 and collected by filtration. CH 2 C 2 was removed in vacuo, leaving a bright red free-flowing powder. Yield 5.54 g (74%) of di(n-butyl)silanediylbis(9-fluorenyl)zirconium dichloride.
1 H NMR (300 MHz, CD 2 Cl 2 , δ, ppm): 7.85 (d, 8H), 7.35 (t, 4H), 7.10 (t, 4H), 2.3 (m, 4H), 2.10 (m, 4H), 1.9 (m, 4H), 1.05 (m, 6H).
EXAMPLE 3
Synthesis of di(n-butyl)silanediylbis(9-fluorenyl)hafnium dichloride--Bu 2 SiFlu 2 hfCl 2
Di-n-butlybis(9-fluorenyl)silane (4.72g, 10 mmol) was dissolved in 100 mL diethyl ether and the temperature was lowered to -78° C. Methyllithium (20 mmol, 1.4 M in Et 2 O, 14.28 mL) was added dropwise to the stirred solution. After the addition was complete, the reaction was allowed to warm to room temperature and stirring was continued overnight. The next morning, the ether was removed in vacuo, and the solids were washed with fresh pentane. Hafnium tetrachloride (3.2 g, 10 mmol) was added as a dry powder and the solids were re-suspended in fresh pentane. The reaction mixture was stirred overnight, after which time the pentane was removed in vacuo, treated with methylene chloride, filtered, and the methylene chloride removed in vacuo producing the product as a bright orange powder. Yield: 1.25 g (17.4%) 1 H-NMR (CD 2 C 2 ), d, ppm: 7.81 (d, 4H), 7.85 (d, 4H), 7.3-7.4 (t, 4H), 7.0-7.1 (t, 4H), 2.2-2.3 (m, 4H), 1.9-2.1 (m, 4H), 1.7-1.9 (m, 4H), 1.1-1.15 (m, 6H).
EXAMPLE 4
Synthesis of di(n-butyl)silanediylbis(9-fluorenyl)zirconium dimethyl--Bu 2 SiFlu 2 ZrMe 2
To a stirred solution containing 1.58 g (2.5 mmol) of the di-n-butyl bis fluorene zirconium dichloride in 75 mLs diethyl ether at -78° C., was added 5 mmol MeLi (3.57 mL of a 1.4M solution in diethyl ether). The solution was stirred overnight, allowing the temperature to warm to ambient slowly overnight. The next morning, the solvents were removed in vacuo, the dark brown solids were taken up in methylene chloride and filtered. The methylene chloride was then removed in vacuo, leaving 0.96 g of a dark brownish red free flowing solid. Yield: 64%; 1 H-NMR indicates ˜90% purity. 1 H-NMR: d; ppm 7.9 (d, 4H), 7.65 (d, 4H), 7.3(t, 4H), 7.05 (t, 4H), 2.0 (m, 8H), 1.7 (m, 4H), 1.05 (t, 6H), -2.5(s, 6H). Note that the ratio of monomethyl to the dimethyl complexes is calculated from the integral heights of the singlet at -2.1 (dimethyl integration is 20 mm, monomethyl is 2 mm).
EXAMPLE 5
Synthesis of n-hexylmethylbis(9-fluorenyl)silane
Fluorene (50.73 g, 0.305 mol) was dissolved in 250 mL of dry THF in a one liter Schlenk flask equipped with an addition funnel and attached to a nitrogen line. The temperature of the fluorene solution was lowered to -78° C. under a positive nitrogen pressure and methyllithium (0.305 mol, 218 mL) was added dropwise via the addition funnel. Once addition was complete the temperature of the stirring solution was allowed to rise to room temperature. The solution was then stirred overnight. Excess solvent was removed under vacuum. The residual fluorene anion was washed with 300 mL of dry hexane in a nitrogen drybox.
n-Hexylmethyldichlorosilane (30.4 g, 0.152 mol) and 300 mL of dry THF were charged to a one liter Schlenk equipped with an addition funnel. Fluorene anion (52.4 g, 0.305 mol) was dissolved in approximately 200 mL of dry THF and charged to the addition funnel. The temperature of the stirring solution was lowered to -78° C. under positive nitrogen pressure. The fluorene anion was added dropwise over two hours. After the anion addition was complete, the reaction mixture was allowed to warm to room temperature. The solution was allowed to stir overnight. The solution was washed with three 200 mL aliquots of water, retaining the organic layer after each washing. The organic layer was dried with magnesium sulfate and filtered. The product was recrystallized from hexane. The yield of this reaction is 19.6%.
EXAMPLE 6
Synthesis of n-hexylmethylsilanediylbis(9-fluorenyl)zirconium dichloride--MeHexSiFlu 2 ZrCl 2
n-Hexylmethylbisfluorenylsilane (5 mmol, 2.3 g) was dissolved in 50 mL diethyl ether and the temperature was lowered to -78° C. Dropwise methyllithium (10 mmol, 1.4M solution in diethyl ether, 7.2 mL)was added. After addition was complete, the flask and contents were allowed to warm to room temperature slowly overnight, after which time the dianion prepared in this fashion was added to a stirred flask containing ZrCl 4 (5 mmol, 1.16 gms) in a pentane slurry at -78° C. The flask and contents were allowed to slowly warm to room temperature overnight, after which time the solvents were evaporated in vacuo. The compound was filtered from a methylene chloride solution, and dried in vacuo. Yield 2.14 gms (69%) of a dark red free flowing powder.
EXAMPLE 7
Synthesis of n-octylmethylbis(9-fluorenyl)silane
Fluorene (47.80 g, 0.288 mol) was dissolved in 300 mL of dry THF in a one liter Schlenk flask equipped with an addition funnel and attached to a nitrogen line. The temperature of the fluorene solution was lowered to -78° C. under a positive nitrogen pressure and methyllithium (0.288 mol, 205 mL) was added dropwise via the addition funnel. Once addition was complete the temperature of the stirring solution was allowed to rise to room temperature. The solution was then stirred overnight. Excess solvent was removed under vacuum. The residual fluorene anion was washed with 300 mL of dry hexane in a nitrogen drybox.
n-Octylmethyldichlorosilane (32.68 g, 0.144 mol) and 200 mL of dry THF were charged to a one liter Schlenk flask equipped with an addition funnel. Fluorene anion (49.50 g, 0.288 mol) was dissolved in approximately 200 mL of dry THF and charged to the addition funnel. The temperature of the stirring solution was lowered to -20° C. under positive nitrogen pressure. The fluorene anion was added dropwise over two hours. After the addition of anion was complete the reaction mixture was allowed to warm to room temperature. The solution was then stirred overnight. The solution was washed with three 200 mL aliquots of water, retaining the organic layer after each washing. The organic layer was dried with magnesium sulfate and filtered. The product was recrystallized from a diethyl ether/methanol solution. The yield of this reaction is 10%.
EXAMPLE 8
Synthesis of n-octylmethylsilylbis(9-fluorenyl)zirconium dichloride--MeOctSiFlu 2 ZrCl 2
4.86 g n-octylmethylbis(9-fluorenyl)silane (10 mmol) was dissolved in 70 mL Et 2 O. The temperature was lowered to -78° C. and 20 mmol methyllithium was added dropwise, as a 1.4M solution in diethylether (14.3 mL). Stirring was continued overnight and the flask and contents were allowed to warm slowly to room temperature. The dianion was isolated by removing the solvents in vacuo and washing the viscous dark yellow dianion with fresh pentane. The dianion was then re-slurried in fresh pentane, and a slurry containing 10 mmol (2.33 g) ZrCl 4 in 20 mL pentane was added dropwise at room temperature. After addition was complete, the flask and contents were stirred overnight. Solvents were then removed by filtration, and the solids were slurried with methylene chloride and filtered. The dark red solution containing the catalyst complex was evaporated to dryness, and washed with fresh pentane, then dried. 5.13 gms of a dark red free flowing powder were isolated in this fashion.
EXAMPLE 9
Synthesis of (2-bicycloheptyl)methylbis(9-fluorenyl)silane
Fluorene (49.6 g, 0.2986 mol) was dissolved in 300 mL of dry diethyl ether in a one liter Schlenk flask equipped with an addition funnel and attached to a nitrogen line. The temperature of the fluorene solution was lowered to -78° C. under a positive nitrogen pressure and methyllithium (0.2986 mol, 213 mL) was added dropwise via the addition funnel. Once addition was complete the temperature of the stirring solution was allowed to rise to room temperature. The solution was then stirred overnight. Excess solvent was removed under vacuum. The residual fluorene anion was washed with 300 mL of dry hexane in a nitrogen drybox.
(2-bicycloheptyl)methyldichlorosilane (31.2 g, 0.1493 mol) and 300 mL of dry diethyl ether were charged to a one liter Schlenk flask equipped with an addition funnel. Fluorene anion was charged to the addition funnel. The temperature of the stirring solution was lowered to -78° C. under positive nitrogen pressure. The fluorene anion was added dropwise over two hours. The solution temperature was allowed to warm to room temperature when anion addition was complete. The solution was then stirred for 72 hours. The solution was washed with one 200 mL aliquot of water added dropwise over 30 minutes. The desired product, a yellowish-white powder precipitated out of solution as the water was added.
EXAMPLE 10
Synthesis of (2-bicycloheptyl)methylsilylbis(9-fluorenyl) zirconium dichloride
(2-cycloheptamethylsilyl) bisfluorene (2.34 g, 5 mmol) was slurried in 100 mL diethyl ether and the temperature reduced to -78° C. A 1.4 mmol solution of methyllithium was added dropwise (7.14 mL) and the reaction allowed to slowly warm to room temperature overnight. The dianion slurry was then cannulated into a flask containing 5 mmol ZrCl 4 slurried in 50 mL pentane at -78° C. The reaction was stirred overnight and the contents of the flask were allowed to slowly warm to room temperature overnight. The solvents were then removed under vacuum, and the solids slurried and filtered from methylene chloride. The methylene chloride was removed under vacuum and 1.17 gms of a dark red free flowing powder were recovered (yield=38%). Crystals suitable for structural determination were grown from hot toluene solution that were slowly cooled over a 24 hour period.
EXAMPLE 11
Synthesis of 3,3,3-trifluoropropyl(methyl)bis(9-fluorenyl) silane
Fluorene (50.00 g, 0.3008 mol) was dissolved in 350 mL of dry diethyl ether in a one liter Schlenk flask equipped with an addition funnel and attached to a nitrogen line. The temperature of the stirring fluorene solution was lowered to -78° C. under a positive nitrogen pressure and methyllithium (0.3010 mol. 215 mL) was added dropwise via the addition funnel. Once addition was complete the temperature of the reaction mixture was allowed to rise to room temperature. The solution was then stirred until gas evolution had ceased for three hours. 3,3,3-trifluoropropyl(methyl)dichlorosilane (31.75 g, 0.301 mol) and 300 mL of dry diethyl ether were charged to a one liter Schlenk flask equipped with an addition funnel. Fluorene anion was charged to the addition funnel. The temperature of the stirring solution was lowered to -78° C. under positive nitrogen pressure. The fluorene anion was added dropwise over two hours. After addition of the anion was complete the reaction mixture was allowed to warm to room temperature. The solution was then stirred overnight. The solution was washed with three 200 mL aliquots of water, retaining the organic layer after each washing. The organic layer was dried with magnesium sulfate and filtered. The product was recrystallized from hexane. The yield of this reaction is 50.5%.
EXAMPLE 12
Synthesis of 3,3,3-trifluoropropyl(methyl)silanediylbis (9-fluorenyl)zirconium dichloride
3,3,3-trifluoropropyl(methyl)bisfluorenylsilane (1.11 g, 2.4 mmol) was dissolved in 60 mL diethylether and the temperature was lowered to -78° C. with an acetone/dry ice slush bath. Methyllithium (4.8 mmol, 1.4 M diethylether solution, 3.4 mL) was added dropwise to the stirred solution. After addition was complete, the flask and contents were allowed to warm to room temperature overnight. In a separate flask, zirconium tetrachloride (0.56 g, 70 mL) was slurried in 70 mL pentane. The temperature of this slurry was then reduced to -78° C., and the dianion (prepared above) was added dropwise. After addition was complete, the flask and contents were allowed to warm to room temperature overnight. The next morning, the solvents were srmoved from the reaction flask in vacuo, and the solids were treated with methylene chloride, filtered, and the filtrate collected and dried in vacuo. In this fashion 0.933 g of a free flowing red powder were isolated. Crystalline materials suitable for X-ray diffraction studies were grown by the slow evaporation of a methylene chloride solution amade from the reaction products.
POLYMERIZATIONS
Methylalumoxane (MAO)
A commercial (Witco, MW 1400) 30% toluene solution of MAO was dried in vacuo until a solid, glassy material was obtained which was finely crushed and further treated in vacuo until all volatiles were removed (4-6 hours, 0.1 mmHg, 40-50° C.) to leave a white, free-flowing powder.
Modified-methylalumoxane (M-MAO)
The commercial (Ethyl) isopar C solution (62 g Al/L) was used as received.
EXAMPLES 13-18
In a 1-L jacketed stainless-steel autoclave, equipped with a helical, magnetically driven stirrer, a 35-mL stainless-steel vial and a thermoresistance, connected to a thermostat for temperature control, previously washed with a solution of AliBu in hexane and then dried at 60° C. under a nitrogen stream, were charged 400 mL of propylene. The autoclave was then thermostatted at 48° C.
The catalyst/cocatalyst mixture was prepared by dissolving the proper amount of metallocene with the methylalumoxane solution (in toluene in the case of MAO or as the commercial solution in isopar-C in the case of M-MAO), obtaining an intensely colored solution which was stirred for 10 min at ambient temperature and then injected into the autoclave at the polymerization temperature in the presence of the monomer.
The catalyst/cocatalyst mixture prepared as described above was injected in the autoclave by means of propylene pressure through the stainless-steel vial, the temperature rapidly brought to 50° C. and the polymerization carried out at constant temperature for 1 hour.
The polymerization conditions and relative characterisation data of the polymer obtained are reported in Table 1. From DSC analysis, no peaks were observed attributable to the melt enthalpy.
EXAMPLE 19 (COMPARISON)
It was worked according to the procedure of examples 13-19, but operating with a 2.3-L autoclave in which 1000 mL of propylene were charged, and using dimethylsilane-diylbis(9-fluorenyl) zirconium dichloride prepared as in Example 1 of EP-A-604,908 instead of di(n-butyl)silanediyl-bis(9-fluorenyl)zirconium dichloride.
The polymerization conditions and relative characterisation data of the polymer obtained are reported in Table 1. From DSC analysis, no peaks were observed attributable to the melting enthalpy.
EXAMPLES 20-21 (COMPARISON)
It was worked according to the procedure of examples 13-19, butusingdimethylsilanediylbis(9-fluorenyl) zirconiumdichloride prepared as in Example 1 of EP-A-604,908 instead of di(n-butyl)silanediylbis(9-fluorenyl)zirconium dichloride.
The polymerization conditions and relative characterisation data of the polymer obtained are reported in Table 1. From DSC analysis, no peaks were observed attributable to the melting enthalpy.
TABLE 1__________________________________________________________________________metallocene Al/Zr yield activity I.V.EXAMPLE type (mgrams) Cocatalyst (mol) (grams) (Kg.sub.pol /g.sub.mol h) (dL/g)__________________________________________________________________________13 Bu.sub.2 SiFlu.sub.2 ZrCl.sub.2 1 MAO 2000 51.75 51.75 2,76 14 " 1 M-MAO 2000 54.85 54.85 2.44 15 " 1 M-MAO 2000 60.25 60.25 2.35 16 " 0.5 M-MAO 1000 53.44 106.88 2.61 17 MeHexSiFlu.sub.2 ZrCl.sub.2 0.5 M-MAO 1000 24.94 49.87 2.47 18 MeOctSiFlu.sub.2 ZrCl.sub.2 0.5 M-MAO 1000 31.34 62.68 2.58 19 CONFR. Me.sub.2 SiFlu.sub.2 ZrCl.sub.2 4 MAO 2355 102.86 25.71 2.57 20 CONFR. " 0.87 M-MAO 2340 27.25 31.33 2.30 21 CONFR. " 1 M-MAO 2000 30.72 30.72 --__________________________________________________________________________ | Metallocene compounds having two fluorenyl ligands bridged with a single silicon or germanium atom, said atom having two substituent groups containing a total of at least four carbon atoms, are useful as catalyst components for the polymerization of olefins. Particularly, it is possible to prepare high molecular weight atactic polypropylene with improved yields with respect to the known catalysts. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national stage application, under 35 U.S.C. §371, of PCT/EP2005/009909, filed Sep. 15, 2005, which claims priority of German Application No. 10 2004 045 879.0, filed Sep. 20, 2004.
BACKGROUND OF THE INVENTION
The invention relates to a process for purifying feed streams comprising aromatics in polymerization or alkylation processes by bringing them into contact with zeolites, which comprises passing the feed stream over at least two zeolites 1 and 2, with zeolite 1 having a mean pore size of from 0.3 to 0.5 nm and zeolite 2 having a mean pore size of from 0.6 to 0.8 nm.
Alkylated aromatics are obtained predominantly by catalytic alkylation of aromatics by means of olefins: ethylbenzene, for example, by alkylation of benzene by means of ethylene, cumene, for example, by alkylation of benzene by means of propylene. Catalysts used in the liquid phase are aluminum chloride and catalysts used in the gas phase are Lewis acids or synthetic zeolites. Zeolites are highly active catalysts both for alkylation and for transalkylation. Since the zeolite catalysts are susceptible to water, sulfur and other catalyst poisons, they lose their activity over time and have to be regenerated periodically.
Various processes have been proposed for lengthening the life of zeolite catalysts for alkylation reactions. WO 98/07673 describes the alkylation of benzene by means of, for example, propylene. The benzene is pretreated by passing it over aluminum oxides, silicates, aluminum silicates or acidic zeolites such as mordenites.
WO 00/35836 describes a method which comprises firstly alkylating an aromatic, purifying the alkyl aromatic obtained by means of a molecular sieve and finally reacting the purified alkyl aromatic with another aromatic in a transalkylation reaction to give a monoalkylaromatic. Suitable molecular sieves are suitable zeolites and mixtures thereof, with acidic zeolites such as MCM-22 being preferred. However, it has now been found that the effectiveness of these acidic zeolites is unsatisfactory.
WO 01/07383 discloses the purification of feed streams comprising olefins in polymerization or alkylation processes by passing the olefin, e.g. ethylene, over an adsorption bed of carbon black, activated carbon, aluminum oxides, silicates, aluminum silicates, various zeolites or molecular sieves. It is stated that the benzene or alkyl benzene feed stream is advantageously passed over an appropriate adsorption bed comprising the adsorbents mentioned; further details are not given.
The purifying action of these processes for aromatics is not satisfactory in all cases, or expensive adsorbents are required.
BRIEF SUMMARY OF THE INVENTION
It was an object of the invention to provide an improved process for purifying aromatics, in particular aromatics which are to be used in a polymerization or alkylation process.
This purification process should increase the life of alkylation or transalkylation catalysts in the catalytic alkylation of aromatics by means of olefins, in particular over zeolite catalysts, and to reduce the need for regeneration.
We have accordingly found the process defined at the outset (hereinafter referred to as purification process). In addition, we have found a process (alkylation process) for preparing alkylated aromatics by reacting aromatics and olefins over a catalyst, wherein the feed stream comprising aromatics is pretreated by means of the purification process. Preferred embodiments of the invention are defined in the subordinate claims.
The purification process of the invention can in principle also be used for feed streams comprising aromatics in other processes. However, it is particularly useful for polymerization and alkylation processes, in particular ones in which catalysts which are sensitive to very small amounts of impurities are used.
DETAILED DESCRIPTION OF THE INVENTION
Aromatics suitable for purification include both unalkylated aromatics, e.g. those which can be reacted with an olefin in an alkylation reaction to give alkylated aromatics, and monoalkylated or polyalkylated aromatics which, for example, can be reacted with other aromatics in a transalkylation reaction to give other alkylated aromatics. Possible unalkylated aromatics are, for example, benzene and fused aromatics such as naphthalene or anthracene. Suitable alkylated aromatics are ones having from 1 to 10 carbon atoms in the alkyl radical, for example monoalkylated aromatics such as toluene or ethylbenzene or polyalkylated aromatics such as xylenes. Preference is given to using benzene as aromatic to be purified.
The aromatic is advantageously dewatered to a water content of less than 100 ppm by weight, preferably less than 30 ppm by weight (measured by the Karl Fischer method in accordance with DIN 51777), before being fed to the purification process. This is achieved in a customary manner, for example by means of drying columns when the process is carried out continuously.
According to the invention, the feed stream comprising aromatics is brought into contact with the zeolites by passing the feed stream over at least two zeolites 1 and 2. The terms zeolite 1 and zeolite 2 serve merely to distinguish the two zeolites from one another for making the text clearly understandable and do not imply any particular type of zeolite structure.
Zeolite 1 has a mean pore size of from 0.3 to 0.5 nm (3 to 5 Å), and zeolite 2 has a mean pore size of from 0.6 to 0.8 nm (6 to 8 Å). Accordingly, zeolite 1 has fine pores and zeolite 2 has medium to large pores.
In a preferred embodiment of the process, use is made of, based on the sum of zeolite 1 and zeolite 2,
a) from 10 to 90% by weight, preferably from 30 to 70% by weight and in particular from 40 to 60% by weight, of zeolite 1, and b) from 10 to 90% by weight, preferably from 30 to 70% by weight and in particular from 40 to 60% by weight, of zeolite 2.
In a likewise preferred embodiment, zeolite 1 has a mean pore size of from 0.38 to 0.42 nm (3.8 to 4.2 Å), in particular about 0.4 nm (4 Å) and zeolite 2 has a mean pore size of from 0.68 to 0.72 nm (6.8 to 7.2 Å), in particular about 0.7 nm (7 Å).
Suitable zeolites 1 are, for example, zeolites of the structure type LTA having pore sizes of from 0.3 to 0.5 nm. Particularly preferred zeolites 1 having pore sizes of about 0.4 nm are LTA zeolites in the sodium form.
Suitable zeolites 2 are, for example, zeolites of the structure type FAU having pore sizes of from 0.6 to 0.8 nm. Particularly preferred zeolites 2 having pore sizes of about 0.7 nm are FAU zeolites in the sodium form or calcium form.
The zeolites 1 and 2 used are preferably not acidic or acid-activated zeolites. Particular preference is given to using neutral zeolites 1 and 2.
It goes without saying that mixtures of a plurality of zeolites 1′, 1″, etc., can also be used as zeolite 1 and mixtures of various zeolites 2′, 2″, etc., can also be used as zeolite 2.
The zeolites mentioned are known and are commercially available. Structure, properties and preparation of zeolites are described, for example, in Zeolite Molecular Sieves, Donald W. Breck, John Wiley & Sons, 1974; in Atlas of Zeolite Framework Types, Ch. Baerlocher/W. M. Meier/D. H. Olson, 5th Ed., Elsevier 2001; or in Handbook of Molecular Sieves, R. Szostak, Chapman & Hall, New York, 1992.
In general, the zeolites are used in the form of spheres, rods or granules having an external dimension of from 0.5 to 10 mm.
In the process of the invention, the zeolites can be present as a fixed, moving or fluidized bed. The zeolites are preferably present as a fixed bed. The zeolites 1 and 2 can be mixed and this mixture can be used as fixed, moving or fluidized bed, or, and this is preferred, zeolite 1 and zeolite 2 can be arranged separately from one another in different beds, with the beds being arranged one after the other (in series) and being able to be, independently of one another, fixed, moving or fluidized. Preference is given to both zeolite 1 and zeolite 2 being present as a fixed bed.
It goes without saying that each bed can also be configured as a plurality of successive beds.
The process of the invention can be carried out batchwise or continuously. The configuration in terms of apparatus of the zeolite bed or beds is the customary configuration; for example, the zeolite bed can be located in an absorber or another suitable vessel through which the aromatic to be purified flows. Preference is given to using fixed-bed absorbers. The absorber or other vessel is preferably filled with the zeolites to from 70 to 90% of its volume.
After a certain period of operation, the zeolites are laden with impurities and the purification performance decreases. Regeneration (removal of the adsorbed impurities) is carried out in a customary fashion, e.g. by treatment of the zeolite bed with hot inert gases at from 200 to 400° C. for a number of hours. It is possible to arrange two or more zeolite beds next to one another (in parallel) and to pass the aromatic to be purified over one bed while the other bed is regenerated with hot inert gas.
The size of the adsorber, the type and amount of the zeolites and the flow velocity of the feed stream or the residence time in the absorber depend on the type and amount of the impurities, the purification performance required (tolerable concentration of impurities in the purified aromatic) and the desired regeneration cycles.
If the zeolites 1 and 2 are not used as a homogeneous mixture but instead are used separately from one another, the aromatic to be purified is preferably passed, viewed in the flow direction, firstly over the coarse-pored zeolite 2 and then over the fine-pored zeolite 1, i.e. the bed of zeolite 1 is arranged downstream of the bed of zeolite 2. However, in particular cases, the reverse order can also be advantageous.
Zeolite 2 can be installed upstream of zeolite 1 in a fixed bed in a simple manner by firstly introducing a layer of coarse-pored zeolite 2 into the adsorber and placing a second layer of fine-pored zeolite 1 on top of this first layer. The feed stream comprising impurities is then fed in at the bottom of the adsorber and taken off again in purified form at the top. In the case of the reverse order of zeolite 1 before zeolite 2, a layer of zeolite 1 is naturally introduced first and a layer of zeolite 2 is introduced on top of this.
The feed stream is preferably passed over the zeolites at a temperature of from 0 to 300° C., in particular from 50 to 200° C. and particularly preferably from 100 to 150° C., and a pressure of from 1 to 50 bar (absolute), in particular from 3 to 30 bar (absolute) and particularly preferably from 5 to 20 bar (absolute). Here, identical or different temperatures or pressures can be set for zeolite 1 and zeolite 2 or for the various zeolite beds, depending on the type and amount of the impurities and the purification performance required.
The aromatic to be purified is, for example, obtained by distillation from mixtures of aromatics or from a catalytic transformation of mixtures of aromatics known as hydrodealkylation. Typical impurities in the feed stream are therefore ones which are obtained in the extractive distillation of mixtures of aromatics, in particular N-methylpyrrolidone, N-formylmorpholine and sulfolane. Such nitrogen- or sulfur-comprising impurities can, for example, be determined by chemiluminescence or other analytical methods which those skilled in the art know to be suitable. The nitrogen content in the feed stream, calculated as N 2 , is typically from about 0.1 to 10 ppm by weight, in particular from 0.5 to 5 ppm by weight, e.g. about 1 ppm by weight, per individual impurity and based on the unpurified aromatic, e.g. benzene. The performance of the catalyst is adversely affected even at concentrations of from 0.5 to 1 ppm of N 2 .
The purification performance and thus the quality of the purification process according to the invention can most certainly be assessed by the behavior of the catalysts used in the polymerization or alkylation processes in which the aromatic which has been purified according to the invention is used further. The longer the life (period of operation) of these polymerization or alkylation catalysts, the lower the concentration of impurities in the starting materials and the better the purification performance of the purification process by means of which the starting materials have been purified beforehand.
The catalysts used in alkylation reactions in particular bind impurities very strongly and quickly become exhausted as a result of poisoning when the starting materials are not purified adequately. In the alkylation reaction, which is usually operated continuously, the catalyst is, for example, arranged as a fixed bed. In the case of a fresh catalyst, the reactive zone, i.e. the region within which the exothermic reaction (e.g. of benzene with ethylene to form ethylbenzene) occurs, is at the beginning of the fixed bed, viewed in the flow direction. As the period of operation increases, the reactive “hot” zone travels further along in the flow direction, since the beginning of the catalyst bed becomes increasingly laden with the impurities and thus deactivated, i.e. is no longer catalytically effective. When the reactive zone finally arrives at the end (outlet) of the fixed bed, the total amount of catalyst has become deactivated.
This effect can, for example, be measured by means of temperature measurements in the fixed catalyst bed: temperature measurement points located in succession along the fixed bed in the flow direction show the profile of the exothermic reaction over the fixed bed. If the temperature at the beginning of the fixed bed rises sharply, based on the temperature of the feed stream, a significant part of the conversion occurs here. If the temperature increase at the beginning of the fixed bed is small but that further downstream is high, the reaction has moved downstream. (If the temperature does not also increase at the end of the fixed bed, the catalyst bed is exhausted over its entire length and has to be replaced or regenerated.)
The purification process of the invention is more economical than the processes of the prior art. In particular, the polymerization and alkylation catalysts have a longer life when an aromatic which has been purified according to the invention is used. This considerably reduces the outlay for catalyst regeneration.
The invention further provides a process for preparing alkylated aromatics (alkylation process) by reacting aromatics and olefins over a catalyst, wherein the feed stream comprising aromatics is pretreated by the process of the invention according to any of claims 1 to 6 (purification process). Suitable catalysts are, in particular, Lewis acids or zeolites. Alkylation includes transalkylation.
Such alkylation processes are described, for example, in Ullmann, Encycl. of Industrial Chemistry, 5 th Ed. Vol A10, pages 35 to 43. It is particularly preferably used in the zeolite-catalyzed alkylation or transalkylation of benzene and ethylene. Such processes and suitable catalysts are described, for example, in U.S. Pat. No. 5,902,917, U.S. Pat. No. 4,891,448, U.S. Pat. No. 5,081,323, U.S. Pat. No. 5,198,595, U.S. Pat. No. 5,243,116 or WO 98/07673.
In the alkylation process of the invention, preference is given to using benzene as aromatic and ethylene (so as to give ethylbenzene) or propylene (so as to give cumene) as olefin.
If zeolites are used as catalysts in the alkylation process, these are preferably different from the zeolites used in the purification process. Used catalysts can be employed as “guard bed”.
In the alkylation of aromatics, it is advantageous to purify not only the aromatic feed stream but also the feed stream comprising olefin (or, in the case of transalkylation, other alkylaromatics). For example, both the benzene and the ethylene can be purified in the preparation of ethylbenzene. For this purpose, the olefin feed stream can, for example, be passed over a suitable adsorption bed as is described in WO 01/07383.
The process of the invention improves the purification of aromatics, in particular of aromatics which are to be used in a polymerization or alkylation process. The process prolongs the life of alkylation or transalkylation catalysts in the catalytic alkylation of aromatics by means of olefins, in particular over zeolite catalysts, and reduces the need for regeneration.
EXAMPLES
The following starting materials were used:
Zeolite 1: zeolite type Z4-04 from Zeochem, Switzerland, a zeolite having a mean pore size of 0.4 nm (4 Å) in the form of spheres having a diameter of from 2 to 3 mm, bulk density: about 730 kg/m 3 Zeolite 2: zeolite type Z10-03 from Zeochem, a zeolite having a mean pore size of 0.7 nm (7 Å) in the form of spheres having a diameter of from 1.6 to 2.3 mm, bulk density: about 650 kg/m 3 Benzene: benzene was dewatered azeotropically to a water content of less than 30 ppm by weight (measured by the Karl Fischer method in accordance with DIN 51777) in an upstream drying column Ethylene: from the stream cracker of BASF in Ludwigshafen.
Example 1
For Comparison
20 t of the coarse-pored zeolite 2 were introduced into an adsorber tower having a diameter of 200 cm and a volume of 35 m 3 and distributed to form a fixed bed having a height of 10 m. Benzene was introduced continuously at the bottom of the adsorber tower and the purified benzene was taken off at the top of the tower. The mass flow of the benzene was 60-70 t/h, corresponding to a volume flow of 2 h −1 . The temperature of the benzene fed in was about 130° C.
The purified benzene obtained was mixed with ethylene in a mass ratio of 55:1 (benzene excess) and the mixture was passed through a fixed-bed reactor comprising a zeolite catalyst. The product obtained from this alkylation reaction was a mixture of unreacted benzene, ethylbenzene and multiply alkylated benzenes.
Four temperature sensors x1 to x4 were installed along the fixed-bed reactor used for the alkylation reaction, with x1 being located at the beginning of the fixed catalyst bed (entry of the reactants) and x4 at the end of the fixed bed (product exit). The sensors measured the increasing temperature ΔT of the reaction mixture in the fixed bed caused by the exothermic reaction. ΔT is based on the temperature of the feed stream.
The experiment was stopped after 4 weeks because the temperature increase ΔT at the beginning of the catalyst bed (x1) had decreased greatly and a drop in temperature at the end of the catalyst bed indicated that reaction was no longer complete. This indicated that the catalyst had become deactivated.
Example 2
According to the Invention
Example 1 was repeated, but 14 t of the coarse-pored zeolite 2 were firstly introduced into the adsorber tower and distributed to form a fixed bed having a height of 6.9 m, and 7 t of the fine-pored zeolite 1 were placed on top of this layer and distributed to form a fixed bed having a height of 3.1 m.
Otherwise, the procedure was as described in example 1, with the fixed-bed reactor for the alkylation reaction naturally comprising a fresh zeolite catalyst. The reaction could be carried out for 10 weeks without the catalyst becoming deactivated.
The table summarizes the results.
TABLE
Temperature increase ΔT at the sensors ×1 to ×4, based
on the temperature of the feed stream (— means no measurement
since the catalyst was exhausted at the beginning of the bed)
Week
0 1)
1
2
3
4
5
6
7
8
9
10
ΔT (×1 = beginning of the catalyst bed)
Ex. 1
15.0
5
2.8
2
1.8
—
—
—
—
—
—
Ex. 2
17
14.1
12.5
11.2
10.7
10.3
10
9.9
9.8
9.7
9.6
ΔT (×2)
Ex. 1
22.4
16
11.1
9.8
9
—
—
—
—
—
—
Ex. 2
23.8
23.3
23
22.7
22.6
22.5
22.5
22.4
22.4
22.3
22.3
ΔT (×3)
Ex. 1
22.8
22.1
19.9
18.2
17.2
—
—
—
—
—
—
Ex. 2
24.1
24.1
24.1
24.1
24.1
24.1
24
24
24
24
24
ΔT (×4 = end of the catalyst bed
Ex. 1
23.2
23.2
23.2
23.2
22.9
—
—
—
—
—
—
EX. 2
24.4
24.4
24.4
24.4
24.4
24.4
24.4
24.3
24.3
24.3
24.3
1) Starting point
The examples show that in the case of comparative example 1, the catalyst at the beginning of the fixed catalyst bed (x1) was exhausted after a period of operation of only 4 weeks, since virtually no temperature increase ΔT was measurable in this region.
In example 2 according to the invention, the temperature increase at the beginning of the catalyst (x1) was still 40% of the temperature increase measured at the end of the catalyst (x4) after a period of operation of 10 weeks; the temperature increase measured at the end of the catalyst (x4) is the maximum possible temperature increase. Even at the measurement point x2, ΔT was still 90% of the maximum increase ΔT at the measurement point x4 after 10 weeks.
The purification process of the invention increased the life of the catalyst considerably. | Processes suitable for purifying aromatic-containing feed streams, and processes using such purified streams are described, wherein the purification processes comprise: (a) providing a process feedstream comprising an aromatic component; and (b) bringing the process feedstream into contact with a first zeolite and a second zeolite; wherein the first zeolite has a mean pore size of 0.3 to 0.5 nm, and wherein the second zeolite has a mean pore size of 0.6 to 0.8 nm. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electronic spinning (electrospinning) apparatus for mass-producing nano fibers, and a process for preparing a non-woven fabric using the same.
[0003] 2. Description of the Related Art
[0004] A conventional electrospinning apparatus and a process for preparing a non-woven fabric using the same have been disclosed under U.S. Pat. No. 4,044,404. As shown in FIG. 1, the conventional electrospinning apparatus of the patent '404 includes; a spinning dope main tank 1 for storing a spinning dope; a metering pump 2 for quantitatively supplying the spinning dope; a plurality of nozzles for discharging the spinning dope; a collector 6 positioned at the lower end of the nozzles, for collecting the spun fibers; a voltage generator 11 for generating a voltage; and a plurality of instruments for transmitting the voltage to the nozzles and the collector 6 .
[0005] The conventional process for preparing the non-woven fabric using the electronic spinning apparatus will now be described in detail. The spinning dope of the spinning dope main tank 1 is consecutively quantitatively provided to the plurality of nozzles supplied with a high voltage through the metering pump 2 .
[0006] Continuously, the spinning dope supplied to the nozzles is spun and collected on the collector 6 supplied with the high voltage through the nozzles, thereby forming a single fiber web.
[0007] Continuously, the single fiber web is embossed or needle-punched to prepare the non-woven fabric.
[0008] However, the conventional electrospinning apparatus and process for preparing the non-woven fabric using the same have a disadvantage in that an effect of electric force is reduced because the spinning dope is consecutively supplied to the nozzles having the high voltage.
[0009] In more detail, the electric force transmitted to the nozzles is dispersed to the whole spinning dope, and thus fails to overcome interface or surface tension of the spinning dopes. As a result, fiber formation effects by the electric force are deteriorated, which hardly achieves mass production of the fiber.
[0010] Moreover, the spinning dope is spun through the plurality of nozzles, not through nozzle blocks. It is thus difficult to control a width and thickness of the non-woven fabric.
SUMMARY OF THE INVENTION
[0011] It is therefore, an object of the present invention to provide an electronic spinning apparatus which can mass-produce nano fibers by enhancing fiber formation effects by maximizing an electric force supplied to a nozzle block in electronic spinning, namely maintaining the electric force higher than interface or surface tension of a spinning dope.
[0012] It is another object of the present invention to provide a process for easily controlling a width and thickness of a non-woven fabric by using an electrospinning apparatus having a nozzle block in which a plurality of pins are connected.
[0013] It is yet another object of the present invention to provide a process for preparing a non-woven fabric irregularly coated with nano fibers by using the electrospinning apparatus.
[0014] In order to achieve the above-described objects, there is provided an electrospinning apparatus comprising: a spinning dope drop device 3 positioned between the metering pump 2 and the nozzle block 6 , and the spinning dope drop device including: (i) a sealed cylindrical shape, (ii) a spinning dope inducing tube 3 c and a gas inletting tube 3 b receiving gas through its lower end and having its gas inletting part connected to a filter 3 a being aligned side by side at the upper portion of the spinning dope drop device, (iii) a spinning dope discharge tube 3 d being protruded from the lower portion of which, and (iv) a hollow unit for dropping the spinning dope from the spinning dope inducing tube 3 c being formed at the middle portion of which.
[0015] In addition, a method for preparing a non-woven fabric drops flowing of a spinning dope at least once by passing the spinning dope through a spinning dope drop device before supplying the spinning dope to a nozzle block supplied with a voltage in electronic spinning.
[0016] An electronic spinning apparatus, and a process for preparing a non-woven fabric using the same in accordance with preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[0017] Referring again to FIG. 1, the electrospinning apparatus includes a spinning dope main tank 1 for storing a spinning dope; a metering pump 2 for quantitatively supplying the spinning dope; a nozzle block 4 having block-type nozzles composed of a plurality of pins, and discharging the spinning dope in a fiber shape; a collector 6 positioned at the lower end of the nozzle block 4 , for collecting spun single fibers; a voltage generator 11 for generating a high voltage; a voltage transmission rod 5 for transmitting the voltage generated in the voltage generator 11 to the upper end of the nozzle block 4 ; and a spinning dope drop device 3 positioned between the metering pump 2 and the nozzle block 4 .
[0018] As illustrated in FIGS. 4 a to 4 d , the spinning dope drop device 3 has a sealed cylindrical shape. A spinning dope inducing tube 3 c for inducing the spinning dope to the nozzle block and a gas inletting tube 3 b are aligned side by side at the upper end of the spinning dope drop device 3 . Here, the spinning dope inducing tube 3 c is formed slightly longer than the gas inletting tube 3 b.
[0019] The gas inlets from the lower end of the gas inletting tube 3 b , and an initial gas inletting portion of the gas inletting tube 3 b is connected to a filter 3 a shown in FIG. 4 d . A spinning dope discharge tube 3 d for inducing the dropped spinning dope to the nozzle block 4 is formed at the lower end of the spinning dope drop device 3 . The center portion of the spinning dope drop device 3 is hollow so that the spinning dope can be dropped from the end of the spinning dope inducing tube 3 c.
[0020] The spinning dope inputted to the spinning dope drop device 3 is flown through the spinning dope inducing tube 3 c , but dropped at the end thereof. Therefore, flowing of the spinning dope is intercepted at least one time.
[0021] The principle of dropping the spinning dope will now be explained in detail. When the gas inlets into the upper end of the spinning dope drop device 3 through the filter 3 d and the gas inletting tube 3 b , a pressure of the spinning dope inducing tube 3 c becomes irregular due to gas eddy. Such a pressure difference drops the spinning dope.
[0022] An inert gas such as air or nitrogen can be used as the gas.
[0023] On the other hand, the nozzles are aligned in block units having at least two pins. One nozzle block 4 includes 2 to 100,000 pins, preferably 20 to 2,000 pins. The nozzle pins have circular or different shape sections. In addition, the nozzle pins can be formed in an injection needle shape. The nozzle pins are aligned in a circumference, grid or line, preferably in a line.
[0024] The process for preparing the non-woven fabric using the electrospinning apparatus in accordance with the present invention will now be described.
[0025] Firstly, a thermoplastic or thermosetting resin spinning dope stored in the main tank 1 is measured by the metering pump 2 , and quantitatively supplied to the spinning dope drop device 3 . Exemplary thermoplastic or thermosetting resins used to prepare the spinning dope include polyester resins, acryl resins, phenol resins, epoxy resins, nylon resins, poly(glycolide/L-lactide) copolymers, poly(L-lactide) resins, polyvinyl alcohol resins and polyvinyl chloride resins. A resin molten solution or resin solution may be used as the spinning dope.
[0026] When the spinning dope supplied to the spinning dope drop device 3 passes through the spinning dope drop device 3 , flowing of the spinning dope is dropped at least once in the mechanism described above. Thereafter, the spinning dope is supplied to the nozzle block 4 having a high voltage.
[0027] The nozzle block 4 discharges the spinning dope in a single fiber shape through the nozzles. The spinning dope is collected by the collector 6 supplied with the high voltage to prepare a non-woven fabric web.
[0028] Here, to facilitate fiber formation by the electric force, a voltage over 1 kV, more preferably 20 kV is generated in the voltage generator 11 and transmitted to the voltage transmission rod 5 and the collector 6 installed at the upper end of the nozzle block 4 . It is advantageous in productivity to use an endless belt as the collector 6 .
[0029] The non-woven fabric web formed on the collector 6 is consecutively processed by an embossing roller 9 , and the prepared non-woven fabric winds on a winding roller 10 . Thus, the preparation of the non-woven fabric is finished.
[0030] In another aspect of the present invention, as shown in FIG. 2 and FIG. 3, nano fibers are elctrospun on one surface or both surfaces of a fiber material by using the electrospinning apparatus, and bonded. Exemplary fiber materials include fiber products such as spun yarns, filaments, textiles, knitted fabrics and non-woven fabrics, paper, films and braids.
[0031] Before spinning the nano fibers on the fiber material, the fiber material can be dipped in an adhesive solution and compressed by a compression roller 15 . When the fiber material is dipped in the adhesive solution and compressed, the fiber material is preferably dried by a drier 16 before being bonded by a bonding device 17 .
[0032] The fiber material on which the nano fibers are spun and adhered can be bonded according to needle punching, compression by a heating embossing roller, high pressure water injection, electromagnetic wave, ultrasonic wave or plasma.
[0033] As depicted in FIG. 3, when at least two electrospinning apparatuses are employed, the spinning dopes supplied to the respective electrospinning apparatuses include different kinds of polymers. Here, the nano fibers can be coated in a hybrid type.
[0034] Still referring to FIGS. 2 and 3, the electrospinning apparatus includes: a spinning dope main tank 1 for storing a spinning dope; a metering pump 2 for quantitatively supplying the spinning dope; a nozzle block 4 having block-type nozzles composed of a plurality of pins, and discharging the spinning dope onto fibers; a voltage transmission rod 5 positioned at the lower end of the nozzle block 4 ; a voltage generator 11 for generating a high voltage; and a spinning dope drop device 3 positioned between the metering pump 2 and the nozzle block 4 .
[0035] The spinning dope drop device 3 was mentioned above.
[0036] The electronspinning process to make the nano fibers by using the electrospinning apparatus of the present invention will now be explained in more detail.
[0037] Firstly, a thermoplastic or thermosetting resin spinning dope stored in the main tank 1 is measured by the metering pump 2 , and quantitatively supplied to the spinning dope drop device 3 . Exemplary thermoplastic or thermosetting resins used to prepare the spinning dope include polyester resins, acryl resins, phenol resins, epoxy resins, nylon resins, poly(glycolide/L-lactide) copolymers, poly(L-lactide) resins, polyvinyl alcohol resins and polyvinyl chloride resins. A resin molten solution or resin solution may be used as the spinning dope.
[0038] Supplied to the spinning dope drop device 3 , the spinning dope passes through it, flowing of the spinning dope is dropped at least once in the mechanism described above. Thereafter, the spinning dope is supplied to the nozzle block 4 having a high voltage.
[0039] Then the nozzle block 4 discharges the spinning dope to the fiber material in a single fiber shape through the nozzles.
[0040] Here, to facilitate fiber formation by the electric force, a voltage over 1 kV, more preferably 20 kV is generated in the voltage generator 11 and transmitted to the upper end of the nozzle block 4 and the voltage transmission rod 5 .
[0041] In accordance with the present invention, when the spinning dope is supplied to the nozzle block 4 , flowing of the spinning dope is dropped at least once by using the spinning dope drop device 3 , thereby maximizing fiber formation. As a result, fiber formation effects by the electric force are improved to mass-produce the nano fibers and non-woven fabrics. Moreover, since the nozzles having the plurality of pins are aligned in block units, a width and thickness of the non-woven fabric can be easily controlled.
[0042] When at least two electrospinning apparatuses are aligned, polymers having a variety of components can be combined one another, which makes it easier to prepare a hybrid non-woven fabric.
[0043] In accordance with the present invention, a diameter of the fiber spun by melting spinning is over 1,000 nm, and a diameter of the fiber spun by solution spinning ranges from 1 to 500 nm. The solution spinning includes wet spinning and dry spinning.
[0044] The non-woven fabric composed of the nano fibers is used as medical materials such as an artificial organisms, hygienic band, filter, synthetic blood vessel, and as industrial materials which is semiconductor wipers and battery.
[0045] For examples, a mask coated with the nano fibers is useful as an anti-bacteria mask, and a spun yarn or filament coated with the nano fibers is useful as a yarn for artificial suede and leather. In addition, coating nylon 6 nano fibers on a paper filter extends a life span of the filter. The fiber material coated with the nano fibers is soft to the touch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] The above objects, features and advantages of the present invention will become more apparent from the following preferred embodiments when taken in conjunction with the accompanying drawings, in which:
[0047] [0047]FIG. 1 is a schematic view illustrating an electrospinning apparatus in accordance with the present invention;
[0048] [0048]FIG. 2 is a schematic view illustrating a process of consecutively coating first component nano fibers in accordance with the present invention;
[0049] [0049]FIG. 3 is a schematic view illustrating a process of consecutively coating second component nano fibers in accordance with the present invention;
[0050] [0050]FIG. 4 a is a cross-sectional view illustrating a spinning dope drop device 3 ;
[0051] [0051]FIG. 4 b is a perspective view illustrating the spinning dope drop device 3 ;
[0052] [0052]FIG. 4 c is a plan view illustrating the spinning dope drop device 3 ;
[0053] [0053]FIG. 4 d is an enlarged view illustrating a filter of the spinning dope drop device 3 ;
[0054] [0054]FIG. 5 is a schematic view illustrating a process of assembling two electronic spinning apparatuses in accordance with the present invention;
[0055] [0055]FIG. 6 is SEM (scanning electron microscope) shown a non-woven fabric prepared by using nylon 6 spinning dope dissolved in formic acid in accordance with the process of the present invention;
[0056] [0056]FIG. 7 is SEM to magnify FIG. 4;
[0057] [0057]FIG. 8 is SEM shown a non-woven fabric prepared with poly(L-lactide) spinning dope dissolved in methylene chloride in accordance with the process of the present invention;
[0058] [0058]FIG. 9 is a diameter distribution of nano fibers elctropsun poly(glycolide-lactide) copolymer spinning dope by using electrospinning in accordance with the process of the present invention;
[0059] [0059]FIG. 10 is SEM shown a non-woven fabric prepared with polyvinyl alcohol spinning dope dissolved in distilled water in accordance with the process of the present invention;
[0060] [0060]FIG. 11 is SEM to magnify FIG. 10;
[0061] [0061]FIG. 12 is SEM shown a non-woven fabric electrospun with a nozzle width of 90 cm;
[0062] [0062]FIG. 13 is SEM shown a paper filter (product of Example 5) coated with polyvinyl alcohol nano fibers;
[0063] [0063]FIG. 14 is thermogravimetric analysis curves shown polyvinyl alcohol nano fibers themselves as a function of curing time;
[0064] [0064]FIG. 15 is differential scanning calorimeter (DSC) curves shown polyvinyl alcohol nano fibers themselves as a function of curing time;
[0065] [0065]FIG. 16 is SEM of polyester fabric (product of Example 6) coated with nylon 6 nano fibers;
[0066] [0066]FIG. 17 is SEM of nylon 6 fabric (product of Example 7) coated with nylon 6 nano fibers;
[0067] [0067]FIG. 18 is SEM of polyester filament (product of Example 8) coated with nylon 6 nano fibers; and
[0068] [0068]FIG. 19 is SEM of nylon 6 non-woven fabrics coated with polyurethane polymers.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0069] Hereinafter, the present invention will be described in more detail through examples, but it is not limited thereto.
EXAMPLE 1
[0070] Nylon 6 chip having relative viscosity of 2.3 was dissolved in formic acid by 20% in 96% of sulfuric acid solution, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 2, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 50 kV, and spun in a fiber shape through the nozzles. The spun fibers were collected on the collector 6 , to prepare a non-woven fabric web having a width of 60 cm and weight of 3.0 g/m 2 . Here, each nozzle block included 200 pins, and 200 nozzle blocks were aligned. Model CH 50 of Symco Corporation was used as the voltage generator. The output rate per one pin was 0.0027 g/min (discharge amount of one nozzle block: 0.54 g/min), and thus a throughput was 108 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 20 pins. A drop speed had 3-second intervals. The non-woven fabric web was transferred and embossed at a speed of 60 m/min, to prepare a non-woven fabric. Table 1 shows tensile strength and tensile elongation at break. FIG. 6 and FIG. 7 are illustrated SEM of the prepared nylon 6 non-woven fabric.
EXAMPLE 2
[0071] Poly(L-lactide) having a viscosity average molecular weight of 450,000 was dissolved in methylene chloride, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 2, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 50 kV, and spun in a fiber shape through the nozzles. The spun fibers were collected on the collector 6 , to prepare a non-woven fabric web having a width of 60 cm and weight of 6.9 g/m 2 . Here, each nozzle block included 400 pins, and 20 nozzle blocks were aligned. Model CH 50 of Symco Corporation was used as the voltage generator. The output rate per one pin was 0.0026 g/min, and thus a throughput was 20.8 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 40 pins. A drop speed had 3.2-second intervals. The non-woven fabric web was transferred and embossed at a speed of 5 m/min, to prepare a non-woven fabric. Table 1 shows tensile strength and tensile elongation at break. SEM of the prepared poly(L-lactide) non-woven fabric was shown in FIG. 8.
EXAMPLE 3
[0072] Poly(glycolide-lactide) copolymer (mole ratio: 50/50) having a viscosity average molecular weight of 450,000 was dissolved in methylene chloride, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 2, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 50 kV, and spun in a fiber shape through the nozzles. The spun fibers were collected on the collector 6 , to prepare a non-woven fabric web having a width of 60 cm and weight of 8.53 g/m 2 . Here, each nozzle block included 400 pins, and 20 nozzle blocks were aligned. Model CH50 of Symco Corporation was used as the voltage generator. The throughput per one pin was 0.0032 g/min (output rate per one nozzle block: 1.28 g/min), and thus a total output rate was 25.6 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 40 pins. A drop speed had 2 second intervals. The non-woven fabric web was transferred and embossed at a speed of 5 m/min, to prepare a non-woven fabric. Table 1 shows tensile strength and tensile elongation at break. FIG. 9 shows the fiber diameter distribution of the prepared non-woven fabric.
EXAMPLE 4
[0073] Polyvinyl alcohol having a number average molecular weight of 20,000 was dissolved in distilled water, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 2, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 50 kV, and spun in a fiber shape through the nozzles. The spun fibers were collected on the collector 6 , to prepare a non-woven fabric web having a width of 60 cm and weight of 3.87 g/m 2 . Here, each nozzle block included 400 pins, and 20 nozzle blocks were aligned. Model CH 50 of Symco Corporation was used as the voltage generator. The output per one pin was 0.0029 g/min (output rate per one block: 1.28 g/min), and thus a total throughput was 23.2 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 40 pins. A drop speed had 2.5-second intervals. The non-woven fabric web was transferred and embossed at a speed of 10 m/min, to prepare a non-woven fabric. Table 1 shows tensile strength and tensile elongation at break. FIG. 10 shows SEM of the prepared poly(vinyl alcohol) non-woven fabric.
TABLE 1 Tensile properties Tensile elongation Classification Strength (kg/cm) at break(%) Example 1 180 25 Example 2 180 25 Example 3 100 28 Example 4 120 32
EXAMPLE 5
[0074] 100 wt % of polyvinyl alcohol having a number average molecular weight of 20,000, 2 wt % of glyoxal and 1.8 wt % of phosphoric acid were dissolved in distilled water, to prepare 15% of spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 4, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 45 kV, and fibers having an average diameter of 105 nm were continuously spun on the paper filter (width: 1 m) transferred at a speed of 20 m/min through the nozzles. The fibers were compressed (bonded) by the embossing roller, to prepare a coating web having a weight of 0.61 g/m 2 . Here, each nozzle block included 250 pins, and 20 nozzle blocks were aligned. Model name CH 50 of Symco Corporation was used as the voltage generator. The output per one pin was 0.0027 g/min, and thus a total throughput was 13.5 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 10 pins. A drop speed had 2.5-second intervals. The pins were formed in a circular shape. FIG. 10 was shown the polyvinyl alcohol nano fibers themselves. SEM of FIG. 10 magnified was shown in FIG. 11. FIG. 12 was the photographs to show the evidence the mass-production by using muti-pins and poly(vinyl alcohol). SEM of paper pulp coated with polyvinyl alcohol was illustrated in FIG. 13. FIG. 14 was shown the thermogravimetric analysis of poly(vinyl alcohol) nano fibers themselves with changing the curing time. Also, differential scanning calorimeter curves of nano fibers themselves as a function of the curing time were shown in FIG. 15. When the coating paper pulp was processed in the drier of 160° C. for 3 minutes and precipitated in toluene in a normal temperature for a day, it was not dissolved.
EXAMPLE 6
[0075] Nylon 6 chip having a relative viscosity of 2.3 was dissolved in formic acid by 25% in 96% of sulfuric acid solution, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 4, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 45 kV, and fibers having an average diameter of 108 nm were continuously spun on polyester plane fabrics (width: 1 m) passed through dipping and compression processes in acryl resin adhesive solution and transferred at a speed of 10 m/min through the nozzles. The fibers were bonded (needle-punched) to prepare a coating web having a weight of 1.2 g/m 2 . Here, each nozzle block included 250 pins, and 20 nozzle blocks were aligned. Model CH 50 of Symco Corporation was used as the voltage generator. The throughput per one pin was 0.0024 g/min, and thus a total output rate was 12.1 g/min. One nozzle block was divided into 10, and one spinning dope-drop device 3 was installed in every 10 pins. A drop speed had 3-second intervals. The pins were formed in a circular shape. SEM of the prepared coating polyester plane fabric was shown in FIG. 16.
EXAMPLE 7
[0076] Nylon 6 chip having a relative viscosity of 2.3 was dissolved in formic acid by 25% in 96% of sulfuric acid solution, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 4, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 45 kV, and fibers having an average diameter of 108 nm were continuously spun on nylon 6 plane fabric (width: 1 m) passed through dipping and compression processes in acryl resin adhesive solution and transferred at a speed of 10 m/min through the nozzles. The fibers were bonded (needle-punched) to prepare a coating web having a weight of 1.29 g/m 2 . Here, each nozzle block included 250 pins, and 20 nozzle blocks were aligned. Model CH 50 of Symco Corporation was used as the voltage generator. The output rate per one pin was 0.0024 g/min, and thus a total throughput was 12.1 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 10 pins. A drop speed had 3-second intervals. The pins were formed in a circular shape. SEM of the nylon 6 plane fabric coated was shown in FIG. 17.
EXAMPLE 8
[0077] Nylon 6 chip having a relative viscosity of 2.3 was dissolved in formic acid by 25% in 96% of sulfuric acid solution, to prepare a spinning dope. The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 3, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 45 kV, and fibers having an average diameter of 108 nm were continuously spun and dried on 75 denier 36 filament polyester filament (alignment of 80 strips in 1 inch, width: 1 m) passed through dipping and compression processes in acryl resin adhesive solution and transferred at a speed of 3 m/min through the nozzles. Here, each nozzle block included 250 pins, and 20 nozzle blocks were aligned, Model CH 50 of Symco Corporation was used as the voltage generator. The output rate a one pin was 0.0024 g/min, and thus a total throughput was 12.1 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 10 pins. A drop speed had 3-second intervals. The pins were formed in a circular shape. A plane fabric (density: 80 threads/inch) was prepared by using the coating polyester filaments as warps and wefts. SEM of the polyester fabric coated was shown in FIG. 18.
EXAMPLE 9
[0078] Poly(glycolide-lactide) copolymer (mole ratio: 50/50) having a viscosity average molecular weight of 450,000 was dissolved in methylene chloride in a normal temperature, to prepare a spinning dope (density: 15%). The spinning dope was stored in the main tank 1 , quantitatively measured by the metering pump 2 , and supplied to the spinning dope drop device 3 of FIG. 4, thereby discontinuously changing flowing of the spinning dope. Thereafter, the spinning dope was supplied to the nozzle block 4 having a voltage of 48 kV, and fibers having an average diameter of 108 nm were continuously spun on poly(L-lactide) membrane film (weight: 10 g/m 2 , width: 60 cm) transferred at a speed of 2 m/min through the nozzles. The fibers were bonded (needle-punched) to prepare a non-woven fabric web having a weight of 2.8 g/m 2 . Here, each nozzle block included 200 pins, and 10 nozzle blocks were aligned. Model CH 50 of Symco Corporation was used as the voltage generator. The output rate per one pin was 0.0028 g/min, and thus a total throughput was 5.6 g/min. One nozzle block was divided into 10, and one spinning dope drop device 3 was installed in every 50 pins. A drop speed had 3-second intervals. The pins were formed in a circular shape. SEM of the non-woven fabric coated was shown in FIG. 19.
INDUSTRIAL APPLICABILITY
[0079] The present invention mass-produces the non-woven fabric composed of the nano fibers, and easily controls the thickness and width of the non-woven fabric. In addition, when at least two electrospinning apparatuses are assembled, multi-component polymers can be easily combined, to prepare the hybrid non-woven fabric. Moreover, the non-woven fabric (fiber material) is coated with the nano fibers, and thus has improved softness and performance. | The present invention relates to an electrospinning apparatus including a spinning dope drop device ( 3 ) formed between a metering pump ( 2 ) and a nozzle block ( 4 ), the spinning dope drop device ( 3 ) including (i) a sealed cylindrical shape, (ii) a spinning dope inducing tube 3 c and a gas inletting tube 3 b receiving gas through its lower end and having its gas inletting part connected to a filter 3 a being aligned side by side at the upper portion of the spinning dope drop device, (iii) a spinning dope discharge tube 3 d being protruded from the lower portion of which, and (iv) a hollow unit for dropping the spinning dope from the spinning dope inducing tube 3 c being formed at the middle portion of which. In addition, a method for preparing a non-woven fabric drops flowing of a spinning dope at least once by passing the spinning dope through a spinning dope drop device ( 3 ) before supplying the spinning dope to a nozzle block ( 4 ) supplied with a voltage in electrospinning. As a result, the present invention can mass-produce the nano fibers and non-woven fabrics by maximizing fiber formation effects in electrospinning, and easily control a with and thickness of the non-woven fabric. | 3 |
CROSS-REFERENCE RELATED TO APPLICATIONS
This application is filed under 35 U.S.C. §120 and §365(c) as a continuation of International Patent Application PCT/DE2011/002077, filed Dec. 5, 2011, which, application claims priority from German Patent Application No. DE 10 2010 055 897.4, filed Dec. 23, 2010, which applications are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to a centrifugal pendulum device, particularly a trapeze centrifugal pendulum device for a damper device and/or a torque transmitting device, particularly for a drivetrain of a motor vehicle. Further, the invention relates to a damper device or a torque transmitting device, particularly for a drivetrain of a motor vehicle; e.g., a centrifugal pendulum, a torque converter, a clutch, a Foettinger-clutch, a clutch assembly, a damper, a torsional vibration damper, a turbine damper, a pump damper, a two-weight converter or a two-weight flywheel, or combinations thereof; with the damper device and/or the torque transmitting device comprising a centrifugal pendulum device according to the invention.
BACKGROUND OF THE INVENTION
At shafts of periodically operating machines, e.g., at a crankshaft of an internal combustion engine of a motor vehicle, during a rotary motion of the shaft interfering torsional vibrations occur, with their frequency changing with the rotation of the shaft. Particularly in the pulling operation, torsional vibrations are generated in the drive train of the motor vehicle by combustion processes of the internal combustion engine. In order to reduce these torsional vibrations, a centrifugal pendulum may be provided, which can compensate the torsional vibrations over a wider range of rotations of the internal combustion engine, ideally over its entire range of rotation. The centrifugal pendulums are based on the principle that due to centrifugal force, the pendulum weights tend to travel around a rotary axis at the largest possible distance when a rotary motion is initiated. The torsional vibrations in the shaft lead to an oscillating relative motion of the pendulum weights, with the centrifugal pendulum showing a natural frequency proportional to the rotation such that torsional vibrations can be compensated with frequencies, which are also equally proportional to the rotation of the shaft over a wide range of rotations.
A centrifugal pendulum comprises a plurality of pendulum weights, which are suspended via guide elements at a rotary pendulum weight carrier and that can perform a relative motion in reference to this pendulum weight carrier along predetermined guide paths, in order to here assume a variable distance from the axis of rotation of the pendulum weight carrier. As a consequence of the torsional vibrations in the drive train, the pendulum weights are excited to oscillate and/or vibrate, with their gravitational center permanently changing, temporarily off-set in reference to the torsional vibrations in the drive train, which causes a damping of the torsional vibrations by a mechanic feedback. An efficient damping can occur by an appropriate adjustment of the pendulum weights and their guide paths. In certain operating states of the centrifugal pendulum an impacting of the pendulum weights at the pendulum weight carrier can occur, an impacting of the faces of the pendulum weights neighboring in the circumferential direction, and/or an impacting of the guide elements in the respective longitudinal ends of the guide paths of the pendulum weight carrier and/or the pendulum weights, whereby malfunctions of the centrifugal pendulum and noise are generated, leading to a subjectively recognizable loss of driving comfort and noise.
The provision of the pendulum weights at a respective safety distance in reference to each other in the circumferential direction leads to an undesired reduction of the pendulum weights and/or the limitation of the escaping arc leads to a loss of efficiency of the centrifugal pendulum. Further, the use of rubber elements is hard to calculate with regards to tolerance under the impact of force with regards to aspects of thermal expansion and deformation. Here, reliability and lifespan of rubber elements are problematic in an oily environment. Further, rubber elements fail to prevent any impacting of pendulum weights adjacent in the circumferential direction, but they prevent it only between pendulum weights and the pendulum weight carrier. Furthermore, the terminals can only be used to a limited extent in centrifugal pendulums with a trapeze arrangement of the pendulum weights.
DE 198 31 160 A1 discloses a centrifugal pendulum for a shaft rotational about an axis with a trapeze arrangement of the pendulum weights. During operation of the centrifugal pendulum, a pendulum weight performs a purely translational motion in reference to the pendulum weight carrier of the centrifugal pendulum. This is achieved by a parallel bifilar suspension of the pendulum weights. In order for a small structural space to be well utilized, comparatively large pendulum weights are provided, with pendulum weights adjacent in the circumferential direction of the pendulum weight carrier being embodied rounded at the sides facing each other and contacting each other loosely independent from any deflection. By the facial, arc-shaped configuration of the pendulum weights, jamming pendulum weights can be essentially excluded, however here the noise development is even greater because the sides of the pendulum weights facing each other contact each other independent from any deflection of the pendulum weights, i.e., repeatedly impact each other when the operating conditions change.
BRIEF SUMMARY OF THE INVENTION
The objective of the invention is to provide an improved centrifugal pendulum device for a damper device and/or a torque transmitting device, particularly for a drivetrain of a motor vehicle. Further, an objective of the invention is to provide an improved damper device and/or an improved torque transmitting device, for example for a drivetrain of a motor vehicle. Here, the centrifugal pendulum device and/or a centrifugal pendulum equipped with the centrifugal pendulum device according to the invention shall show low noise emissions. Further, malfunctions of the centrifugal pendulum device caused by uncontrolled motions of the pendulum weights shall be reduced. Here, particularly any impacting of the pendulum weight at the pendulum weight carrier, any impacting of faces of the pendulum weights adjacent in the circumferential direction, and/or any impacting of the guide elements in the respective longitudinal ends of the guide paths of the pendulum weight carrier and/or the pendulum weights shall be reduced.
The objective of the invention is attained via a centrifugal pendulum device, particularly a trapeze centrifugal pendulum device, for a damper device and/or a torque transmitting device, particularly for a drivetrain of a motor vehicle, and via a damper device or a torque transmitting device, preferably for a drivetrain of a motor vehicle; e.g., a centrifugal pendulum, a torque converter, a clutch, a Foettinger-clutch, a clutch assembly, a damper, a torsional vibration damper, a turbine damper, a pump damper, a two-weight converter or a two-weight flywheel, or combinations thereof.
The centrifugal pendulum device according to the invention comprises a pendulum weight carrier, that can rotate about a rotary axis, at which in the circumferential direction a plurality of pendulum weights or pairs of pendulum weights are provided, which can be moved in reference to the pendulum weight carrier. According to the invention, two pendulum weights or pairs of pendulum weights directly adjacent to each other in the circumferential direction of the pendulum weight carrier are mechanically coupled to each other or can be coupled via a damper element according to the invention. Preferably the invention can be used in centrifugal pendulums with a trapeze arrangement and a controllable progression of the compensation for shock absorption and for preventing rattling noises. In the following only the respective or concerned pair and/or pairs of pendulum weights are discussed; however the following statements also apply to the respective and/or concerned (individual) pendulum weights. In such a case only a second axial section of the centrifugal pendulum device is omitted, designed symmetrical in reference to a first axial section, i.e., in case of pairs of pendulum weights the two axial sections are configured similarly or essentially identical and only separated from each other by the pendulum weight carrier. Further, the respective embodiments of the first and second variant of the damper element according to the invention described in the following can also be independent from the centrifugal pendulum device according to the invention.
In the first variant of the invention, the damper element is embodied as a spring element between the two directly adjacent, i.e., respective or concerned pairs of pendulum weights, mechanically connecting this pair of pendulum weights to each other. Here, the spring element may be embodied soft-springy between the respective pairs of pendulum weights at certain relative motions and hard-springy between the respective pairs of pendulum weights at certain other relative motions, i.e., in certain sections the spring element is embodied soft-springy and in certain sections the spring element is embodied hard-springy, whereby these sections may be provided separated from each other or each other overlapping in the spring element. The spring element according to the invention may here be provided soft-springy in the radial direction of the centrifugal pendulum device, particularly in the circumferential direction except for a spring section also soft-springy, preferably in an axial direction hard-springy and particularly preferred in the spring section also embodied hard-springy. By the spring element, elastically embodied in the radial and the circumferential direction, except for the spring section, any yielding in these directions during a vibration of the pendulum weight can occur without any relevant resistance. Any compensation of the respective pairs of pendulum weights with each other occurs, e.g., only when the respective pairs of pendulum weights collide with each other, i.e., when the spring element with a spring side essentially contacts a pair of pendulum weights entirely and the other pair of pendulum weights approaches the first one.
Preferably all pairs of pendulum weights of the pendulum weight carrier are annularly connected to an assembly via spring elements. Here the setting of the spring elements should be symmetrical, so that no shifting of the point of gravity of the pairs of the pendulum weights and tipping moments develop at the pairs of pendulum weights. In particular, by a hard-springy embodiment of the spring elements in the axial direction any impacting of the pairs of pendulum weights at the pendulum weight carrier can be effectively prevented. Further, collisions of the respective pendulum weights at maximum deflection and in the transitional phases during the operation of the centrifugal pendulum can be effectively prevented by the spring elements preferably being embodied as flat springs. In preferred embodiments of the invention the spring element is embodied as a lamella or a strip spring, which mechanically connects the respective pairs of pendulum weights to each other, whereby these pairs of pendulum weights can be provided in a mutually springy fashion depending on an opposite position. Preferably one fastening section each of the lamella spring can be fastened at a respective pair of pendulum weights, with the elastic section of the lamella spring extending between the two fastening sections between the respective pairs of pendulum weights.
In preferred embodiments of the invention a respective penetrating recess of the pendulum weight carrier, through which a pin, e.g., a rivet or a spacer rivet of the fastening section of the spring element extends, is designed such that the pin remains distanced from any boundary of the penetrating recess in essentially all possible positions during the operation of the centrifugal pendulum device and/or the centrifugal pendulum. This means, here respective clearance angles are provided which enlarge the penetrating recess such that the pin of the fastening section of the spring element cannot impact the boundary of this penetrating recess in most operating states. Further, a guide path of the pendulum weight carrier, a guide path of the respective pair of pendulum weights, and/or a respective guide element may be adjusted to each other or embodied such that in the transitional phases of the moving pairs of pendulum weights and/or a maximum pivotal angle of the centrifugal pendulum device any mutual impacting occurs almost exclusively between the pairs of pendulum weights, except for the spring elements, with further preferred a mutual impacting of these three components essentially being prevented in the essential circumferential direction.
In the exemplary embodiments of the invention, respective pairs of pendulum weights can be mechanically coupled via a single spring element at a single axial side, or via spring elements respectively on both axial sides of the pendulum weight carrier. Further, it is preferred that a fastening section of the spring element holds two axially directly adjacent pendulum weights of a pair of pendulum weights at a certain distance from each other, this may occur e.g., via the pin, the rivet, or the spacer rivet. The guide paths of the pendulum weight carrier and/or the pairs of pendulum weights may show a clearance angle to avoid collisions between the guide elements and the pendulum weight carrier (for reference see above). Preferably a maximum axial depth of the spring element or the spring section is equivalent to an axial depth of a pendulum weight, i.e., they are aligned to each other in the circumferential direction. In a transitional section from the fastening section to the spring section of the lamella spring said lamella spring may be embodied soft-springy. Further, the spring section of the lamella spring is designed essentially hard-springy over its entire extension, with the spring section at least comprising one spring path, particularly a zigzag, a curved, or a triangular path. Other forms of such a spring path may be used, of course, as long as the spring section provides a spring force between the two pairs of pendulum weights. Furthermore, the spring section of the lamella spring may show two elastic sections radially opposite each other.
In the second variant of the invention, the damper element is embodied between the two directly adjacent, i.e., respective or concerned, pairs of pendulum weights as a terminal at which the respective pairs of pendulum weights can abut and/or can collide in the circumferential direction. The terminal is preferably provided in a mobile fashion in a guide path for a guide element in the pendulum weight carrier, with in this guide path preferably also at least one pair of pendulum weights is guided with a guide element. Here, the preferably integral terminal and/or the respective guide path are sized in the pendulum weight carrier such that the terminal can be laterally inserted or adjusted therein with its longitudinal extension. In a lateral connection thereat, the pendulum weights are inserted and fastened to each other, preferably riveted, whereby in each possible position of the pendulum weights in reference to each other the terminals cannot fall out; this means the respective guide path in the pendulum weight carrier, the terminal, and the pair of pendulum weights are arranged and/or designed such that even in disadvantageous positions of the pairs of pendulum weights the terminal cannot fall out of the respective guide path during operation of the centrifugal pendulum device.
In one embodiment of the invention the terminal, particularly an impact body of the terminal, represents a massive element which is preferably made from plastic. Here, the terminal is preferably embodied in one piece, particularly made in one piece from the same material, and the plastic is preferably a hard and/or wear-resistant plastic. The terminal itself is particularly embodied as an oblong body, with its impact areas for the respective pairs of pendulum weights being aligned essentially parallel in reference to each other in the circumferential direction. In another embodiment of the invention, the terminal is embodied as a spring terminal, which shows in the circumferential direction of the pendulum weight carrier at least one spring device each at its both longitudinal sides. A single spring device of the spring terminal is here preferably embodied as a parallel or serial arrangement of flat springs with one or more steps, where a pair of pendulum weights can abut and/or collide. Here, the terminal is also preferably embodied in one piece, particularly made from the same material throughout, with the terminal preferably being bent into the desired shape from a (punched) blank comprising spring steel.
In preferred embodiments of the invention, a guide path of the pendulum weight carrier, a respective guide path of a pair of pendulum weights, and a corresponding guide element are designed and/or adjusted to each other such that in transitional phases of the respective pair of pendulum weights moving and/or a maximum escaping arc of the centrifugal pendulum device, except for the spring terminals, any mutual collision occurs exclusively between the pairs of pendulum weights, with further preferred a mutual collision of these three components in the circumferential direction being essentially avoided. Preferably here the guide paths of the pendulum weight carrier and/or the pairs of pendulum weights show a clearance angle between the guide elements, the pendulum weight carrier, and/or the pairs of pendulum weights so as to avoid collisions. Further, the terminal is preferably embodied in duplicate for the respective pairs of pendulum weights, with the two elements particularly being fixed to each other via a spacer rivet. The terminal, which can be fastened in the pendulum weight carrier, can be embodied wider in the circumferential direction at one radial exterior longitudinal end section than in a central section or a radially interior end section. A maximum axial depth of an impact area or the spring sections of the terminal is equivalent to that of a pendulum weight; i.e., they are aligned to each other in the circumferential direction.
The invention further relates to a damping device or a torque transmission device, in particular for a drive train or a motor vehicle; for example, a centrifugal pendulum, a torque converter, a clutch, a fluid coupling, a clutch assembly, a damper, a torsional vibration damper, a turbine damper, a pump damper, a dual mass converter, or a dual mass flywheel, or combinations thereof; wherein the damping device or the torque transmission device has a centrifugal pendulum mechanism according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention is explained in greater detail based on exemplary embodiments in view of the drawings in which:
FIGS. 1 to 3 illustrate a first exemplary embodiment of a first variant for a centrifugal pendulum device according to the invention, whereby a circumferential direction between two directly adjacent pendulum weights a damper element is provided embodied according to the invention as a simple lamella spring element;
FIGS. 4 and 5 illustrate a second embodiment of the first variant of the invention, with between respective pendulum weights a damper element being provided embodied as a double-sided lamella spring element;
FIG. 6 illustrates a single pendulum weight;
FIGS. 7 to 10 illustrate two relatively stable extreme positions of the centrifugal pendulum device according to the invention as in the first embodiment of the first variant in a minimal ( FIGS. 7 and 8 ) and a maximal escaping arc ( FIGS. 9 and 10 );
FIG. 11 illustrates a pendulum weight carrier for the second variant of the invention;
FIG. 12 illustrates a first embodiment of a second variant of a damper element according to the invention, with the damper element being embodied as a terminal;
FIGS. 13 and 14 illustrate a suspension of the terminal of FIG. 12 in the pendulum weight carrier of FIG. 11 ;
FIGS. 15 and 16 illustrate two relatively stable extreme positions of the centrifugal pendulum device according to the invention as in the first embodiment of the second variant in a minimal and ( FIG. 15 ) a maximal escaping arc ( FIG. 16 ); and,
FIGS. 17 to 21 illustrate two embodiments of the second variant of the damper element according to the invention, with the damper element respectively being embodied as a spring terminal.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, the respectively explained features may also be applied in the respectively other embodiment and/or variant of the invention; this particularly applies to the embodiments of a respective variant.
In the first embodiment of the first variant of the invention (see FIGS. 1 to 3 , and also FIGS. 7 to 10 ), the damper element 40 according to the invention is embodied as a spring element 42 for a centrifugal pendulum device 1 , the spring element 42 in turn is designed as a lamella 42 and/or strip spring element 42 , with the spring element 42 in certain situations and/or arrangements acting like a pressure spring element 42 . Here, the lamella spring element 42 preferably comprises a thin folded spring blade, which in the circumferential direction U of a pendulum weight carrier 10 of the centrifugal pendulum device 1 is provided between two directly adjacent pendulum weights 22 or pairs of pendulum weights 20 and is here respectively fastened via a fastening section 422 . The spring section 424 of the lamella spring element 42 extends between the two fastening sections 422 , directly adjacent to each other in the circumferential direction U, which preferably only in certain situations, i.e., at certain relative positions of the pendulum weights 22 and/or pairs of pendulum weights 20 in reference to each other applies an essential spring force between the pendulum weights 22 and/or upon the pairs of pendulum weights 20 . In situations different therefrom and/or opposite positions of the pendulum weights 22 and/or pairs of pendulum weights 20 , the lamella spring element 42 is embodied elastically and/or soft and/or soft-springy (here see the following).
The equivalent applies preferably to all other pendulum weights 22 and/or pairs of pendulum weights 20 directly adjacent to each other in the circumferential direction U, so that an annular assembly develops of pendulum weights 22 and/or pairs of pendulum weights 20 , which are elastically connected and/or fixed to each other via spring elements 42 and/or lamella spring elements 42 in the circumferential direction U. According to the invention, between two pairs of pendulum weights 20 , directly adjacent in the circumferential direction U, only a single spring element 42 and/or labella spring element 42 can be provided on only one of the two axial sides of the pendulum weight carrier 10 between the (four) pendulum weights 22 , with only two pendulum weights 22 , adjacent in the circumferential direction U, are directly elastically connected via the spring element 42 and/or lamella spring element 42 . Of course it is also possible to provide spring elements 42 and/or lamella spring elements 42 at both axial sides of the pendulum weight carrier 10 , which is preferred. The latter is illustrated in the exemplary embodiments according to FIGS. 1 to 3 for the first embodiment and FIGS. 4 and 5 for the second embodiment (see below). The first and also the latter are shown in the drawing according to FIGS. 7 to 10 . Here, it is possible to provide the spring elements 42 and/or lamella spring elements 42 at opposite sides. Further, it is possible, instead of pairs of pendulum weights 20 , to provide only pendulum weights 22 on one axial side of the pendulum weight carrier 10 , which is also shown in FIGS. 7 to 10 . In the following essentially only one pendulum weight 22 and/or respective pendulum weights 22 are discussed, i.e., pendulum weights 22 directly adjacent in the circumferential direction U of the pendulum weight carrier 10 . However, the statements made in the following shall also apply equivalently to pairs of pendulum weights 20 and/or the remaining pendulum weights 22 and/or pairs of pendulum weights 20 , as well as the here presented embodiments of the invention.
An individual fastening range 422 of the lamella spring element 42 preferably comprises a flat flap, which particularly contacts flat at a radial side of a pendulum weight 22 and is fastened via a pin and/or a rivet at/in the pendulum weight 22 , with the pendulum weight 22 here preferably showing a fastening recess for this purpose (see FIGS. 8 and 10 ). Here, the pendulum weight 22 may show at the radial side a flat recess corresponding to the fastening section 422 , in which the fastening section 422 can be accepted such that it is aligned thereto at least with a radial area of the pendulum weight 22 (not shown in the drawing). For the assembly at the axially opposite pendulum weight 22 of a pair of pendulum weights 20 , the fastening section 422 (see FIGS. 2 and 3 ) opposite the first pendulum weight 22 may show a pin 423 , such as a rivet 423 or a spacer bolt 423 , which extends through the pendulum weight carrier 10 into a fastening recess in the axially adjacent pendulum weight 22 and is here fastened (see FIGS. 7 to 10 ). Further, the respective fastening section 422 of the axially adjacent lamella spring element 42 comprises for this purpose also preferably a penetrating recess, in which the pin 423 is also fixed. For the rest, this second lamella spring element 42 is designed like the first one. The same process is used for the other pendulum weight 22 directly adjacent in the circumferential direction U.
If pairs of pendulum weights 20 are used, it is preferred that the pin/pins 423 extending through the pendulum weight carrier 10 is/are not guided therein (see FIGS. 8 and 9 ). This means that the pendulum weight carrier 10 is recessed in this area such that the pin 423 in essentially all of its positions shows in later operation of the centrifugal pendulum device 1 no contacting impact with the pendulum weight carrier 10 . For this purpose the respective penetrating recess 123 in the pendulum weight carrier 10 shows, e.g., a respective clearance angle. The pin 423 shows only the pendulum weights 22 of a pair of pendulum weights 20 on an opposite axial distance. Further, it is preferred that the fastening section 422 encompasses the respective pendulum weights 22 at a radial end at the outside or inside, and for this purpose analogue to the above statements once more a recess may be provided in the respective pendulum weight 22 . Here, then the spring section 424 is mechanically connected in the circumferential direction U to the section of the lamella spring element 42 encompassing the radial end. Furthermore, the respective pendulum weights 22 may be embodied such that the lamella spring element 42 is provided radially outside (see FIG. 2 ) or radially inside (see FIG. 3 ) between the pendulum weights 22 .
The spring section 424 of the lamella spring elements 42 comprises at least one spring path in a spring, which provides a spring force between the respective pendulum weights 22 . This spring path may be a zigzag, a curved, or a triangular path; of course other forms are possible as well. Here, preferred is, e.g., at least a single zigzag or triangular path as shown in FIGS. 1 to 3 and in FIGS. 7 to 10 . This means the two fastening sections 422 of the lamella spring element 42 are radially fastened at the respective pendulum weight 22 at the same height, with the spring section 424 extending between these pendulum weights 22 in the radial direction R and in the circumferential direction U. As shown, e.g., in FIG. 2 , the spring section 424 extends, starting at a pendulum weight 22 , with one leg first in the radial direction R inwardly and approximately at half the distance between the respective pendulum weights 22 after a reversal point (bend, arch with small radius) in the radial direction R with another leg back outwardly. FIG. 3 shows an inverse example. Of course it is also possible to apply a plurality of such spring paths. A stiffness of the spring section 424 can perhaps be adjusted by a length, a quantity, and/or a material of said legs.
According to the invention the lamella spring element 42 may be designed such that at certain relative motions between the respective pendulum weights 22 it is embodied soft-springy, i.e., elastic, and at certain other relative motions between the respective pendulum weights 22 hard-springy, i.e., spring-like. The first (option) is preferred when the respective pendulum weights 22 are relatively far apart from each other in the circumferential direction U iii (see FIGS. 7 and 8 ). The latter e.g., when the respective pendulum weights 22 are arranged comparatively close together (see FIGS. 9 and 10 ). Thus, in the radial direction R the lamella spring element 42 is preferably essentially soft-springy and in particular essentially in the circumferential direction U, except for the spring section 424 , also preferably embodied soft-springy. Of course, the spring of the lamella spring element 42 is essentially embodied spring-like, thus hard-springy essentially in the circumferential direction U. In preferred exemplary embodiments at least one or a respective connection of the spring section 424 and/or the spring is embodied elastic at the respective fastening section 422 , i.e., soft-springy. This way, respective pendulum weights 22 can move in reference to each other over a wide range without this motion being significantly influenced by the lamella spring elements 42 . Only if the respective pendulum weights 22 come close to each other, which is the case, e.g., when one leg of the spring of the spring section 424 with its longitudinal extension contacts a face of a pendulum weight 22 in the circumferential direction U; only in such a case the lamella spring element 42 begins to apply a significant force between the two pendulum weights 22 . Further, it is preferred that the lamella spring element 42 is embodied hard-springy in the axial direction A, so that here collisions can be avoided between the pendulum weights 22 and the pendulum weight carrier 10 .
FIGS. 4 and 5 show the second embodiment of the first variant of the invention. This is designed analogue to the first embodiment, whereby in the spring section 424 of the lamella spring element 42 two springs are provided with one spring path each, opposite each other i.e., separated in the radial direction R. Further, the respective fastening range 422 for the respective pendulum weight 22 extends entirely along the radial direction R of the pendulum weight 22 and encompasses it preferably at both radial ends in the axial and the circumferential direction. The two separate springs of the spring section 424 then follow the encompassed sections of the fastening section 422 first in the circumferential direction U and then each approach in the direction of a radial center in the circumferential direction between the respective pendulum weights 22 . Before the separated springs contact, they extend each in an opposite direction and approach the respectively other fastening section 422 . Further, the features of the first embodiment can be applied to the second embodiment and vice versa. According to the invention, spring elements 42 can be applied, which are fastened radially inside at one pendulum weight 22 and radially outside at the respectively other one, with then the spring section 424 extending diagonally between these fastenings; here the connections of the spring section 424 to the fastenings are preferably embodied hard-springy (not shown in the drawing).
In order to guide the pendulum weights 22 at/in the pendulum weight carrier 10 , both the pendulum weight carrier 10 and the pendulum weights 22 preferably comprise oppositely curved guide paths 130 , 230 , in which guide elements 30 guide the pendulum weights 22 articulate at the pendulum weight carrier 10 depending on a rotation of the pendulum weight carrier 10 about a rotary axis S. According to the invention, in both embodiments of the first variant the guide paths 130 , 230 may be designed such that no hard impacts and/or shocks of the guide elements 30 at a respectively inner longitudinal end of the guide paths 130 , 230 occur in the pendulum weight carrier 10 and/or in the pendulum weight 20 . For this purpose, the guide paths 130 , 230 show a respective clearance angle and/or an expansion, which extends the guide path or paths 130 , 230 such that before a guide element 30 impacts at a longitudinal end of the respective guide path 130 , 230 respective pendulum weights 22 have approached each other maximally, as shown e.g., in FIGS. 9 and 10 , and preferably no other essentially impact-like displacement of the guide element 30 occurs in the guide path 130 , 230 . In a maximal deflection, the respective pendulum weights 22 laterally fold together in the circumferential direction U such that, except for the lamella spring element 42 , any further collision occurs between the pendulum weights 22 and not between a pendulum weight 22 , a respective guide element 30 , and/or the pendulum weight flange 10 . The guide element 30 may be embodied, e.g., as a rolling element 30 , a cylinder roll 30 , a glide element 30 , a rivet 30 , or a pin 30 .
According to a first variant of the invention, a centrifugal pendulum device 1 and/or a centrifugal pendulum is provided, with its pendulum weights 22 being mechanically coupled and/or connected to each other in an elastic fashion via spring elements 42 , particularly flat springs 42 , with the guide paths 130 , 230 for the guide elements 30 showing a clearance angle for the purpose of reducing noise and shock absorption in the pendulum carrier 10 and/or in the pendulum weights 20 , as well as penetrating recesses 123 in the pendulum weight carrier 10 for the pins 423 of the spring elements 42 .
In the first embodiment of the second variant of the invention (see FIGS. 11 to 16 ), the damper element 40 according to the invention for the centrifugal pendulum device 1 is embodied as a terminal 44 and/or an impact buffer 44 . Here, the terminal 44 preferably comprises a massive element, which is made particularly from a hard and/or a wear-resistant plastic, which is provided in the circumferential direction U of the pendulum weight carrier 10 between two directly adjacent pendulum weights 22 or pairs of pendulum weights 20 . The terminal 44 is here suspended in a guide path 130 of the pendulum weight carrier 10 , in which preferably also a pendulum weight 22 and/or a pair of pendulum weights 22 is guided. During operation of the centrifugal pendulum device 1 , the respective pendulum weight 22 or the respective pair of pendulum weights 20 can impact the terminal 44 . Preferably, in the guide path 130 directly neighboring each other, thus respective pendulum weights 22 or pairs of pendulum weights 20 are supported with the terminal 44 also being provided between these two in this guide path 130 . The terminal 44 is embodied such that in a simultaneous direct contacting of respective pendulum weights 22 or pairs of pendulum weights 20 they cannot directly collide with each other in the circumferential direction U. In the transitional phases of the centrifugal pendulum device 1 as well as in a maximum deflection (see FIG. 16 ) of the pendulum weights 22 or the pairs of pendulum weights 20 any collisions between them is effectively prevented. Similar to the statements made above, in the following once more only one axial side of the pendulum weight flange 10 is referenced, with these statements may also relate analogue to the second axial side.
The terminal 44 is embodied on an axial side of the pendulum weight carrier 10 as an oblong body, which is preferably rounded at the longitudinal end sections. Here, a radially exterior longitudinal end section can be embodied widened in the circumferential direction U. A cross-section of this body is designed in a central section preferably essentially square or rectangular, with the two impact sides located in the circumferential direction U, which the pendulum weights 22 can impact, being preferably located essentially parallel in reference to each other. They may also include a small angle, which is equivalent to the one assumed by the faces of the respective pendulum weights 22 in a mutual contact. The terminal 44 is suspended with a cylinder section, projecting from the body essentially at a right angle, in the guide path 130 , with, at the axial side of the pendulum weight carrier 10 opposite the first oblong body preferably a second essentially identical oblong body follows, which is also provided at the cylinder section. Here, the cylinder section is arranged off-set in reference to a longitudinal end of an terminal 44 , so that a longer section extends radially inwardly at the pendulum weight carrier 10 (see FIGS. 14 and 15 ), however it may of course also be embodied such that the cylinder section is arranged centrally or adjacent to the other longitudinal end of the terminal 44 .
In preferred embodiments of the invention, the terminal 44 is configured such that its largest radial cross-section can be included in a cross-section of the guide path 130 , which is illustrated in FIG. 13 . This way, the terminal 44 can easily be suspended in the guide path 130 . In a temporal succession thereto the pendulum weights 22 are provided, which constrict in all positions of the centrifugal pendulum device 1 the remaining space for the terminal 44 such that it cannot be falling out of the guide path 130 . In a side view of the terminal 44 according to the invention for pairs of pendulum weights 20 , it essentially shows the form ‘H’, with a bar being arranged between the two legs of the ‘H’ offset towards a center of the legs (see FIG. 12 ). Within the guide path 130 the respective terminal 44 can move oscillating along the guide path 130 .
In the second embodiment of the second variant of the invention (see FIGS. 17 to 21 ) the damper element 40 according to the invention is realized for the centrifugal pendulum device 1 as a spring terminal 44 . Here, once more a single body can be used for the respective pendulum weight 22 or two bodies for pairs of pendulum weights 20 can be used analogue to the statements above. In the latter case, two bodies and/or halves ( FIGS. 19 to 22 ) preferably formed from a spring steel, e.g., by way of riveting with a spacer rivet, are fastened together to form a unit. Here, a body shows preferably spring devices 444 on both sides in the circumferential direction U, so that collisions can be prevented between respective pendulum weights 22 . The spring devices 444 are located laterally at a basic body 442 of the spring terminal 44 parallel in reference to the radial side of the pendulum weight carrier 10 , with the spring devices 444 at both circumferential sides being bent away at a right angle. Here, the flat sides of the spring devices 444 extend in the radial direction R (and/or the) axial direction A. An individual spring device 444 is particularly embodied at least as a spring arm 444 or a spring bar 444 , which can be supported at a flap projecting essentially perpendicular from the basic body 442 . Here, a spring device 444 may be embodied as a one-stage ( FIGS. 17 and 19 ) or a multi-stage flat spring ( FIGS. 18, 20 and 21 ).
According to the invention, in the two embodiments of the second variant, the guide paths 130 , 230 may be embodied such that no hard collisions and/or contacts occur of the guide element 30 at a respectively inner longitudinal end of the guide paths 130 , 230 in the pendulum weight carrier 10 and/or in the pendulum weight 20 . For this purpose, the guide paths 130 , 230 show a respective clearance angle and/or an expansion, which extends the guide path or paths 130 , 230 such that before a guide element 30 impacts a longitudinal end of the respective guide path 130 , 230 respective pendulum weights 22 , as shown in FIG. 16 , have maximally approached each other and no additional impact-like displacement of the guide element 30 occurs in the guide path 130 , 230 . In a maximal deflection, e.g., in a run under load, the pendulum weights 22 laterally fold together so that further the collision of the pendulum weights 22 occurs at both sides of the respective terminal 44 and not between a respective pendulum weight 22 , a respective guide element 30 , and/or the pendulum weight flange 10 .
According to the second variant of the invention, a centrifugal pendulum device 1 and/or a centrifugal pendulum is provided, whereby their pendulum weights 22 can be supported via terminal 44 against each other and/or the guide paths 130 , 230 each show a clearance angle for the purpose of noise reduction and shock absorption for the guide elements 30 in the pendulum weight carrier 10 and in the pendulum weights 20 .
REFERENCE VARIABLES
1 Centrifugal pendulum device, particularly trapeze centrifugal pendulum device; device for a rotationally adaptive vibration damping
10 Pendulum weight carrier, pendulum flange
20 Pair of pendulum weights, pair of compensation weights, pair of inertia weights
22 Individual pendulum weight, individual compensation weight, individual inertia weight
30 Guide element, particularly roller element, cylinder roll, gliding element, rivet, pin
40 Damper element, shock absorber
42 Spring element, pressure spring element, lamella spring (element), strip spring (element)
44 Terminal, Impact buffer, particularly massive element (plastic) or spring terminal (metal and/or metal alloy)
123 Penetrating recess for pin 123 of the fastening section 422
130 Guide path for guide element 30 and perhaps terminal 44 at the pendulum weight carrier 10
230 Guide path for guide element 30 in the pendulum weight 20
422 Fastening section
423 Pin, rivet, spacer rivet, spacer bolt
424 Spring section
442 Basic body
444 Spring device, particularly spring arm, spring bar
A Axial direction of the centrifugal pendulum device 1 , the pendulum weight carrier 10 , the pair of pendulum weights 29 , etc.
R Radial direction of the centrifugal pendulum device 1 , the pendulum weight carrier 10 , the pair of pendulum weights 20 , etc.
S Rotary axis of the centrifugal pendulum device 1
U Circumferential direction of the centrifugal pendulum device 1 , the pendulum weight carrier 10 , the pair of pendulum weights 20 , etc. | A centrifugal pendulum mechanism, in particular a trapezoidal centrifugal pendulum mechanism, for a damping device and/or a torque transmission device, in particular for a drive train of a motor vehicle, comprising a pendulum mass carrier, which can be rotated about a rotational axis (S) and on which a plurality of pendulum masses or pendulum mass pairs that can be moved relative to the pendulum mass carrier are provided in the circumferential direction, wherein two pendulum masses or pendulum mass pairs directly adjacent in the circumferential direction of the pendulum mass carrier are or can be mechanically coupled to each other by means of a damping element. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/305,820, filed on Dec. 15, 2005; which is a continuation-in-part of U.S. patent application Ser. No. 11/190,496, filed on Jul. 26, 2005; which is a continuation-in-part of U.S. patent application Ser. No. 11/079,006, filed on Mar. 10, 2005; which is a continuation-in-part of U.S. patent application Ser. No. 11/052,002 filed on Feb. 4, 2005; which is a continuation-in-part of U.S. patent application Ser. No. 11/006,502 filed on Dec. 6, 2004; which is a continuation-in-part of U.S. patent application Ser. No. 10/970,843 filed on Oct. 20, 2004; all of the above are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention is directed towards the treatment of spinal disorders and pain. More particularly, the present invention is directed to systems and methods of treating the spine, which eliminate pain and enable spinal motion, which effectively mimics that of a normally functioning spine.
BACKGROUND OF THE INVENTION
FIG. 1 illustrates a portion of the human spine having a superior vertebra 2 and an inferior vertebra 4 , with an intervertebral disc 6 located in between the two vertebral bodies. The superior vertebra 2 has superior facet joints 8 a and 8 b , inferior facet joints 13 a and 13 b , and spinous process 25 . Pedicles 3 a and 3 b interconnect the respective superior facet joints 8 a , 8 b to the vertebral body 2 . Extending laterally from superior facet joints 8 a , 8 b are transverse processes 7 a and 7 b , respectively. Extending between each inferior facet joints 13 a and 13 b and the spinous process 25 are laminal zones 5 a and 5 b , respectively. Similarly, inferior vertebra 4 has superior facet joints 15 a and 15 b , superior pedicles 9 a and 9 b , transverse processes 17 a and 17 b , inferior facet joints 19 a and 19 b , laminal zones 21 a and 21 b , and spinous process 27 .
The superior vertebra with its inferior facets, the inferior vertebra with its superior facet joints, the intervertebral disc, and seven spinal ligaments (not shown) extending between the superior and inferior vertebrae together comprise a spinal motion segment or functional spine unit. Each spinal motion segment enables motion along three orthogonal axes, both in rotation and in translation. The various spinal motions are illustrated in FIGS. 2A-2C . In particular, FIG. 2A illustrates flexion and extension motions and axial loading, FIG. 2B illustrates lateral bending motion and FIG. 2C illustrated axial rotational motion. A normally functioning spinal motion segment provides physiological limits and stiffness in each rotational and translational direction to create a stable and strong column structure to support physiological loads.
Traumatic, inflammatory, metabolic, synovial, neoplastic and degenerative disorders of the spine can produce debilitating pain that can affect a spinal motion segment's ability to properly function. The specific location or source of spinal pain is most often an affected intervertebral disc or facet joint. Often, a disorder in one location or spinal component can lead to eventual deterioration or disorder, and ultimately, pain in the other.
Spine fusion (arthrodesis) is a procedure in which two or more adjacent vertebral bodies are fused together. It is one of the most common approaches to alleviating various types of spinal pain, particularly pain associated with one or more affected intervertebral discs. While spine fusion generally helps to eliminate certain types of pain, it has been shown to decrease function by limiting the range of motion for patients in flexion, extension, rotation and lateral bending. Furthermore, the fusion creates increased stresses on adjacent non-fused motion segments and accelerated degeneration of the motion segments. Additionally, pseudarthrosis (resulting from an incomplete or ineffective fusion) may not provide the expected pain-relief for the patient. Also, the device(s) used for fusion, whether artificial or biological, may migrate out of the fusion site creating significant new problems for the patient.
Various technologies and approaches have been developed to treat spinal pain without fusion in order to maintain or recreate the natural biomechanics of the spine. To this end, significant efforts are being made in the use of implantable artificial intervertebral discs. Artificial discs are intended to restore articulation between vertebral bodies so as to recreate the full range of motion normally allowed by the elastic properties of the natural disc. Unfortunately, the currently available artificial discs do not adequately address all of the mechanics of motion for the spinal column.
It has been found that the facet joints can also be a significant source of spinal disorders and debilitating pain. For example, a patient may suffer from arthritic facet joints, severe facet joint tropism, otherwise deformed facet joints, facet joint injuries, etc. These disorders lead to spinal stenosis, degenerative spondylolithesis, and/or isthmic spondylotlisthesis, pinching the nerves that extend between the affected vertebrae.
Current interventions for the treatment of facet joint disorders have not been found to provide completely successful results. Facetectomy (removal of the facet joints) may provide some pain relief; but as the facet joints help to support axial, torsional, and shear loads that act on the spinal column in addition to providing a sliding articulation and mechanism for load transmission, their removal inhibits natural spinal function. Laminectomy (removal of the lamina, including the spinal arch and the spinous process) may also provide pain relief associated with facet joint disorders; however, the spine is made less stable and subject to hypermobility. Problems with the facet joints can also complicate treatments associated with other portions of the spine. In fact, contraindications for disc replacement include arthritic facet joints, absent facet joints, severe facet joint tropism, or otherwise deformed facet joints due to the inability of the artificial disc (when used with compromised or missing facet joints) to properly restore the natural biomechanics of the spinal motion segment.
While various attempts have been made at facet joint replacement, they have been inadequate. This is due to the fact that prosthetic facet joints preserve existing bony structures and therefore do not address pathologies that affect facet joints themselves. Certain facet joint prostheses, such as those disclosed in U.S. Pat. No. 6,132,464, are intended to be supported on the lamina or the posterior arch. As the lamina is a very complex and highly variable anatomical structure, it is very difficult to design a prosthesis that provides reproducible positioning against the lamina to correctly locate the prosthetic facet joints. In addition, when facet joint replacement involves complete removal and replacement of the natural facet joint, as disclosed in U.S. Pat. No. 6,579,319, the prosthesis is unlikely to endure the loads and cycling experienced by the vertebra. Thus, the facet joint replacement may be subject to long-term displacement. Furthermore, when facet joint disorders are accompanied by disease or trauma to other structures of a vertebra (such as the lamina, spinous process, and/or transverse processes) facet joint replacement is insufficient to treat the problem(s).
Most recently, surgical-based technologies, referred to as “dynamic posterior stabilization,” have been developed to address spinal pain resulting from more than one disorder, when more than one structure of the spine have been compromised. An objective of such technologies is to provide the support of fusion-based implants while maximizing the natural biomechanics of the spine. Dynamic posterior stabilization systems typically fall into one of two general categories: posterior pedicle screw-based systems and interspinous spacers.
Examples of pedicle screw-based systems are disclosed in U.S. Pat. Nos. 5,015,247, 5,484,437, 5,489,308, 5,609,636 and 5,658,337, 5,741,253, 6,080,155, 6,096,038, 6,264,656 and 6,270,498. These types of systems involve the use of screws that are positioned in the vertebral body through the pedicle. Certain types of these pedicle screw-based systems may be used to augment compromised facet joints, while others require removal of the spinous process and/or the facet joints for implantation. One such system, the Zimmer Spine Dynesys® employs a cord which is extended between the pedicle screws and a fairly rigid spacer which is passed over the cord and positioned between the screws. While this system is able to provide load sharing and restoration of disc height, because it is so rigid, it does not effective in preserving the natural motion of the spinal segment into which it is implanted. Other pedicle screw-based systems employ articulating joints between the pedicle screws. Because these types of systems require the use of pedicle screws, implantation of the systems are often more invasive to implant than interspinous spacers.
Where the level of disability or pain to the affected spinal motion segments is not that severe or where the condition, such as an injury, is not chronic, the use of interspinous spacers are preferred over pedicle based systems as they require a less invasive implantation approach and less dissection of the surrounding tissue and ligaments. Examples of interspinous spacers are disclosed in U.S. Pat. Nos. Re. 36,211, 5,645,599, 6,149,642, 6,500,178, 6,695,842, 6,716,245 and 6,761,720. The spacers, which are made of either a hard or compliant material, are placed in between adjacent spinous processes. The harder material spacers are fixed in place by means of the opposing force caused by distracting the affected spinal segment and/or by use of keels or screws that anchor into the spinous process. While slightly less invasive than the procedures required for implanting a pedicle screw-based dynamic stabilization system, implantation of hard or solid interspinous spacers still requires dissection of muscle tissue and of the supraspinous and interspinous ligaments. Additionally, these tend to facilitate spinal motion that is less analogous to the natural spinal motion than do the more compliant and flexible interspinous spacers. Another advantage of the compliant/flexible interspinous spacers is the ability to deliver them somewhat less invasively than those that are not compliant or flexible; however, their compliancy makes them more susceptible to displacement or migration over time. To obviate this risk, many of these spacers employ straps or the like that are wrapped around the spinous processes of the vertebrae above and below the level where the spacer is implanted. Of course, this requires some additional tissue and ligament dissection superior and inferior to the implant site, i.e., at least within the adjacent interspinous spaces.
With the limitations of current spine stabilization technologies, there is clearly a need for an improved means and method for dynamic posterior stabilization of the spine that address the drawbacks of prior devices. In particular, it would be highly beneficial to have a dynamic stabilization system that involves a minimally invasive implantation procedure, where the extent of distraction between the affected vertebrae is adjustable upon implantation and at a later time if necessary. It would be additionally advantageous if the system or device was also removable in a minimally invasive manner.
SUMMARY OF THE INVENTION
The present invention provides devices, systems and methods for stabilizing at least one spinal motion segment. The stabilizing devices include an expandable spacer or member having an unexpanded configuration and an expanded configuration, wherein the expandable member in an expanded configuration has a size, volume, diameter, length, cross-section and/or shape configured for positioning between the spinous processes of adjacent vertebrae in order to distract the vertebrae relative to each other.
In certain embodiments, the expandable member is a helical body having a varying cross-section along its longitudinal axis, such that compression, squeezing, or other longitudinal translation of the helical body causes the helical body to expand in at least one direction. When placed between two spinous processes, the expansion allows support and stabilization of the processes relative to each other.
The stabilizing devices may be configured such that the transformation from the low-profile state to the high-profile state is immediate or gradual, where the extent of expansion is controllable. The transformation may occur in one-step or evolve in continuous fashion where at least one of volume, shape, size, diameter, length, etc. is continually changing until the desired expansion end point is achieved. This transformation may be reversible such that after implantation, the stabilizing device may be partially or completely unexpanded, collapsed, deflated or at least reduced in size, volume, etc. in order to facilitate removal of the member from the implant site or to facilitate adjustment or repositioning of the member in vivo.
The stabilizing devices may be configured to stay stationary in the implant site on their own (or “float”) or may be further fixed or anchored to surrounding tissue, e.g., bone (e.g., spinous processes, vertebrae), muscle, ligaments or other soft tissue, to ensure against migration of the implant. In their final deployed state, the stabilizing devices may be flexible to allow some degree of extension of the spine or may otherwise be rigid so as prevent extension altogether. Optionally, the devices may include one or more markers on a surface of the expandable member to facilitate fluoroscopic imaging.
The invention further includes methods for stabilizing at least one spinal motion segment which involve the implantation of one or more devices or expandable spacers of the present invention, in which the expandable member is positioned between the spinous processes of adjacent vertebrae in an unexpanded or undeployed condition and then subsequently expanded or deployed to a size and/or shape for selectively distracting the adjacent vertebrae. The invention also contemplates the temporary implantation of the subject devices which may be subsequently removed from the patient once the intended treatment is complete. The methods may also include adjustment of the implants in vivo.
Many of the methods involve the percutaneous implantation of the subject devices from either an ipsolateral approach or a mid-line approach into the interspinous space. Certain methods involve the delivery of certain components by a lateral approach and other components by a mid-line approach. The implantation methods may involve the use of cannulas through which the stabilizing devices are delivered into an implant site, however, such may not be required, with the stabilizing devices be configured to pass directly through an incision.
These and other objects, advantages, and features of the invention will become apparent to those persons skilled in the art upon reading the details of the invention as more fully described below.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:
FIG. 1 illustrates a perspective view of a portion of the human spine having two vertebral segments.
FIGS. 2A , 2 B and 2 C illustrate left side, dorsal and top views, respectively, of the spinal segments of FIG. 1A under going various motions.
FIG. 3A illustrates a side view of a spacer device according to an embodiment of the present invention in an unexpanded or collapsed state coupled to a cannula of the delivery system of the present invention.
FIG. 3B is a cross-sectional view of a spacer device consistent with FIG. 3A .
FIG. 3C is a cross-sectional view of the spacer device of FIG. 3A in an expanded configuration.
FIG. 3D is a detailed view of the cross-section of an spacer device consistent with FIG. 3A , having oppositely-angled helical turns compared to the embodiment of FIG. 3C , also shown in an expanded configuration, showing the varying cross-section of the continuous helical segment.
FIG. 3E is a more detailed view of certain of the varying cross-sections of the helical segment.
FIG. 3F is a side view illustrating the longitudinal and rotational movements employed in deploying certain embodiments of the invention.
FIG. 4 is a cross-sectional view of a spacer device according to an embodiment of the present invention employing a threaded screw to deploy the device.
FIG. 5 is a cross-sectional view of a spacer device according to an embodiment of the present invention employing a ratchet to deploy the device.
FIG. 6 is a cross-sectional view of a spacer device according to an embodiment of the present invention employing a groove to engage a segment of the vertebrae.
FIGS. 7(A) and (B) illustrate stages of deployment of a spacer device according to an embodiment of the present invention employing cooperating segments.
FIG. 8 shows a spacer device according to an embodiment of the present invention employing a drive module.
FIG. 9 shows a portion of a spacer device employing a generic set of elements that move radially upon application of a force along an axis.
DETAILED DESCRIPTION OF THE INVENTION
Before the subject devices, systems and methods are described, it is to be understood that this invention is not limited to particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Unless defined otherwise, 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.
It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a spinal segment” may include a plurality of such spinal segments and reference to “the screw” includes reference to one or more screw and equivalents thereof known to those skilled in the art, and so forth.
Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.
The present invention will now be described in greater detail by way of the following description of exemplary embodiments and variations of the devices and methods of the present invention. The invention generally includes an interspinous spacer device as well as instruments for the percutaneous implantation of the interspinous spacer. A key feature of the interspinous spacer device is that it is expandable from a low profile configuration to a higher profile or operative configuration. This design allows the device, when in the low profile condition, to be delivered by percutaneous means without requiring the removal of any portion of the spinal motion segment into which the device is implanted.
Referring now to the drawings and to FIGS. 3A-F in particular, an exemplary interspinous spacer device 10 of the present invention is illustrated in collapsed and expanded configurations, respectively. Interspinous device 10 includes an expandable spacer body 14 that has a size and shape when in the expanded condition for operative positioning between the spinous processes of adjacent superior and inferior vertebrae of the spinal motion segment being treated. It should be noted that embodiments of the current invention may be employed, e.g., as spacers, void creators, etc., and may be particularly useful between the interspinous processes or in other sections of the spine. However, other embodiments may be employed in any other location where a void is desired to be created or filled.
The interspinous device 10 includes a distal end 11 and a proximal end (not shown). At the distal end 11 is disposed a tip 12 , which may be made of a biocompatible material such as polymers, metals, nitinol, etc. The expandable member 14 has a distal end 22 and a proximal end 18 , with the distal end 22 adjacent the tip 12 and the proximal end 18 adjacent a delivery shaft 16 . Interior of the delivery shaft 16 and the expandable member 14 , and coupled to tip 12 , is a central shaft 24 .
The expandable spacer body 14 is generally formed by a helical body having a cross-sectional shape that varies along at least a portion of a longitudinal axis such that longitudinal translation of the proximal end 18 towards the distal end 22 , or vice-versa or both, effectively squeezing the expandable spacer body 14 in a longitudinal fashion, causes portions of the expandable spacer body 14 to expand to provide a spacer support between the spinous processes. In particular, various portions of the expandable spacer body 14 expand in a radial dimension from a value r 0 to a value r>r 0 , up to a maximum value of r max . In certain embodiments, the axial dimension of the expandable spacer body in the undeployed configuration is greater than that in the deployed configuration.
The distal end 22 of the expandable spacer body may be affixed to the tip 12 and to the central shaft 24 such that a sliding longitudinal translation of the proximal end 18 over the central shaft leads to expansion. Various other combinations of affixations and sliding members may also be employed. In general, the longitudinal translation over a distance x leads to expansion of the expandable spacer body 14 .
The expandable spacer body 14 is made of a biocompatible material such as a non-porous material, e.g., nitinol, polymers, or titanium. The shaft 16 may be made of various biocompatible materials, including titanium, stainless steel, etc. The spacer body and/or the shaft may be coated with a lubricious coating or other such treatment to facilitate sliding. These may include, e.g., Teflon®, silicone, surface energy treatments, etc.
As noted above, translation of the proximal and distal ends towards each other leads to radial expansion of portions of the expandable spacer body 14 . In more detail, the expandable spacer body 14 is formed of a helical body. The cross-section of the helical body changes to cause the expansion upon longitudinal translation. Referring in particular to FIGS. 3B-3E , cross-sections of various helical segments 14 a , 14 b , 14 c , . . . , 14 max, . . . , 14 n are shown for a helical body having n turns.
Of course, it is noted that these elements reflect cross-sections that in an actual device may be continuously changing along the helix. For clarity, these two-dimensional cross-sections are discussed here, with the understanding that they refer to a three-dimensional helical structure that may be continuously changing in cross-section. For example, portions of the helical body between segments 14 b and 14 c emerge above the plane of the page and descend below the plane of the page. These portions may have cross-sectional shapes that are the same as or different than that of segments 14 b and 14 c . In general, they may be close to the same, and may be shaped in a fashion intermediate to that of 14 b and 14 c.
In an unexpanded configuration, all segments 14 a - 14 n may have substantially the same radius r 0 . In an expanded configuration, as shown in FIGS. 3B and 3C , the radius generally varies from r 0 to an r>r 0 to r max back to r>r 0 and finally back to r 0 . The segment at r max is denoted 14 max. The variation of r with respect to the longitudinal translation x depends on the way the cross-sections of 14 a - n vary. As may be seen, the cross-sections of 14 a - n may vary not haphazardly but in a regular fashion. Certain typical segment cross-sections may be seen in FIG. 3E .
While the general system of variation of cross-sections depends on the usage and geometry of the desired spacer, some general rules may apply in certain embodiments, but it should be especially noted that these do not apply to all systems. First, 14 i may be closer or more similar in shape to 14 j than the same is to 14 a or 14 n . Next, if 14 a has a distal edge that is at an angle θ a1 and a proximal edge that is at an angle θ a2 , then θ a1 and θ n2 may be equal to zero. If θ b1 up to θ max1 , i.e., angles distal of segment 14 max, are considered to have a positive value of angle, then θ max2 up up to θ n1 , i.e., angles proximal to segment 14 max, may be considered to have a negative value of angle. For the segment with the maximal radial dimension, 14 max, its distal edge may have an angle with opposite sign to that of its proximal edge. It is noted again that these are general statements that hold for certain embodiments but do not hold for others.
It is additionally noted that the embodiment of FIGS. 3B and 3C differs from that of FIG. 3D , in that the angles of the segments are the opposite. While the embodiment of FIG. 3D may be easier to implement, either system may be employed.
Referring to FIG. 3F , the way in which the longitudinal translation A may occur can vary. In one embodiment, the device may be inserted between the spinous processes in a manner disclosed in, e.g., U.S. patent application Ser. No. 11/190,496, filed Jul. 26, 2005, entitled “SYSTEMS AND METHODS FOR POSTERIOR DYNAMIC STABILIZATION OF THE SPINE”, which is incorporated by reference herein in its entirety. One or both of the central shaft 24 or the delivery shaft 16 may be rotated as shown by B to cause the relative motion of the distal end and the proximal end towards each other via a screw, ratchet, or thread arrangement. In general, any deployment arrangement may be employed that causes the relative movement of the distal and proximal ends towards each other. Further details of deployment, arrangements that may be used with embodiments of the current invention are described in the patent application just incorporated by reference above.
As one example, referring to FIG. 4 , a method and device for causing translation of the proximal and/or distal ends of the spacer body 50 is shown as employing a threaded shaft assembly 34 having a distal end 28 which is fixed to the distal tip of the device, a proximal end 32 , a threaded section 24 , and a non-threaded section 22 . The threaded shaft assembly may be part of the implanted device or may be removable. In the case of a removable threaded shaft assembly, the assembly 34 is in two parts or is otherwise detachable, e.g., at release element 23 . Release element 23 may employ a magnet to releasably hold the two segments together, a fusible link, a “pull-out” or threaded shaft, and so on.
A fixed segment or threaded module 26 is provided which the threaded segment may be rotated against to, e.g., pull the distal tip toward the proximal end to deploy the spacer. In an alternative embodiment, a balloon or other such expandable member within the device may be employed to expand the same in the absence of a compressional force. A “filler” material can be disposed within the helical spacer body to maintain the expansion. This may include compressible materials such as elastomers or uncompressible materials such as cements. A locking mechanism may be similarly employed, and the locking may be permanent or reversible. In a related embodiment, the locking may allow a limited range of translation, including translation after the device is implanted, to accommodate movement, loads, etc.
The device may be afforded a capability to reposition the same following implantation, and this reposition may be done in a minimally-invasive manner. For example, a tool may be percutaneously placed to engage the compression assembly, e.g., to turn the screw, or to provide additional compression or tension which corresponds to additional radial expansion or contraction.
In an alternative embodiment, as shown in FIG. 5 , a ratchet assembly 100 is shown with an expandable body 14 , a distal ratchet shaft 122 with a proximal catch 125 , a one-way ratchet 126 , a proximal ratchet lumen 134 , and a deployment pull string 136 . In use, by pulling pull string 136 , catch 126 moves in a one-way manner into ratchet 126 , compressing body 14 and expanding the spacer body 14 . A release mechanism as described can be employed to detach the spacer body from the deployment device.
Referring to FIG. 6 , for any of the embodiments, the spacer body 14 may include a void or recess 20 which may be employed to capture or engage a vertebral segment such as an interspinous process.
Referring to FIG. 7 , the spacer segments 14 i may be provided with tracks, tongues, or grooves, etc., between the translating elements to facilitate sliding, limit travel, prevent undesired rotation, torquing, stabilize the elements, force directionality of motion, etc. In FIG. 7 , the same are shown as projections 14 i ′ on each side of segment 14 i . Segment 14 i is intended to generally refer to a generic segment. In FIG. 7 , only segments 14 a - 14 d and 14 max are shown. FIG. 7(A) shows an undeployed configuration, and FIG. 7(B) shows a deployed configuration.
FIG. 8 shows a perspective cross-sectional segment of an alternative embodiment of a spacer body according to the principles of the invention. Similar elements have similar reference numerals as the figures above, and are not described again. The embodiment of FIG. 8 further includes a covering 138 and a drive module 146 . The covering 138 may be, e.g., a mesh bag, a balloon, etc. The drive module 146 is shown coupled to rods 142 and 144 , and allow deployment of the device in an automatic fashion. The drive module may include a power supply such as an integral battery, may be controlled wirelessly, and may have one or two (as shown) motorized lead screws. One rod 144 may be coupled to distal end 154 , and the other rod 142 may be coupled to proximal end 148 . Alternatively, proximal end 152 and distal end 156 may be employed.
It should be noted that while a helical body is shown, the same is not required in certain embodiments of the invention. For example, as shown in FIG. 9 , any system with two or more elements 14 i , 14 j , may be employed, where compression causes one element or both to move radially away from a central axis 158 . In this system, the first element has a first surface that mates with a second surface of a second element, and the mating surfaces lie at an angle not equal to 90 degrees from the central axis 158 . The compressive force exerted between the first and second elements, acting along axis 158 , causes either or both to move radially away from the central axis.
In certain embodiments, the expandable body is made of a non-compliant or semi-compliant material so as to maintain a substantially fixed shape or configuration and ensure proper, long-term retention within the implant site. In other embodiments, the expandable member may be made of a compliant material. In any embodiment, the compressibility and flexibility of can be selected to address the indications being treated.
In certain embodiments of present invention, either during the implant procedure or in a subsequent procedure, the size or volume of the implanted expandable spacer may be selectively adjusted or varied. For example, after an initial assessment upon implant, it may be necessary to adjust, either reduce or increase, the size or volume of the spacer to optimize the intended treatment. Further, it may be intended to only temporarily implant the spacer for the purpose of treating a temporary condition, e.g., an injured or bulging or herniated disk. Once the repair is achieved or the treatment completed, the spacer may be removed, either with or without substantially reducing the size or volume of the spacer. In other embodiments, the spacer may be made of biodegradable materials wherein the spacer degrades after a time in which the injury is healed or the treatment completed.
When unexpanded or deflated, as shown in FIGS. 3A and 3B , the expandable spacer body 14 has a low profile, such as a narrow, cylindrical, elongated shape, to be easily translated through a delivery cannula.
The device may further include radiopaque markers on the surface of the expandable body 14 visible under fluoroscopic imaging to facilitate positioning of the expandable body. Any number of markers may be employed anywhere on the expandable body 14 , or the helical body itself may be radiopaque. Other markers may also be employed, including ultrasound markers. Any of the markers described, or other such markers, may be employed to determine the level of deployment or the sufficiency of deployment. For example, two markers may be disposed on the device such that if the markers are seen to be in a particular alignment, the device is considered to be fully deployed. One of ordinary skill in the art given this teaching will see numerous other ways in which the use of markers can provide significant information about the position, orientation, and deployment of the device.
Once installed, the interspinous device may be further secured to the spinous processes 18 , 22 to ensure that the expandable body does not slip or migrate from its implanted position. Any type of anchoring means, such as screws, tacks, staples, adhesive, etc. may be employed. The delivery shaft 16 may be removed from the expandable spacer body 14 using devices and techniques disclosed in the patent application incorporated by reference above.
The subject devices and systems may be provided in the form of a kit which includes at least one interspinous device of the present invention. A plurality of such devices may be provided where the devices have the same or varying sizes and shapes and are made of the same or varying biocompatible materials. Possible biocompatible materials include polymers, plastics, ceramic, metals, e.g., titanium, stainless steel, tantalum, chrome cobalt alloys, etc. The kits may further include instruments and tools for implanting the subject devices, including but not limited to, a cannula, a trocar, a scope, a device delivery/inflation/expansion lumen, a cutting instrument, a screw driver, etc., as well as a selection of screws or other devices for anchoring the spacer to the spinous processes. Instructions for implanting the interspinous spacers and using the above-described instrumentation may also be provided with the kits.
The preceding merely illustrates the principles of the invention. It will be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents and equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure. The scope of the present invention, therefore, is not intended to be limited to the exemplary embodiments shown and described herein. Rather, the scope and spirit of present invention is embodied by the appended claims. | Devices, systems and methods for dynamically stabilizing the spine are provided. The devices include an expandable spacer having an undeployed configuration and a deployed configuration. The spacer has axial and radial dimensions for positioning between the spinous processes of adjacent vertebrae. The systems include one or more spacers and a mechanical actuation device for delivering and deploying the spacer. The methods involve the implantation of one or more spacers within the interspinous space. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to a computing system and method. Specifically, the present invention relates to a cipher system and method for encrypting and decrypting computer information.
BACKGROUND OF THE INVENTION
A common method of encrypting a plaintext message starts by substituting integers for plaintext characters according to some standard alphabet such as ITA2, ITA5, ASCII, or EBCDIC. These integers are then written in binary form to create a first string, or sequence, of 0's and 1's. To the first string is modulo 2-added another, second sequence of 0's and 1's to produce still a third sequence of 0's and 1's. The third sequence of 0's and 1's is transmitted as the encrypted message. The sender's object if to make this third string of 0's and 1's appear to be a random sequence of digits in binary form the intended receiver modulo 2-adds the second sequence to the third sequence to recover the first sequence. Thereafter, the original plaintext message is derived from the standard alphabet that was used, e.g., ITA2, ITA5, ASCII, or EBCDIC. If the second sequence is truly random, an interceptor-attacker will be unable to reproduce the first sequence. Thus, the plaintext message is preserved.
There are a number of problems with this scheme: First, random number strings are a relatively scarce commodity. Second, the receiver must have at hand exactly the same random number sequence the sender used or must be able to reproduce it. Having at hand exactly the same random number sequence the sender used requires the sharing of an enormous amount of key material. The sharing of an enormous amount of key material is impractical. Reproducing exactly the same random number sequence the sender used is impossible.
To avoid these two difficulties, a pseudo-random number generator is commonly employed by both sender and receiver. A pseudo-random number generator is a deterministic machine which, when initialized by a "seed" number, produces a string of digits which appears to be random (by passing various statistical tests). The output of a pseudo-random number generator is periodic, but the period can be made very long. When sender and receiver use pseudo-random number generators to produce the second, key, or encrypting sequence, they start with a common initializing "seed" and synchronize the outputs of their generators. Starting with a common initializing "seed" and synchronizing the outputs of the generators allows a known-plaintext attack in which an interceptor-attacker gains access to plaintext (hence to its binary digit string equivalent in terms of some standard numerical alphabet) and to the corresponding ciphertext. Knowing the digits of the binary plaintext string enables the attacker to reproduce the corresponding pseudo-random number sequence. This frequently allows the attacker to determine the algorithm, initializing "seed," and output sequence of the system's pseudo-random number generator, thus "breaking" the code.
Gaining access to plaintext and to the corresponding ciphertext as described above, with its defects, is the intended use of the pseudo-random number generator described in U.S. Pat. No. 2,949,501. U.S. Pat. No. 3,911,216 reveals a well known non-linear shift register for the same purpose. Further, U.S. Pat. No. 4,202,051 describes linear shift register used with a non-linear function to generate a pseudo-random second sequence for use in the encrypting process as previously described.
U.S. Pat. No. 4,341,925 describes an encryption process in which the signals of two pseudo-random number generators are modulo 2-added, and then the resultant sum is modulo 2-added to a binary digitalized plaintext stream prior to transmission. One of the two original pseudo-random number sequences is multiplexed with the encrypted data stream and transmitted as a synchronizing signal. Modulo 2-adding the two pseudo-random sequences increases the period of the resultant sequence, and provision is made for sender-receiver synchronized changes in the two component streams sufficiently often to avoid revealing the period of their combined output. Since this is just an enhanced pseudo-random-number stream-modulo 2-added-to-the-plaintext scheme, it will be evident that it does not bear on the present invention.
U.S. Pat. No. 4,369,434 pertains to modification of existing proprietary encryption machines which require a secret primary code known to both sender and receiver, a transmitted synchronizing signal and a randomly generated auxiliary code which is transmitted in clear. The choice of initializing secret primary code is randomly made and its address, in a memory commonly held by sender and receiver, is transmitted in clear. The secret primary codes are functionally short and subsequently changed by a predetermined secret scheme.
The system described in U.S. Pat. No. 4,369,434 superficially resembles that of the present invention in that the starting address for the first secret primary code is transmitted, as is the initializing integer of the "masking tape" in the present invention. In the system described in U.S. Pat. No. 4,369,434, however, the primary codes must be changed if the message is lengthy. In the present invention, the masking tape simply continues to run for both sender and receiver. Further, the present invention requires neither transmission of a synchronizing signal nor transmission of an auxiliary code. In short, the encrypting-decrypting algorithm described in U.S. Pat. No. 4,369,434 is different from that of the present invention.
U.S. Pat. No. 4,638,120 describes a digitalized data encryption scheme in which a time-variable random number sequence, E, is generated by the sender and transmitted to the receiver. Sender and receiver share a secret code, S, and a set of identification codes, I n , one of which is associated with each message M. To encrypt a message, the sender forms the concatenated binary sequence EI n , call it R 1 . An intermediate sequence, S 1 , is formed by adding R 1 and S modulo 2, S 1 =R 1 ⊕S, where S is a secret code shared by sender receiver. Finally, an intrinsic code, R, is formed by ordinarily multiplication of the integers S, S 1 and R 1 and reducing the product modulo (2 64 -1). R=S×S 1 ×R 1 (mod (2 64 -1)). Since the address of I n is transmitted to the receiver, the receiver can reconstruct the intrinsic code R. The message, as a binary bit sequence, is added modulo 2 to the intrinsic key R in binary representation. The result is the message encryption. To decrypt, the binary sequence R is modulo 2-added to the transmission. For effective communication, sender and receiver share a secret code, S, and a commonly indexed set of message identification codes. Required to be transmitted are: the encrypted message, the time variable random (or pseudo-random) digit sequence, a synchronization signal and an address for the identification code. The process described in U.S. Pat. No. 4,638,120 has no material relationship with the encrypting-decrypting algorithm or shared information of the present invention.
U.S. Pat. No. 4,791,669 pertains to a method for error reduction in the encryption of a randomized digital encrypting string, Y, added modulo 2 to a digitalized plaintext stream. To shorten lengths of garbled portions of a ciphertext string, the message is broken into chunks or "frames" with a new construction of the sequence of binary encryption bits, Y, in each frame. To do this, bits from previous frames are used to call, randomly, out of memory sequences of bits for Y. Identical machinery and memories at the receiver likewise produce successive chunks of Y and permit decryption by modulo 2 addition of Y to the ciphertext stream. It should be remarked that complicating the construction of Y increases the probability that equipment error at either sender or receiver will degrade individual framed portions of the transmission. This may even increase message degradation overall. The randomizing of the encrypting string Y differs from that of the present invention in that it requires periodic reference to memories which contain stored integers at specific addresses instead of a memory which is simply a string of pseudo-randomly selected digits as in the present invention. Moreover, synchronizing signal transmissions are required in the system of the patent, but not in that of the present invention. Finally, and perhaps most importantly, the act of encryption as described in U.S. Pat. No. 4,791,669 involves the familiar addition modulo 2 of randomized bit string, Y, and digitalized, unencrypted plaintext. As remarked above, this invites known plaintext attacks.
The following four patents, although included for completeness, have no bearing on the present invention. U.S. Pat. No. 4,206,315 reveals a method of verifying signatures appended to a digitalized message transmission. The signing process requires transmission of successive compressed encodings of successive validation tables and the existence of an independent verifier. Specific cryptosystems are irrelevant except as they are required to fit into the construction of validation tables. Hence, there is no necessary connection between the art revealed in U.S. Pat. No. 4,206,315 and that of the present invention. U.S. Pat. No. 4,326,098 describes the use of a "vault," or verifying structure, through which users of terminals in a computer network exchange encrypted messages, thus providing for authentication by a neutral part of the network. Step coding and the Data Encryption Standard are employed for encryption, although, presumably, other cryptographic schemes could also be used. Since U.S. Pat. No. 4,326,098 does not reveal any new cryptosystems as such, it also does not suggest or disclose the present invention. U.S. Pat. No. 4,418,275 pertains to a method of and apparatus for having keys to a data file, as stated therein: "In computerized processing of data it is common practice to store like data items as multiple entries within a named data file." "A portion of each record, referred to as the kay, is used to reference a specific record." "Fundamental to the processing of the data file is the search for a data record associated with a specific key. A number of techniques have been developed which perform this specific function. A class of these techniques is referred to as hashing access methods." "A hashing access method is commonly used when the number of actual keys is a small percentage of the total number of possible keys." The scheme of U.S. Pat. No. 4,418,275 is claimed to be an improved hashing access method. U.S. Pat. No. 4,418,275 has nothing to do with data encryption or rendering stored data secure. Hence, it has nothing to do with the present invention. U.S. Pat. No. 4,667,301 involves a method of generating pseudo-random numbers. U.S. Pat. No. 4,667,301 has no connection with encryption-decryption of data (except as one might wish to employ this pseudo-random number generator); hence, it has no connection with the present invention.
SUMMARY OF THE INVENTION
To achieve the foregoing objects, features, and advantages and in accordance with the purpose of the invention as embodied and broadly described herein, a cipher system is provided comprising a plaintext alphabet each character of which is coded by a multiplicity of integers of a given length. The numerical synonyms of each of the plaintext characters are randomly distributed in the collection of all integers of length that of the numerical synonyms. Numerical synonyms corresponding to particular plaintext alphabet characters are selected pseudo-randomly from among the numerical synonyms associated with each such character. Wherein, the concatenation of numerical synonyms constitutes a plaintext message string integer, corresponding to a plaintext message. A string of consecutive digits comprising the output of a pseudo-random number generator is used to encrypt a plaintext message string integer whereby the string of consecutive digits is called a masking tape string. The initializing "seed" for the output of the pseudo-random number generator is concealed as a subset (possibly permuted) of the digits of an initializing integer to be transmitted with the encrypted message. The masking tape string integer is added to the right, with carries to the right, to the plaintext message string integer to form the ciphertext string integer. Pseudo-random integers of possibly variable length are prefixed, suffixed or interspersed among the digits of the ciphertext string according to prior arrangements between sender and receiver. Permutations are applied to the digits of successive blocks of digits of the ciphertext string. A leader integer coded to identify prefixes, suffixes, interspersions and block permutations is inserted into the transmitted digit string between the initializing integer and ciphertext message string. The initializing integer-ciphertext string is super-encrypted by addition to a second masking tape string identified by a second initializing integer.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention and together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a flow chart illustrating a basic embodiment of the invention associated with the receipt of the first plaintext character to be transmitted using the present invention;
FIG. 2 is a flow chart illustrating a basic embodiment of the invention associated with receipt of a second and subsequent plaintext characters to be transmitted;
FIG. 3 is a flow chart illustrating a basic embodiment of the invention associated with the reception and decryption of the encoded message;
FIG. 4 is a flow chart illustrating a preferred embodiment of the invention in which the initializing integer initiates adulteration and permutation of the ciphertext string;
FIG. 5 is a flow chart illustrating a preferred embodiment of the invention in which the initializing integer initiates the undoing of permutations and the removal of adulterations from the ciphertext string;
The above general description and the following detailed description are merely illustrative of the generic invention, and additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the present preferred embodiments of the invention. We now describe the invention and indicate how it avoids the problems associated with the common encryption method of adding, modulo 2, a pseudo-random bit string to a digitalized plaintext string.
First, a definition is provided of specific terms which are incorporated herein:
Digits are the first ten non-negative integers, 0, 1, . . . , 9. A pseudo-random integer is a finite sequence of pseudo-randomly selected digits. All integers are to be regarded as non-negative unless otherwise indicated. For an integer, n, 1 n is the number of digits making up n, i.e., the length of n.
A masking tape is a sequence of digits output by a pseudo-random number generator. The name "masking tape" is not purely facetious. A sequence of digits, serially accessed, may be regarded as and stored on a tape. The reference to "masking" will be apparent later.
A plaintext alphabet is a set of linguistic characters sufficient to generate to-be-encrypted message. It might consist of, say, the English alphabet, common words, digits, digraphs, acronyms and punctuation marks, for example. A plaintext alphabet might be represented by codes suitable for computer use, such as ASCII or EBCDIC.
A thesaurus, a dictionary of synonyms, is a many-to-one function, t, from the set of all integers, of common length, l v onto a plaintext alphabet, or onto a numerical coding for a plaintext alphabet.
It is desirable, first, to make the cardinality of the domain of the thesaurus function much larger than that of the range (plaintext alphabet--128 characters for ASCII and 256 characters for EBCDIC). This permits large cardinality pre-images of plaintext characters and makes the probability of randomly selecting a particular integer from the pre-image of a particular plaintext character small. Each integer in the domain of t is a numerical synonym for the plaintext character to which it is mapped.
Second, the cardinality of the pre-image of a range element of a thesaurus should, as a fraction of the cardinality of the domain of the thesaurus, as nearly as possible, approximate the relative frequency of that range element in the plaintext language of encrypted messages. The desired result of course is that the number of numerical synonyms for a plaintext character is proportional to the frequency of its use in transmitted messages, providing greater ambiguity in the ciphertext for frequently used plaintext characters.
The result of these two requirements is that the probability of the use of any given numerical synonym is very small, and that the individual probabilities of use of any two numerical synonyms (representing the same or different plaintext characters) are nearly equal.
Further, each pre-image set of each plaintext character is to be randomly distributed among the set of integers of length 1 v 10 l .sbsp.t in number. That is, the probability that an integer of length l t is in t -1 (p 8 ), for each p i in the plaintext alphabet is the cardinality of t -1 (p i ) divided by 10 l .sbsp.t, card t -1 (p i ))/10 l .sbsp.t.
The encryption of a message consisting of a sequence of plaintext characters of length m, p 1 , . . . , p m , begins as follows: For the first character, p 1 , pseudo-randomly select an element of t -1 (p 1 ). Henceforth abusing notation, since t -1 (p 1 ) is, as used above, always really a set of integers, call the selected integer t -1 (p l ). It is a numerical synonym of p l . Successively repeat the process for each of p 2 through p m . Concatenating the t -1 (p i )'S, in order gives us a plaintext message string of digits of length m•l t . This selection of numerical synonyms for plaintext characters is by itself, a homophonic substitution cipher.
To encrypt the plaintext message string, the sender selects an initializing "seed" integer to start the output of a pseudo-random number generator. The sender reads out the output digits of the pseudo-random number generator to a total of m•l t .
Call this retrieved digit string, the masking tape string.
Now the sender adds the plaintext message string (an integer) to the masking tape string (also an integer). Addition starts with the left most, or most significant, digit of each (instead of the least significant, or right most, digit of each). Addition is to the right (instead of to the left) with carries to the right (instead of to the left). This "backwards" addition permits decryption of the message in the order in which the cipher synonyms appear in the plaintext message string. The sum of the plaintext message string and the masking tape string is the ciphertext string.
The initializing "seed" for the output of the pseudo-random number generator is concealed in a prearranged (known to sender and receiver) way in an initializing integer. The "seed" may in fact be a prearranged permutation of a prearranged subset of a pseudo-randomly chosen initializing integer. The initializing integer followed by the ciphertext string is then transmitted to the receiver. The receiver retrieves the initializing "seed" from the initializing integer, supplies it to a pseudo-random number generator identical to that of the sender and recreates the sender's making tape string. Subtracting this "backwards" or to the right from the ciphertext string, gives the plaintext message string of digits in successive blocks, t -1 (p i ), of length l t . Finding the successive images in the thesaurus, t(t -1 (p i ))=p i , yields the string of plaintext characters which constituted the original message.
Consider now the advantages of the present system, in its simplest form as described above, over the summation of a pseudo-random sequence of digits and a stream of integers corresponding one-for-one to the characters of a plaintext alphabet. First, since the masking tape string only appears to an eavesdropper as a summand of the known ciphertext string, reconstructing it depends upon knowing the plaintext message string. Since, for a given encrypted message, there will be many equally probably possible plaintext message strings, there will be as many equally probable possible masking tape strings. In short, the plaintext message string "masks" the masking tape string.
Conversely, the masking tape string conceals the choices of the numerical synonyms in the plaintext message string, since each of many equally probably masking tape strings is associated with a corresponding plaintext message string. The masking tape string "masks" the plaintext message string. This latter function is the only masking commonly employed.
To confuse attackers about the length of the message, sender and receiver can conceal the beginning and ending of the actual ciphertext string by the use of prefix and suffix pseudo-random integers, of agreed-upon length, transmitted preceding and following the actual ciphertext string. This might be done in such a way as to keep the transmitted digit string from having length a multiple of l t .
Further to confuse an attacker about the true nature of the ciphertext string, sender and receiver might also adulterate the ciphertext string by using interspersed pseudo-random integers not necessarily of length l v between selected pairs of numerical synonyms in the plaintext message string. Placement of the integers might be varied, from message to message, by successive selections from a list, by some function of the initializing integer or by some function of a prefix pseudo-random integer. Knowing the algorithm for selecting the insertion schemes, the receiver, but not an attacker, would be able to edit them out of transmitted and received messages.
A ciphertext string with prefixed or suffixed pseudo-random integers or with interspersed pseudo-random integers is an adulterated ciphertext string.
What has been described so far is a stream cipher in which the ciphertext string of digits decrypts to the plaintext message. There is nothing to prevent permutations of successive blocks of digits (or of zeros and ones for digits in binary form), followed by transmission of the string of permuted blocks. These blocks may be of fixed or variable length as long as they, and the order of their application, are known to both sender and receiver. They may be obtained by cycling through a list known to sender and receiver or obtained as a function of the initializing integer. A (an adulterated) ciphertext string subjected to block permutations prior to transmission is a purmuted (adulterated) ciphertext string.
The receiver, knowing which succession of permutations has been applied, knows which succession of inverse permutations to apply, restoring the ciphertext string. Using permutations of digit blocks of length greater than 1 l will intermingle digits arising from different numerical synonyms, further confusing attackers.
Naturally, the last permutation of ciphertext digits may require adding digits to the transmission. Determining how many digits are extraneous after the sequence of inverse permutations has been applied is solved by having the sender "sign" the message by sending an encrypted signature (one of many supposedly known only to the receiver-sender pair). When the receiver comes to the end of the decrypted signature or pass code, he regards all subsequent digits as extraneous and ignores them.
In order that a ciphertext string not end in a sequence of zeros, thus limiting the number of ways in which it can be decomposed into a masking tape string and a plaintext message string, extraneous digits other than zero may be added at the end of the ciphertext string and recognized by the receiver as such as indicated above. If the ciphertext string is a permuted (or permuted and adulterated) ciphertext string, this may not be necessary.
In the invention disclosed in application Ser. No. 07/577,936, now U.S. Pat. No. 5,113,444, of which the present invention is a further development, an extensive masking tape of random digits was used to generate masking tape strings. In situations in which it is impractical to share a very long collection of random digits, sender and receiver may employ the method of the present invention, sharing, instead, identical pseudo-random number generators to generate the masking tape string. This is cone by concealing, for each message, the initializing "seed" integer, which determines the common output of the generators, in an initializing integer which replaces the starting integer of the system as previously described in the parent invention. For example, if the initializing seed integer were concealed as an agreed-upon permutation of ten digits, it could be any one of approximately 10 14 possibilities in a 30-digit initializing integer. ( 30 P 10 >1.09×10 14 .)
Changing the initializing seed with each message would slow down known plaintext attacks. Still, a known plaintext attack might ultimately succeed were it not for a second unique feature of the present invention: The plaintext message string integer, consisting as it does of a sequence of randomly occurring integer codings of plaintext message characters, "masks" the masking tape out of the pseudo-random number generators.
The initializing integer may serve other functions as well, namely, determining prefixed, suffixed and interspersed integers as well as block permutations of digits.
Additionally, an initializing integer could contain numerically coded instructions for altering the numerical synonym output of the thesaurus in at least two ways: first, by permuting the digits of the numerical synonym selected for each plaintext alphabet character, and second, by shifting each numerical synonym by a common fixed added integer (modulo the value of the numerically largest numerical synonym). Undoing the digit permutations and removing the added "shift" would be accomplished by the receiving unit based upon instructions contained in the initializing integer. These functions, sending and receiving, could be handled in the central processing units of FIGS. 1-5, as described below.
The use of memory cards ("IC cards"), which store programs and data on computer chips, suggests an authentication scheme, which is suitable for securing access to confidential computer networks and their storage files: A memory card stores the processor's account number, a brief masking tape and the algorithm for computing the function value, f(x 1 , . . . , x n ), for some function of n digits, x 1 , . . . , x n , possibly utilized in blocks. For example, the x 1 , . . . , x n might be divided into blocks, all but the last of which provide the absolute values of the coefficients of a polynomial form, while the last provides the value of the variable of the polynomial. A verifier or "guardian" of the information stores each of these short masking tape and functional algorithm pairs, indexed by users' account numbers.
When a memory card is presented to the memory car reader--a simple computer linked to the verifier computer--for entry to the system, the verifier calls up the masking tape and algorithm corresponding to the card's account number and generates a pseudo-random starting integer which is sent to the memory card reader. The starting integer locates a string, d 1 , . . . , d n , of n consecutive digits in the masking tape of the memory card, which the memory card reader uses to calculate f(d 1 , . . . , d n ) from the card's stored algorithm. This number, f(d 1 , . . . , d n ) is transmitted back to the verifier, which has made the same calculation based on the value of the starting integer. If the two function values agree, the possessor of the memory card, is free to enter into the system.
According to an Associated Press release of Sep. 14, 1991, as reported in the Houston Chronicle, memory cards with four megabytes of capacity will be available by the end of 1991, and it is expected that they will have a capacity of 40 megabytes in four years.
FIG. 1 is a flow chart illustrating a basic embodiment of the invention associated with the receipt of the first plaintext character to be transmitted using the present invention. The first plaintext character of a message to be encrypted is input to the Central Processing Unit, the CPU. The CPU activates the Pseudo-Random Number Generator, PRNG, via a link 1. The PRNG generates the initializing integer for the message which it transmits to the CPU via a link 2. The CPU stores the initializing integer for the duration of the message and extracts an initializing "seed" from the initializing integer which it transmits back to the PRNG via a link 3. The PRNG takes the initializing "seed" and uses it to generate a pseudo-random string of digits of length l t for submission via a link 4 to the Adder/Subtracter. The initializing integer is also transmitted via a link 5 to the Transmitting Means (radio transmitter, wire link, etc.) and is transmitted as the first digit substring of the cryptogram.
The CPU via the link 1 next causes the PRNG to send a pseudo-random integer to the Thesaurus via a link 6. The Thesaurus, in a natural embodiment, looks up the first numerical synonym greater (or lesser or nearest) than the pseudo-random integer, input via the link 6, which corresponds to the numerically coded first plaintext character input from a link 7. It sends this numerical synonym via a link 8 to the Adder/Subtracter. The Adder/Subtracter adds the first numerical synonym to the first masking tape substring of length l l and sends it off for transmission via a link 9 to the Transmitting Means, following the initializing integer.
FIG. 2 is a flow chart illustrating a basic embodiment of the invention associated with receipt of a second and subsequent plaintext characters to be transmitted. In FIG. 2, the second plaintext message character is converted to a numerical equivalent in the CPU and this integer is sent via the link 7 to the Thesaurus. The CPU also instructs the PRNG to produce its next succeeding masking tape substring of length l l and to transmit it via the link 4 to the Adder/Subtracter. Meanwhile, again via the link 1, the CPU has also instructed the PRNG via the link 6 to send another pseudo-randomly integer to the Thesaurus.
As with the first plaintext character, the Thesaurus takes the second pseudo-random integer and looks up the first numerical synonym greater (or lesser, etc.) than this pseudo-random integer, which numerical synonym corresponds to the second plaintext character of the message, This numerical synonym goes, via the link 8, to the Adder/Subtracter where it is added to the corresponding, second, piece of masking tape. Provision is made of course for any carryover from the first such sum for the first plaintext character. This second summation then also goes off, via the link 9, for transmission as part of the ciphertext string.
Third and subsequent plaintext characters are handled correspondingly until the completed cryptogram has been transmitted.
FIG. 3 is a flow chart illustrating a basic embodiment of the invention associated with the reception and decryption of the encoded message. Upon receipt of the initializing integer of a cryptogram from the Receiving Means (radio receiver, etc.) via a link 10, the CPU communicates via a link 11 to the PRNG, identical to the one used by the sender, the value of the initializing "seed" extracted from the initializing integer. The PRNG then starts generating the sequence of masking tape digits used by the sender. These are sent via the link 12 to the Adder/Subtracter.
The Adder/Subtracter receives the ciphertext string (minus the initializing integer) from the CPU via a link 13, subtracts the masking tape string supplied by the PRNG and sends the resulting sequence of numerical synonyms via a link 14 to the Thesaurus.
The Thesaurus sequentially looks up the numerically coded equivalents of the plaintext message characters and sends these via a link 15 to the CPU. The CPU converts the integer codings to plaintext characters and sends via a link 16 the plaintext message out to e.g., a printer.
FIG. 4 is a flow chart illustrating a preferred embodiment of the invention in which the initializing integer initiates adulteration and permutation of the ciphertext string. A preferred embodiment as illustrated in FIG. 4 is basically identical to that described with reference to FIGS. 1 and 2. However, in this embodiment, provision is made for the transmission of an adulterated (by prefix, suffix and interspersed pseudo-random integer) and permuted (by permutations of blocks of digits) ciphertext string. In this embodiment, the initializing integer is used to select places for and lengths of interspersed pseudo-random integers and the choice of the sequence of integer block permutations. These two initializing integer-based selection processes must, of course, be shared by sender and receiver, most readily perhaps, in their respective CPU's.
In this embodiment, an Intersperser receives the initial ciphertext stream via a link 17 from the Adder/Subtracter. The ciphertext string is interrupted by the Intersperser by instructions from the CPU carried by a link 18. The gaps are filled by pseudo-random integers received via a link 19 from the PRNG. The CPU instructs the PRNG, via the link 1, to send these pseudo-random integers to the Intersperser.
From the Intersperser via a link 20 the adulterated ciphertext string is conveyed to the Block Permuter where a sequence of digit-block permutations is applied to successive blocks of ciphertext digits upon instructions by the CPU conveyed to the Block Permuter via the link 21.
The CPU, having kept track of the length of the adulterated ciphertext string, instructs the PRNG via the link 1 to send, via a link 22, sufficient pseudo-random digits to permit the application of the last indicated block permutation.
Finally, the adulterated permuted ciphertext string falls in behind the initializing integer and is sent, via the link 9, to the Transmission Means for transmission to a receiver.
FIG. 5 is a flow chart illustrating a preferred embodiment of the invention in which the initializing integer initiates the undoing of permutations and the removal of adulterations from the ciphertext string. The reception-decrypting process of this preferred embodiment is identical to that of FIG. 3, except that further provision must be made for unscrambling the permuted digit blocks and removing the adulterating integers before the ciphertext is fed to the Adder/Subtracter.
Upon receiving the cryptogram, beginning with the initializing integer, from the Receiving Means via the link 10, the CPU transmits the adulterated permuted ciphertext string via a link 23 to the Block Permuter. Using the initializing integer, the CPU sends instructions by a link 24 to the Block Permuter, causing ti to apply the inverses of the sequence of digit-block permutations to the received ciphertext string. The result is the unpermuted, but still adulterated, ciphertext string which is sent via a link 25 to the Intersperser to delete the prefixed, suffixed and interspersed random integers. By link a 26, the CPU instructs the Intersperser to delete the prefixed, suffixed and interspersed random integers. The now unadulterated, unpermuted ciphertext string is conveyed by a link 27 to the Adder/Subtracter.
The CPU sends the initializing "seed" by the link 11 to the PRNG and initiates the transmission of the masking tape string to the Adder/Subtracter by the link 12. The Adder/Subtracter subtracts the masking tape string from the ciphertext string, revealing the plaintext message string.
The plaintext message string goes by the link 14 to the Thesaurus where the sequence of numerical synonyms is converted to a sequence of integers numerically coding the sequence of plaintext alphabet characters. This is sent by the link 15 to the CPU for conversion to the original plaintext message, which is output by the link 16.
A simple way of further encrypting a permuted and/or adulterated ciphertext string would be to add another masking tape string to the permuted, adulterated ciphertext string prior to transmission--using, of course, a second initializing integer. | A cipher system is disclosed in which each character of a plaintext alphabet has associated with it a randomly distributed collection of integers of a given length. This collection of integers is secretly shared by a sender and receiver pair. The plaintext characters of a message are sequentially coded by pseudo-randomly selecting representatives from the integer collections corresponding to the plaintext characters. To this sequence of concatenated integers, regarded as a single integer, is added a pseudo-random integer of length equal to that of the coded-for-message integer string. This pseudo-random integer is generated by a pseudo-random number generator (The receiver has a corresponding generator.), the output of which is initialized by a "seed" integer concealed in the cryptogram. The summed pseudo-random integer plus the coding integer string is transmitted as the body of the cryptogram. To decrypt, the receiver subtracts the pseudo-random integer from the transmitted integer, breaks up the remaining integer into the blocks numerically coding the plaintext characters and retrieves the plaintext characters of the message. Provision is made for further obscuring the cryptogram integer. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 11/154,365, filed Jun. 15, 2005, pending, which is a continuation of application Ser. No. 10/629,641, filed Jul. 29, 2003, now U.S. Pat. No. 6,908,715, issued Jun. 21, 2005, which is a continuation of application Ser. No. 09/809,720, filed Mar. 15, 2001, now U.S. Pat. No. 6,599,666, issued Jul. 29, 2003. The disclosures of the previously referenced U.S. patent applications referenced are hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to photolithography techniques used in semiconductor device manufacturing processes. Specifically, the present invention relates to a multi-layer, attenuated phase-shifting mask or reticle that reduces problems associated with side lobe printing in areas including closely spaced or nested features, while maximizing resolution and depth-of-focus performance for isolated features of a semiconductor device.
[0004] 2. State of the Art
[0005] Photolithography processes are essential to the fabrication of state of the art semiconductor dice. Such processes are used to define various semiconductor die features included in semiconductor dice and generally include exposing regions of a resist layer to patterned radiation corresponding to the semiconductor die circuit feature to be defined in a substrate underlying the layer of resist. After exposure, the resist layer is developed to selectively reveal areas of the substrate that will be etched to define the various device features while selectively protecting those areas of the substrate which are not to be exposed to the etching process. In order to properly form a radiation pattern over a resist layer, the radiation is generally passed through a reticle or mask which projects the semiconductor die feature pattern to be formed in the resist layer.
[0006] Various types of photolithographic masks are known in the art. For example, known masks often include a transparent plate covered with regions of a radiation blocking material, such as chromium, which define the semiconductor die feature pattern projected by the mask. Such masks are called binary masks since radiation is completely blocked by the radiation blocking material and fully transmitted through the transparent plate in areas not covered by the radiation blocking material. However, binary masks cause significant fabrication problems, particularly where semiconductor die dimensions shrink below 1 Φm.
[0007] As the pattern features of a binary mask are defined by boundaries between opaque, radiation blocking material and material which is completely radiation transmissive, radiation passing through a binary mask at the edge of a pattern feature will be diffracted beyond the intended image boundary and into the intended dark regions. Such diffracted radiation prevents formation of a precise image at the feature edge, resulting in semiconductor die features which deviate in shape or size from the intended design. Because the intensity of the diffracted radiation drops off quickly over a fraction of a micron, diffraction effects are not particularly problematic where semiconductor dice have dimensions on the order of 1 Φm. However, as feature dimensions of state of the art semiconductor dice shrink well below 0.5 Φm, the diffraction effects of binary masks become terribly problematic.
[0008] Another type of mask known in the art is an attenuated phase shift mask (APSM). APSMs were developed to address the diffraction problems produced by binary masks and are distinguished from binary masks in that, instead of completely blocking the passage of radiation, the less transmissive regions of the mask are actually partially transmissive. Importantly, the attenuated radiation passing through the partially transmissive regions of an APSM generally lacks the energy to substantially affect a resist layer exposed by the mask. Moreover, the partially transmissive regions of APSMs are designed to shift the passing radiation 180° relative to the radiation passing through the completely transmissive regions and, as a consequence, the radiation passing through the partially transmissive regions destructively interferes with radiation diffracting out from the edges of the completely transmissive regions. Thus, the phase shift greatly reduces the detrimental effects of diffraction at the feature edges, thereby increasing the resolution with which sub-micron features may be patterned on a resist layer.
[0009] A conventional APSM 4 is illustrated in drawing FIG. 1 . As can be seen, the APSM 4 includes a transparent substrate 6 coated with a partially transmissive material 7 (to ease description, drawing FIG. 1 provides a greatly simplified APSM). The partially transmissive material 7 has been patterned to form a completely transmissive region 8 and two attenuated regions 10 a , 10 b . The attenuated regions 10 a , 10 b of a typical APSM 4 are typically designed to allow the passage of between about 4% (low transmission) and 20% (high transmission) of the incident radiation 12 . The partially transmissive material 7 forming the attenuated regions 10 a , 10 b is formed to a thickness that shifts the incident radiation 12 one hundred eighty degrees (180°) out of phase.
[0010] Also provided in drawing FIG. 1 is a graph 16 illustrating the electromagnetic intensity (plotted on the vertical axis) of the radiation passing through the APSM 4 relative to the position (plotted on the horizontal axis) on the surface of the exposed resist. As shown, the intensity curve 18 includes a first component 20 located primarily between the edges 22 a , 22 b formed between the attenuated regions 10 a , 10 b and the completely transmissive region 8 of the APSM 4 . The first component 20 of the intensity curve 18 corresponds to the electromagnetic intensity of the radiation passing through the completely transmissive region 8 of the APSM 4 illustrated in drawing FIG. 1 . As can be seen in the graph 16 , the electromagnetic intensity of the radiation falls to zero at points 24 a , 24 b , which are near the edges 22 a , 22 b . Points 24 a , 24 b correspond to the locations where the magnitudes of the in phase radiation passing through the completely transmissive region 8 and the out of phase radiation passing through the attenuated regions 10 a , 10 b are equal. Beyond points 24 a , 24 b and moving away from the edges 22 a , 22 b , the electromagnetic intensity of the transmitted radiation grows again to a steady value as indicated by the second curve components 26 a , 26 b . The second curve components 26 a , 26 b represent the electromagnetic intensity of the radiation passing through the attenuated regions 10 a , 10 b of the APSM 4 .
[0011] The electromagnetic intensity represented by the second curve components 26 a , 26 b is also known as “ringing effects,” and one significant disadvantage of APSMs is that such ringing effects become much more severe as feature density of an APSM increases. As device features designed into an APSM are spaced closer and closer together, the ringing effects of adjacent device features begin to overlap, and as the ringing effects overlap, the electromagnetic intensity of such ringing effects becomes additive. These increased ringing effects are known as “additive side lobes,” “additive ringing effects,” or “proximity effects.” In contrast to isolated ringing effects produced by isolated device features, the electromagnetic intensity of additive side lobes created by closely spaced (i.e., # 0.5 Φm) or nested device features often becomes sufficiently intense to cause printing of the resist layer, which is commonly termed “side lobe printing.”
[0012] Illustrated in drawing FIG. 2 is the additive ringing effects associated with conventional APSMs having closely spaced feature formations. As illustrated in drawing FIG. 2 , a second APSM 30 includes a transparent substrate 32 coated with a partially transmissive phase-shifting film 34 (again, for ease of description, drawing FIG. 2 provides a greatly simplified APSM). The partially transmissive phase-shifting film 34 has been patterned to form four attenuating regions 36 a - 36 d and three completely transmissive regions 38 a - 38 c , which are closely spaced. Radiation 39 incident on the APSM 30 passes through the completely transmissive regions 38 a - 38 c and the attenuated regions 36 a - 36 d and impinges upon the surface of the resist layer to be patterned (not illustrated in drawing FIG. 2 ).
[0013] Included in drawing FIG. 2 is a graph 40 illustrating the electromagnetic intensity of the radiation incident upon the surface of the resist layer to be patterned. The graph 40 includes an intensity curve 42 made up of various components, with the first components 43 a - 43 c illustrating the electromagnetic intensity of the radiation passing through the completely transmissive regions 38 a - 38 c of the APSM 30 , the second components 44 a , 44 b illustrating the electromagnetic intensity of the ringing effects produced by the radiation passing through the isolated attenuated regions 36 a , 36 d , and the third components 46 a , 46 b illustrating the electromagnetic intensity of the additive side lobes produced by the dense feature arrangement formed by the closely spaced attenuated regions 36 b , 36 c . As can be seen in drawing FIG. 2 , the magnitude of the second components 44 a , 44 b (represented by line “I 1 ”), which illustrate the intensity of the ringing effects produced by isolated attenuated regions 36 a , 36 d , is significantly lower than that of the third components 46 a , 46 b (represented by line “I 2 ”), which illustrate the electromagnetic intensity of the additive side lobes.
[0014] Provided in drawing FIG. 3 is a cross-sectional view of a partially fabricated structure 50 after exposure through the APSM 30 illustrated in drawing FIG. 2 . The partially fabricated structure 50 includes a semiconductor substrate 52 and a developed resist layer 54 . The developed resist layer 54 exhibits a set of depressions 56 a , 56 b resulting from the relatively high electromagnetic intensity of the additive side lobes caused by the dense feature arrangement of the APSM 30 . As device feature density increases, so will the intensity of the additive side lobes and the extent to which the resist layer is patterned due to exposure to additive ringing effects. Thus, depressions in the resist layer due to additive ringing effects may, in some situations, degrade the resist layer to such an extent that entire semiconductor dice become unusable due to damage incurred during a subsequent etch process.
[0015] As is well known in the art, the ringing intensity is inversely related to the attenuation of the partially transmissive material used in APSMs. Increasing the attenuation of the partially transmissive material will, therefore, decrease any resultant ringing effects, while decreasing the attenuation will increase any resultant ringing effects. Thus, the intensity of additive side lobes produced by closely formed features in an APSM may be decreased simply by increasing the attenuation of the partially transmissive regions included therein.
[0016] However, increasing the attenuation of the partially transmissive areas of APSMs also has significant drawbacks. For example, increasing the attenuation of the partially transmissive areas decreases print performance as well as the resolution and depth-of-focus achievable by the APSM. Reduction of depth-of-focus and resolution characteristics of an APSM are particularly problematic in the fabrication of state of the art semiconductor devices, which requires that an APSM accurately project images corresponding to sub-0.5 Φm device features while focusing such images through relatively thick layers of resist. In addition, even with the most precise fabrication equipment, sub-micron deviations from the optimum focus position of the APSM relative to the resist layer to be patterned will occur, and decreasing the depth-of-focus of an APSM increases the probability that fabrication defects may result from such slight deviations. Therefore, increasing the attenuation of the partially transmissive materials included in state of the art APSMs requires a careful compromise between control of additive ringing effects and maximization of resolution and depth-of-focus performance.
[0017] Furthermore, state of the art semiconductor dice often include closely spaced or nested features as well as features which are isolated. It would, therefore, be an improvement in the art to provide an APSM that includes highly attenuated regions (i.e., attenuating regions allowing about 4% to about 10% transmittance of incident radiation) where necessary to control additive ringing but also includes slightly attenuated regions (i.e., attenuating regions allowing about 12% to about 20% transmittance of incident radiation) where isolated device features are to be formed. Such an APSM would enable control of additive ringing effects where needed without compromising resolution and depth-of-focus performance where additive ringing effects are of little or no concern.
BRIEF SUMMARY OF THE INVENTION
[0018] The present invention addresses the foregoing needs by providing an APSM that, in each embodiment, includes completely transmissive regions sized and shaped to define desired device features, slightly attenuated regions at the edges of completely transmissive regions corresponding to isolated device features, highly attenuated regions at the edges of completely transmissive regions corresponding to closely spaced or nested device features, and completely opaque areas where it is desirable to block transmission of all radiation through the APSM. The present invention further provides methods for fabricating the APSMs according to the present invention.
[0019] In one embodiment, the method of fabricating an APSM according to the present invention includes providing a transparent substrate. The transparent substrate is coated with a first attenuating layer that shifts the phase of transmitted radiation by 180° and is only slightly attenuated. The first attenuating layer is coated with a second attenuating layer that does not shift the phase of passing radiation, but further attenuates the intensity of any radiation passing therethrough. An opaque layer is then formed over the second attenuating layer. Using this intermediate structure, a desired APSM according to the present invention may be formed.
[0020] To form a desired APSM, the opaque layer is coated with a resist. The resist is then patterned to create a first patterned resist defining the semiconductor die feature pattern to be projected by the finished APSM. The opaque layer is then etched.
[0021] After the opaque layer is etched, the first patterned resist may be left in place and the second and first attenuating layers may be etched using the first patterned resist as a template. The first patterned resist is then stripped, leaving a first intermediate mask structure including completely transmissive regions corresponding to the pattern to be projected by the mask and completely opaque regions where the opaque layer and first and second attenuating layers remain intact. Alternatively, the first patterned resist may be removed after etching the opaque layer, and the opaque layer alone may be used as the template for etching the first and second attenuating layers.
[0022] A second layer of resist is deposited over the first intermediate mask structure. The second layer of resist is patterned to define a second patterned resist, which exposes areas of the intermediate mask structure wherein slightly attenuated regions will be formed. The opaque layer and the second attenuating layer in the areas exposed by the second patterned resist are then etched, revealing slightly attenuating regions formed from portions of the first attenuating layer. The second patterned resist is then stripped, and the resulting second intermediate mask structure includes completely transmissive regions sized and shaped in accordance with the device pattern to be protected by the mask, slightly attenuated regions, which shift passing radiation one hundred eighty degrees (180°), and opaque regions where the opaque layer, as well as the first and second attenuating layers, remain intact. Preferably, the slightly attenuated regions are provided at the edges of each of the completely transmissive regions corresponding to isolated device features, thereby maximizing image resolution and depth-of-focus performance where it is not necessary to increase attenuation to combat the negative effects produced by additive side lobes.
[0023] A third resist is deposited over the second intermediate mask structure. The third resist is then patterned to form a third patterned resist, which exposes areas of the second intermediate mask structure wherein highly attenuated regions will be formed. The areas exposed by the third patterned resist are then etched to remove only the opaque layer, thereby defining regions were incident radiation is phase shifted one hundred eighty degrees (180°) and highly attenuated as it passes through both the first and second attenuating layers. Preferably, such highly attenuated regions are formed at the edges of completely transmissive regions corresponding to closely spaced or nested device features, thereby increasing the resolution of such semiconductor die features projected by the finished mask, while minimizing or eliminating any defects from additive ringing effects.
[0024] The third patterned resist is then stripped leaving a completed mask according to the present invention. The completed mask, therefore, includes completely transmissive regions corresponding to the pattern to be projected by the mask, slightly attenuated regions, which phase shift passing radiation one hundred eighty degrees (180°), highly attenuated regions, which also shift passing radiation 180°, and opaque regions where the opaque layer and first and second attenuating layers remain intact.
[0025] As can be appreciated, the method of the present invention is highly adaptable and can be used to fabricate APSMs having any desired feature pattern. Moreover, the steps of the method can be modified in several aspects while still obtaining a desired APSM. For example, etch stop techniques can be incorporated into the method of the present invention to eliminate one or more etching steps. However, in each of its embodiments, the method of the present invention advantageously produces APSMs including completely transmissive regions, slightly attenuated regions, and highly attenuated regions, and the size, shape, and position of these various regions can be modified or adjusted to produce any desirable semiconductor die feature pattern.
[0026] Other features and advantages of the present invention will become apparent to those of skill in the art through a consideration of the ensuing description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0027] The figures presented in conjunction with this description are not actual views of any particular portion of a device or component, but are merely representations employed to more clearly and fully depict the present invention.
[0028] FIG. 1 provides a schematic illustration of a prior art APSM as well as a graph depicting the electromagnetic intensity of radiation projected through the prior art APSM;
[0029] FIG. 2 provides a schematic illustration of a second prior art APSM as well as a graph depicting the electromagnetic intensity of radiation projected through the second prior art APSM;
[0030] FIG. 3 schematically illustrates a cross-section of a partially fabricated semiconductor device structure after exposure through the second prior art APSM illustrated in FIG. 2 ;
[0031] FIG. 4 schematically illustrates a cross-section of a first intermediate mask structure formed in the first embodiment of the method of the present invention;
[0032] FIG. 5 schematically illustrates a first patterned resist formed over the first intermediate mask structure of FIG. 4 ;
[0033] FIG. 6 provides a schematic illustration of a second intermediate mask structure formed in the first embodiment of the method of the present invention;
[0034] FIG. 7 schematically illustrates the intermediate mask structure depicted in FIG. 6 , after a second patterned resist for creating slightly attenuated regions is formed thereover;
[0035] FIG. 8 provides a schematic illustration of a third intermediate mask structure formed in the first embodiment of the method of the present invention;
[0036] FIG. 9 and FIG. 10 schematically illustrate the third intermediate mask structure depicted in FIG. 8 , after a third patterned resist for creating highly attenuated regions is formed thereover and the resulting structure is subjected to a selective etch process;
[0037] FIG. 11 schematically illustrates a first embodiment of the APSM of the present invention;
[0038] FIG. 12 schematically illustrates a cross-section of a first intermediate mask structure formed in the second embodiment of the method of the present invention;
[0039] FIG. 13 schematically illustrates a first patterned resist formed over the first intermediate mask structure of FIG. 12 ;
[0040] FIG. 14 provides a schematic illustration of a second intermediate mask structure formed in the second embodiment of the method of the present invention;
[0041] FIG. 15 schematically illustrates the intermediate mask structure depicted in FIG. 14 , after a second patterned resist for creating slightly attenuated regions is formed thereover;
[0042] FIG. 16 provides a schematic illustration of a third intermediate mask structure formed in the second embodiment of the method of the present invention;
[0043] FIG. 17 and FIG. 18 schematically illustrate the third intermediate mask structure depicted in FIG. 16 , after a third patterned resist for creating highly attenuated regions is formed thereover and the resulting structure is subjected to a selective etch process; and
[0044] FIG. 19 schematically illustrates a second embodiment of the APSM of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0045] A first embodiment of the method of forming an APSM according to the present invention is schematically illustrated in drawing FIG. 4 through drawing FIG. 11 . In each of these figures, the structures representing the various intermediate APSM structures, as well as the complete APSM, are greatly simplified for ease of description.
[0046] As is illustrated in drawing FIG. 4 , the method of the present invention includes providing a transparent substrate 60 , such as quartz, fused silica, or other type glass substrates, etc. The transparent substrate 60 is then coated with a first attenuating layer 62 , such as a layer of chromium oxynitride (CrO x N y ) or chromium fluoride (CrF x ). The first attenuating layer 62 is preferably highly transmissive (i.e., allows about 12%-20% transmission) and shifts the phase of any passing radiation by 180°. The first attenuating layer 62 is then coated with a second attenuating layer 64 , such as a layer of molybdenum silicide oxynitride (MoSiO x N y . The second attenuating layer 64 is formed such that the second attenuating layer 64 does not shift the phase of passing radiation, but simply further attenuates the intensity of any passing radiation. Preferably, the total attenuation of radiation passing through the first attenuating layer 62 and the second attenuating layer 64 is about 90% to about 96%, allowing about 4% to about 10% transmission. An opaque layer 66 , for example, a layer of chromium, is then formed over the second attenuating layer 64 , resulting in a first intermediate mask structure 70 that may be used to form a desired mask according to the first embodiment of the APSM of the present invention.
[0047] As is illustrated in drawing FIG. 5 , to form a desired APSM according to the first embodiment of the APSM of the present invention using the first intermediate mask structure 70 , a first patterned resist 72 is formed over the opaque layer 66 . The first patterned resist 72 is formed by first coating the opaque layer 66 with any suitable resist and patterning the resist by known methods to define a desired feature pattern to be projected by the completed mask. After formation of the first patterned resist 72 , the opaque layer 66 is etched to reveal areas of the second attenuating layer 64 . Any suitable etch process may be used to etch the opaque layer. For example, where the opaque layer includes chromium, a Cl 2 /O 2 plasma etch process or a suitable wet etch process may be used to etch the opaque layer 66 .
[0048] After the opaque layer 66 is etched, the first patterned resist 72 may be left in place. The second attenuating layer 64 and the first attenuating layer 62 may then be etched using the first patterned resist 72 as a template, revealing the underlying transparent substrate 60 and forming various completely transmissive regions 74 a - 74 f (shown in drawing FIG. 6 ), which correspond in size, shape, and location to the device pattern to be projected by the completed APSM. The second attenuating layer 64 and first attenuating layer 62 are etched using any suitable method. However, where the second attenuating layer 64 includes MoSiO x N y , an SF 6 or CF 4 based plasma etch process is preferably used, and where the first attenuating layer 62 includes CrF x , the first attenuating layer 62 is preferably etched in a Cl 2 /O 2 plasma. Moreover, where it is used as a template for the formation of the completely transmissive regions 74 a - 74 f , the first patterned resist 72 is stripped after the completely transmissive regions 74 a - 74 f are formed, leaving a second intermediate mask structure 76 , which is illustrated in drawing FIG. 6 , including completely transmissive regions 74 a - 74 f.
[0049] Once the second intermediate mask structure 76 is formed, slightly attenuated regions are formed where desired. Slightly attenuated regions are created using a second patterned resist 78 formed over the second intermediate mask structure 76 , as shown in drawing FIG. 7 . The second patterned resist 78 is formed by first coating the first intermediate mask structure 76 with any suitable resist and patterning the resist by known methods to create exposed areas 77 a - 77 b on the second intermediate mask structure 76 , wherein slightly attenuated regions are to be created.
[0050] As is shown in drawing FIG. 8 , which illustrates a third intermediate mask structure 82 , the slightly attenuated regions 80 a - 80 d are created by etching the opaque layer 66 and the second attenuating layer 64 in the exposed areas 77 a - 77 b created by the second patterned resist 78 . Again, the opaque layer 66 and the second attenuating layer 64 can each be etched by known etch processes, such as those already discussed. As can also be seen in drawing FIG. 8 , the slightly attenuated regions 80 a - 80 d are preferably formed at the edges of isolated completely transmissive regions 74 a , 74 f . Because the slightly attenuated regions 80 a - 80 d are formed using portions of the first attenuating layer 62 , which shifts transmitted radiation 180°, radiation transmitted through the slightly attenuated regions 80 a - 80 d destructively interferes with radiation diffracting out from the edges of the isolated completely transmissive regions 74 a , 74 f , thereby greatly increasing the resolution with which the isolated completely transmissive regions 74 a , 74 f define desired device features. Moreover, because slightly attenuated regions 80 a - 80 d allow transmission of about 12% to about 20% of the incident radiation, the slightly attenuated regions 80 a - 80 d serve to maximize depth-of-focus performance.
[0051] As shown in drawing FIG. 9 , to create highly attenuated regions where desired, a third patterned resist 84 is formed over the third intermediate mask structure 82 . The third patterned resist 84 is created by first coating the third intermediate mask structure 82 with a suitable resist. The resist is then patterned by known methods to expose an area 85 of the third intermediate mask structure 82 wherein highly attenuated regions are to be created.
[0052] Highly attenuated regions 86 a - 86 e are then formed by selectively etching the opaque layer 66 in the exposed area 85 (see drawing FIG. 10 ). The opaque layer 66 can be etched using any suitable etch process, such as the processes already discussed herein. After formation of the highly attenuated regions, the third patterned resist 84 is stripped, leaving a complete APSM 88 according to the first embodiment of the APSM of the present invention (shown in drawing FIG. 11 ). It is easily appreciated from reference to drawing FIG. 11 that the highly attenuated regions 86 a - 86 e are preferably formed at the edges of closely spaced transmissive regions 74 b - 74 e which are closely spaced. Because of the one hundred eighty degree (180°) phase shift provided by the first attenuating layer 62 and the high total attenuation provided by the highly attenuated regions 86 a - 86 e , the highly attenuated regions 86 a - 86 e formed at the edges of closely spaced completely transmissive regions 74 b - 74 e greatly increase the resolution with which the isolated completely transmissive regions 74 a , 74 f define desired device features, while minimizing or eliminating any fabrication defects that may otherwise occur due to additive ringing effects.
[0053] As can be appreciated by reference to drawing FIG. 11 , even after formation of completely transmissive regions 74 a - 74 f , slightly attenuated regions 80 a - 80 d , and highly attenuated regions 86 a - 86 e , portions of the opaque layer 66 remain, forming opaque regions 90 a - 90 d . Opaque regions 90 a - 90 d may be maintained on the finished APSM to prevent exposure to even attenuated radiation where attenuated radiation is not needed to increase image resolution. The first embodiment of the method of the present invention, therefore, provides an APSM having completely transmissive regions, highly attenuated regions, slightly attenuated regions, and opaque regions, which work in concert to maximize image resolution and depth-of-focus for isolated features, while minimizing or eliminating any defects caused by additive ringing effects in areas of high feature density and preventing any defects caused by transmission of attenuated radiation where attenuated radiation is not needed to enhance resolution and depth-of-focus.
[0054] In a second embodiment, described in conjunction with drawing FIG. 12 through drawing FIG. 19 , the method of the present invention involves the use of etch stop technology. As illustrated in drawing FIG. 12 , the method of the second embodiment also involves providing a transparent substrate 60 , which may also be, for example, a quartz, fused silica, or other glass substrate. A first attenuating layer 100 comprising CrF x is deposited over the transparent substrate, followed by the formation of an etch stop layer 102 over the first attenuating layer 100 . The etch stop layer 102 may be formed of any suitable etch stop material that will allow for an etch selectivity between it and the etching chemistry utilized to etch the material adjacent to it (i.e., second attenuating layer 104 shown in FIG. 12 ). For example, the first etch stop layer 102 may be formed of silicon dioxide (SiO 2 ).
[0055] The first attenuating layer 100 is only slightly attenuating, allowing about 12% to about 20% transmission. Moreover, the first attenuating layer 100 may be formed such that the first attenuating layer 100 induces a one hundred eighty degree (180°) phase shift in radiation passing through the first attenuating layer 100 . Alternatively, the first etch stop layer 102 may be formed to induce a one hundred eighty degree (180°) phase shift, while the first attenuating layer 100 serves only to attenuate passing radiation, or the first attenuating layer 100 and first etch stop layer 102 may be formed such that radiation must pass through both layers 100 , 102 to be shifted one hundred eighty degrees (180°) out of phase. Where the first attenuating layer 100 is formed such that the first attenuating layer 100 both attenuates passing radiation and shifts the passing radiation one hundred eighty degrees (180°) out of phase, the first etch stop layer 102 is formed to allow passage of radiation without inducing any further phase shifts.
[0056] As shown in drawing FIG. 12 , a second attenuating layer 104 is formed over the etch stop layer 102 . The second attenuating layer 104 is also preferably formed of CrF x and further attenuates passing radiation. The second attenuating layer 104 is preferably formed such that radiation passing through both the first attenuating layer 100 and the second attenuating layer 104 is highly attenuated (i.e., the combined attenuation of the first attenuating layer 100 and the second attenuating layer 104 is about 90% to about 96%, resulting in about 4% to about 10% transmittance). However, the second attenuating layer 104 does not induce any phase shift in radiation passing therethrough. Once the second attenuating layer 104 is formed, an opaque layer 106 is provided over the second attenuating layer 104 , resulting in a first intermediate mask structure 108 . As is true in the first embodiment of the method of the present invention, the opaque layer 106 may be formed of any suitable material known in the art and by any suitable method, such as a deposited chromium layer.
[0057] Using the first intermediate mask structure 108 , an APSM according to the second embodiment of the APSM of the present invention may be fabricated. Forming an APSM according to the second embodiment using the first intermediate mask structure 108 involves formation of a first patterned resist 110 over the opaque layer 106 of the first intermediate mask structure 108 , as is shown in drawing FIG. 13 . The first patterned resist 110 is created by first coating the opaque layer 106 with any suitable resist and patterning the resist by known methods to define the desired feature pattern to be projected by the completed APSM. After formation of the first patterned resist 110 , the opaque layer 106 and the second attenuating layer 104 are etched in a single step using a Cl 2 /O 2 plasma etch process, which will stop at the etch stop layer 102 . With the first patterned resist 110 still in place, the etch stop layer 102 is etched using a fluorine-based plasma etch process, and the first attenuating layer 100 is then etched using a second Cl 2 /O 2 plasma etch process.
[0058] After etching the first attenuating layer 100 , the first patterned resist 110 is stripped, leaving a second intermediate mask structure 112 , as illustrated in drawing FIG. 14 . The second intermediate mask structure 112 includes completely transmissive regions 114 a - 114 f which correspond in size, shape and location to the device pattern to be projected by the mask.
[0059] As can be seen in drawing FIG. 15 , a second patterned resist 116 is then formed over the second intermediate mask structure 112 , in order to form slightly attenuated regions where desired. The second patterned resist 116 is formed by first coating the second intermediate mask structure 112 with any suitable resist and patterning the resist by known methods to create exposed areas 118 a , 118 b of the second intermediate mask structure 112 wherein slightly attenuated regions are to be formed.
[0060] As can be appreciated by reference to drawing FIG. 16 , which illustrates a third intermediate mask structure 120 , the slightly attenuated regions 122 a - 122 d are then created by etching the opaque layer 106 and the second attenuating layer 104 in a single step using a Cl 2 /O 2 plasma etch process, which stops at the exposed portions 124 a - 124 d of the etch stop layer 102 , thereby reducing the number of etch steps necessary to form the slightly attenuated regions 122 a - 122 d relative to the first embodiment of the method of the present invention.
[0061] Further illustrated in drawing FIG. 16 is that the slightly attenuated regions 122 a - 122 d , are preferably formed only at the edges of isolated completely transmissive regions 114 a , 114 f . Because the slightly attenuated regions 122 a - 122 d are formed of portions of the first attenuating layer 100 as well as portions of the etch stop layer 102 , the slightly attenuating regions 122 a - 122 d shift transmitted radiation one hundred eighty degrees (180°), and the radiation transmitted through the slightly attenuated regions 122 a - 122 d destructively interferes with radiation diffracting out from the edges of the isolated completely transmissive regions 114 a , 114 f , thereby greatly increasing the resolution with which the isolated completely transmissive regions 114 a , 114 f define desired device features. Moreover, because slightly attenuated regions 122 a - 122 d allow transmission of about 12% to about 20% of the incident radiation, the slightly attenuated regions 122 a - 122 d serve to maximize depth-of-focus performance.
[0062] As illustrated in drawing FIG. 17 , a third patterned resist 128 is formed over the third intermediate mask structure 120 to create highly attenuated regions where desired. The third patterned resist 128 is created by first coating the third intermediate mask structure 120 with any suitable resist. The resist is then patterned by known methods to expose an area 130 of the third intermediate mask structure 120 wherein highly attenuated regions are to be created.
[0063] Highly attenuated regions 132 a - 132 e are then formed by selectively etching the opaque layer 106 in the exposed area 130 (see drawing FIG. 18 ). Though the opaque layer 106 can be etched using any suitable etch process, where chromium is used as the opaque layer 106 , for example, a Cl 2 /O 2 plasma etch process or a suitable wet etch process may be used. After formation of the highly attenuated regions 132 a - 132 e , the third patterned resist 128 is stripped, leaving a complete APSM 134 according to the second embodiment of the APSM of the present invention (shown in drawing FIG. 19 ).
[0064] As was true in the first embodiment of the APSM of the present invention, the highly attenuated regions 132 a - 132 e included in the second embodiment of the APSM 134 of the present invention are preferably formed at the edges of the closely spaced completely transmissive regions 114 b - 114 e . The one hundred eighty degree (180°) phase shift provided by the first attenuating layer 100 and/or the etch stop layer 102 and the high total attenuation provided by the combined attenuations of the first attenuating layer 100 and the second attenuating layer 104 , enhance the resolution of the images projected by the closely spaced completely transmissive regions 114 b - 114 e , while minimizing or eliminating any fabrication defects that may otherwise occur due to additive side lobes produced by the closely spaced completely transmissive regions 114 b - 114 e.
[0065] Reference to drawing FIG. 19 highlights that, even after formation of completely transmissive regions 114 a - 114 f , slightly attenuated regions 122 a - 122 d , and highly attenuated regions 132 a - 132 e , portions of the opaque layer 106 remain, forming opaque regions 140 a - 140 d . Again, opaque regions 140 a - 140 d may be maintained on the finished APSM to prevent exposure to even attenuated radiation where attenuated radiation is not needed to increase image resolution. The second embodiment of the method of the present invention, therefore, also provides APSMs having completely transmissive regions, highly attenuated regions, slightly attenuated regions, and opaque regions, which work in concert to maximize image resolution and depth-of-focus for isolated features, while minimizing or eliminating any defects caused by additive ringing effects in areas of high feature density and preventing any defects caused by transmission of attenuated radiation where attenuated radiation is not needed to enhance resolution and depth-of-focus.
[0066] Though the method and APSM of the present invention have been described and illustrated herein with reference to two different embodiments, such descriptions and illustrations do not limit the scope of the present invention. The method of the present invention and design of an APSM according to the present invention are highly adaptable. For example, the method disclosed herein can be used to fabricate APSMs having any desired feature pattern. Moreover, the steps of the method and composition of the APSMs can be modified in several aspects while still obtaining an APSM according to the present invention. For instance, the method of the present invention may utilize etching processes different from those discussed herein. Additionally, materials different than those described herein, such as, different substrate materials, different attenuating materials, different light blocking materials, or different etch stop materials, may be used in conjunction with the method of the present invention to fabricate APSMs according to the present invention having a different material composition than the APSMs according to the first and second embodiments. Therefore, the present invention is not to be defined or limited by the illustrative and descriptive examples provided herein, but, instead, the scope of the present invention is defined by the appended claims. | The present invention provides an attenuated phase shift mask (“APSM”) that, in each embodiment, includes completely transmissive regions sized and shaped to define desired semiconductor device features, slightly attenuated regions at the edges of the completely transmissive regions corresponding to isolated device features, highly attenuated regions at the edges of completely transmissive regions corresponding to closely spaced or nested device features, and completely opaque areas where it is desirable to block transmission of all radiation through the APSM. The present invention further provides methods for fabricating the APSMs according to the present invention. | 6 |
FIELD OF THE INVENTION
This invention discloses a dynamic bandwidth allocation system to optimize the transmission of information from a local office to the customer premises equipment along a twisted pair.
BACKGROUND
As deregulation of the telephone industry continues and as companies prepare to enter the local telephone access market, there is a need to offer new and innovative services that distinguish common carriers from their competitors. This cannot be accomplished without introducing new local access network architectures that will be able to support these new and innovative services.
Conventionally, customer premises telephone and/or data connections contain splitters for separating analog voice calls from other data services such as Ethernet transported over digital subscriber line (DSL) modems. Voice band data and voice signals are sent through a communications switch in a central or local office to an interexchange carrier or Internet service provider. DSL data is sent through a digital subscriber loop asynchronous mode (DSLAM) switch which may include a router. The DSLAM switch connects many lines and routes the digital data to a telephone company's broadband digital switch (for example, ATM).
A major problem with this configuration is that interexchange carriers attempting to penetrate the local telephone company's territory must lease trunk lines from the local telephone company switch to the interexchange company's network for digital traffic. Furthermore, the Internet service provider must lease a modem from the local phone company in the DSLAM switch and route its data through the local phone company's digital broadband switch. Thus, the local phone company leases and/or provides a significant amount of equipment, driving up the cost of entry for any other company trying to provide local telephone services and making it difficult for the interexchange companies to differentiate their services. Furthermore, since DSL modem technology is not standardized, in order to ensure compatibility, the DSL modem provided by the local telephone company must also be provided to the end user in the customer premises equipment (CPE). Additionally, since the network is not completely controlled by the interexchange companies, it is difficult for the interexchange companies to provide data at committed delivery rates. Any performance improvements implemented by the interexchange companies may not be realized by their customers, because the capabilities of the local telephone company equipment may or may not meet their performance needs. Thus, it is difficult for the interexchange companies to convince potential customers to switch to their equipment or to use their services. These factors ensure the continued market presence of the local telephone company.
As part of this system, there is a need for improved architectures, services and equipment utilized to distinguish the interexchange companies' products and services.
The current bandwidth allocation scheme devotes the entire channel to a specific mode of service, forcing customers to choose one mode of traffic for use with the twisted pair, e.g. voice, facsimile or Internet. As demand for simultaneous traffic increases, multiple twisted pair lines are required increasing the costs for the users and increasing the investment capital required by the service providers.
This invention addresses these problems by dynamically allocating bandwidth on the twisted pair to support multiple, simultaneous services. By providing for multiple, simultaneous services, the requirement for the installation of multiple twisted pairs dedicated to specific services is minimized. These schemes could be employed for use in other physical transmission media such as coaxial cable and fiber.
SUMMARY OF THE INVENTION
In order to provide an improved network, it is desirable for the interexchange companies to have access to at least one of the twisted-pair lines or alternate wireless facility connecting each of the individual users to the local telephone network before the lines are routed through the conventional local telephone network equipment. It is preferable to have access to these lines prior to the splitter and modem technology offered by the local service providers. By having access to the twisted-pair wires entering the customer's premises, interexchange companies can differentiate their services by providing higher bandwidth, improving the capabilities of the customer premises equipment, and lowering overall system costs to the customer by providing competitive service alternatives.
The new architecture may utilize a video phone and/or other devices to provide new services to an end user; an intelligent services director (ISD) or terminal block disposed near the customer's premises for multiplexing and coordinating many digital services onto a single twisted-pair line; a facilities management platform (FMP) disposed in the local telephone network's central office for routing data to an appropriate interexchange company network; and a network server platform (NSP) coupled to the FMP for providing new and innovative services to the customer and for distinguishing services provided by the interexchange companies from those services provided by the local telephone network.
As part of this system, one aspect of the invention provides a dynamic bandwidth allocation system to optimize the transmission of traffic on the line connecting the customer premises equipment with the local office. As demand for simultaneous traffic at the customer premises equipment increases, the requirement for multiple twisted pair lines is minimized by dynamically allocating an available bandwidth of the twisted pair.
Additional efficiencies for simultaneous transmission of traffic can be achieved by restricting or reducing the available bandwidth for the existing services currently in use. This will likely affect the quality of some services but in many cases the impact will be minimal. Voice quality will be allowed to deteriorate to a predetermined level and facsimile or other data traffic will be transmitted at a slower transmission rate. At some predetermined level, traffic quality will degrade to a level such that service will be unacceptable. At this point, a prioritization scheme will buffer certain traffic at the intelligent services director or the facilities management platform. New requests for services are denied until the required bandwidth required for the service is free. Once the required bandwidth becomes available, buffered traffic is allowed to flow again and service availability will resume.
An alternative scheme allows all services to maintain their highest quality and instead ranks all traffic by a priority scheme and sequentially transmits services. Once the allocated bandwidth is used, the priority scheme discontinues or buffers lower ranking traffic. Once bandwidth resources are released by the higher ranking traffic, the lower ranking traffic is allowed to proceed if the information was buffered. By optimizing the traffic on the twisted pair, requirements for the installation of multiple twisted pairs is minimized as services are added by the user.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary of the invention, as well as the following detailed description of preferred embodiments, is better understood when read in conjunction with the accompanying drawings, which are included by way of example, and not by way of limitation with regard to the claimed invention.
FIG. 1 illustrates an embodiment of a hybrid fiber twisted pair local loop architecture.
FIG. 2 is a block diagram of an embodiment of an intelligent services director consistent with the architecture shown in FIG. 1 .
FIGS. 3A and 3B illustrate an embodiment of a video phone consistent with the architecture shown in FIG. 1 .
FIG. 4A is a block diagram of an embodiment of a facilities management platform consistent with the architecture shown in FIG. 1 .
FIG. 4B illustrates a block diagram of an embodiment of a network server platform consistent with the architecture shown in FIG. 1 .
FIG. 5 illustrates a diagram of the available spectrum of a twisted pair.
FIGS. 6A and 6B illustrate diagrams of the ASDL frame format.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following applications, filed concurrently herewith, are hereby incorporated by reference:
1. A Hybrid Fiber Twisted-pair Local Loop Network Service Architecture U.S. application Ser. No. 09/001,360, filed Dec. 31, 1997;
2. The VideoPhone U.S. application Ser. No. 09/001,905, filed Dec. 31, 1997;
3. VideoPhone Privacy Activator U.S. application Ser. No. 09/001,909, filed Dec. 31, 1997;
4. VideoPhone Form Factor U.S. application Ser. No. 09/001,583, filed Dec. 31, 1997;
5. VideoPhone Centrally Controlled User Interface With User Selectable Options U.S. application Ser. No. 09/001,576, filed Dec. 31, 1997;
6. VideoPhone User Interface Having Multiple Menu Hierarchies U.S. application Ser. No. 09/001,908, filed Dec. 31, 1997;
7. VideoPhone Blocker U.S. application Ser. No. 09/001,353, filed Dec. 31, 1997;
8. VideoPhone Inter-com For Extension Phones U.S. application Ser. No. 09/001,358, filed Dec. 31, 1997;
9. Advertising Screen Saver U.S. application Ser. No. 09/001,574, filed Dec. 31, 1997;
10. Information Display for a Visual Communication Device U.S. application Ser. No. 09/001,906, filed Dec. 31, 1997;
11. VideoPhone Multimedia Announcement Answering Machine U.S. application Ser. No. 09/001,911, filed Dec. 31, 1997;
12. VideoPhone Multimedia Announcement Message Toolkit U.S. application Ser. No. 09/001,345, filed Dec. 31;
13. VideoPhone Multimedia Video Message Reception U.S. application Ser. No. 09/001,362, filed Dec. 31, 1997;
14. VideoPhone Multimedia Interactive Corporate Menu Answering Machine Announcement U.S. application Ser. No. 09/001,575, filed Dec. 31, 1997;
15. VideoPhone Multimedia Interactive On-Hold Information Menus U.S. application Ser. No. 09/001,356, filed Dec. 31, 1997;
16. VideoPhone Advertisement When Calling Video Non-enabled VideoPhone Users U.S. application Ser. No. 09/001,361, filed Dec. 31, 1997;
17. Motion Detection Advertising U.S. application Ser. No. 09/001,355, filed Dec. 31, 1997;
18. Interactive Commercials U.S. application Ser. No. 09/001,578, filed Dec. 31, 1997;
19. VideoPhone Electronic Catalogue Service U.S. application Ser. No. 09/001,421, filed Dec. 31, 1997;
20. A Multifunction Interface Facility Connecting Wideband Multiple Access Subscriber Loops With Various Networks (U.S. application Ser. No. 09/001,422, filed Dec. 31, 1997);
21. Life Line Support for Multiple Service Access on Single Twisted-pair U.S. application Ser. No. 09/001,343, filed Dec. 31, 1997;
22. A Network Server Platform (NSP) For a Hybrid Fiber Twisted-pair (HFTP) Local Loop Network Service Architecture U.S. application Ser. No. 09/001,582, filed Dec. 31, 1997;
23. A Communication Server Apparatus For Interactive Commercial Service U.S. application Ser. No. 09/001,344, filed Dec. 31, 1997;
24. NSP Based Multicast Digital Program Delivery Services (U.S. application Ser. No. 09/001,580, filed Dec. 31, 1997);
25. NSP Internet, JAVA Server and VideoPhone Application Server U.S. application Ser. No. 09/001,354, filed Dec. 31, 1997;
26. NSP WAN Interconnectivity Services for Corporate Telecommuting (U.S. application Ser. No. 09/001,540, filed Dec. 31, 1997;
27. NSP Telephone Directory White-Yellow Page Services U.S. application Ser. No. 09/001,426, filed Dec. 31, 1997;
28. NSP Integrated Billing System For NSP services and Telephone services U.S. application Ser. No. 09/001,350, filed Dec. 31, 1997;
29. Network Server Platform/Facility Management Platform Caching Server U.S. application Ser. No. 09/001,419, filed Dec. 31, 1997;
30. An Integrated Services Director (ISD) Overall Architecture (U.S. application Ser. No. 09/001,417, filed Dec. 31, 1997;
31. ISD VideoPhone (Customer Premises) Local House Network (U.S. application Ser. No. 09/001,418, filed Dec. 31, 1997;
32. ISD Wireless Network U.S. application Ser. No. 09/001,363, filed Dec. 31, 1997;
33. ISD Controlled Set-Top Box U.S. application Ser. No. 09/001,424, filed Dec. 31, 1997;
34. Integrated Remote Control and Phone U.S. application Ser. No. 09/001/423, filed Dec. 31, 1997;
35. Integrated Remote Control and Phone User Interface U.S. application Ser. No. 09/001,420, filed Dec. 31, 1997;
36. Integrated Remote Control and Phone Form Factor U.S. application Ser. No. 09/001,910, filed Dec. 31, 1997;
37. VideoPhone Mail Machine (U.S. application Ser. No. 60/070,104);
38. Restaurant Ordering Via VideoPhone (U.S. application Ser. No. 60/070,121);
39. Ticket Ordering Via VideoPhone (U.S. application Ser. No. 60/070,103);
40. Multi-Channel Parallel/Serial Concatenated Convolutional Codes And Trellis Coded Modulation Encode/Decoder U.S. application Ser. No. 09/001,342, filed Dec. 31, 1997;
41. Spread Spectrum Bit Allocation Algorithm U.S. application Ser. No. 09/001,842, filed Dec. 31, 1997;
42. Digital Channelizer With Arbitrary Output Frequency U.S. application Ser. No. 09/001,581. filed Dec. 31, 1997;
43. Method And Apparatus For Allocating Data Via Discrete Multiple Tones U.S. application Ser. No. 08/997,167, filed Dec. 23, 1997;
44. Method And Apparatus For Reducing Near-End Cross Talk In Discrete Multi-Tone Modulators/Demodulators U.S. application Ser. No. 08/997,176, filed Dec. 23, 1997.
In addition, the following two patent applications are hereby incorporated by reference:
1. U.S. patent application Ser. No. 08/943,312 filed Oct. 14, 1997 entitled Wideband Communication System for the Home, to Robert R. Miller, II and Jesse E. Russell, and
2. U.S. patent application Ser. No. 08/858,170, filed May 14, 1997, entitled Wide Band Transmission Through Wire, to Robert R. Miller, II, Jesse E. Russell and Richard R. Shively.
Referring to FIG. 1, a first exemplary communication network architecture employing a hybrid fiber, twisted-pair (HFTP) local loop 1 architecture is shown. An intelligent services director (ISD) or terminal block 22 may be coupled to a central office 34 via a twisted-pair wire, hybrid fiber interconnection, wireless and/or other customer connection 30 , a connector block 26 , and/or a main distribution frame (MDF) 28 . The ISD 22 and the central or local office 34 may communicate with each other using, for example, framed, time division, code division, frequency-division, synchronous, asynchronous and/or spread spectrum formats, but in exemplary embodiments uses DSL modem technology. The central office 34 preferably includes a facilities management platform (FMP) or access module 32 for processing data exchanged across the customer connection 30 . The FMP 32 may be configured to separate the plain old telephone service (POTS) from the remainder of the data on the customer connection 30 using, for example, a tethered virtual radio channel (TVRC) modem (shown in FIG. 4 A). The remaining data may be output to a high speed backbone network (e.g., a fiber optic network) such as an asynchronous transfer mode (ATM) switching network. The analog POTS data may be output directly to a public switch telephone network (PSTN) 46 , and/or it may be digitized, routed through the high speed backbone network, and then output to the PSTN 46 .
The FMP 32 may process data and/or analog/digitized voice between customer premise equipment (CPE) 10 and any number of networks. For example, the FMP 32 may be interconnected with a synchronous optical network (SONET) 42 for interconnection to any number of additional networks such as an InterSpan backbone 48 , the PSTN 46 , a public switch switching network (e.g. call setup SS7-type network 44 ), and/or a network server platform (NSP) system management server 36 . Alternatively, the FMP 32 may be directly connected to any of these networks. One or more FMPs 32 may be connected directly to the high speed backbone network (e.g., direct fiber connection with the SONET network 42 ) or they may be linked via a trunk line (e.g., trunks 40 or 42 ) to one or more additional networks.
The NSP 36 may provide a massive cache storage for various information that may be provided across the SONET net 42 to the FMP 32 and out to the ISD 22 . The NSP 36 and the FMP 32 may collectively define an access network server complex 38 . The NSP 36 may be interconnected with multiple FMPs 32 . Furthermore, each FMP 32 may interconnect with one or more ISDs 22 . The NSP 36 may be located anywhere but is preferably located in a point-of-presence (POP) facility. The NSP 36 may further act as a gateway to, for example, any number of additional services.
The ISD 22 may be interconnected to various devices such as a videophone 130 , other digital phones 18 , set-top devices, computers, and/or other devices comprising the customer premise equipment 10 . The customer premise equipment may individually or collectively serve as a local network computer at the customer site. Application applets may be downloaded from the NSP 36 into some or all of the individual devices within the customer premise equipment 10 . Where applets are provided by the NSP 36 , the programming of the applets may be updated such that the applets are continually configured to the latest software version by the interexchange carrier. In this way, the CPE 10 may be kept up to date by simply re-loading updated applets. In addition, certain applets may be resident on any of the CPE 10 . These resident applets may be periodically reinitialized by simply sending a request from, for example, a digital phone 18 and/or a videophone 130 to the FMP 32 and thereafter to the NSP 36 for reinitialization and downloading of new applets. To ensure widespread availability of the new features made possible by the present architecture, the customer premise equipment may be provided to end users at either a subsidized cost or given away for free, with the cost of the equipment being amortized over the services sold to the user through the equipment.
Referring to FIG. 2, the ISD 22 may connect with a variety of devices including analog and digital voice telephones 15 , 18 ; digital videophones 130 , devices for monitoring home security, meter reading devices (not shown), utilities devices/energy management facilities (not shown), facsimile devices 16 , personal computers 14 , and/or other digital or analog devices. Some or all of these devices may be connected with the ISD 22 via any suitable mechanism such as a single and/or multiple twisted-pair wires and/or a wireless connection. For example, a number of digital devices may be multi-dropped on a single twisted-pair connection. Similarly, analog phones and other analog devices may be multi-dropped using conventional techniques.
The ISD 22 may be located within the home/business or mounted exterior to the home/business. The ISD 22 may operate from electrical power supplied by the local or central office 34 and/or from the customer's power supplied by the customer's power company. Where the ISD 22 includes a modem, it may be desirable to power the ISD 22 with supplemental power from the home in order to provide sufficient power to enable the optimal operation of the modem.
As shown in FIG. 2, in some embodiments the ISD 22 may include a controller 100 which may have any of a variety of elements such as a central processing unit 102 , a DRAM 103 , an SRAM 104 , a ROM 105 and/or an Internet protocol (IP) bridge router 106 connecting the controller 100 to a system bus 111 . The system bus 111 may be connected with a variety of network interface devices 110 . The network interface devices 110 may be variously configured to include an integrated services digital network (ISDN) interface 113 , an Ethernet interface 119 (e.g., for 28.8 kbps data, 56 kbps data, or ISDN), an IEEE 1394 “fire wire” interface 112 (e.g., for a digital videodisc device (DVD)), a TVRC modem interface 114 (e.g., for a digital subscriber line (DSL) modem), a residential interface 114 , (e.g., standard POTS phone systems such as tip ring), a business interface 116 (e.g., a T 1 line and/or PABX interface), a radio frequency (RF) audio/video interface 120 (e.g., a cable television connection), and a cordless phone interface 123 (e.g., a 900 MHZ transceiver). Connected to one of the network interfaces and/or the system bus 111 may be any number of devices such as an audio interface 122 (e.g., for digital audio, digital telephones, digital audio tape (DAT) recorders/players, music for restaurants, MIDI interface, DVD, etc.), a digital phone 121 , a videophone/user interface 130 , a television set-top device 131 and/or other devices. Where the network interface is utilized, it may be desirable to use, for example, the IEEE 1394 interface 112 and/or the Ethernet interface 119 .
A lifeline 126 may be provided for continuous telephone service in the event of a power failure at the CPE 10 . The lifeline 126 may be utilized to connect the ISD 22 to the local telecommunications company's central office 34 and, in particular, to the FMP 32 located in the central office 34 .
The ISD may be variously configured to provide any number of suitable services. For example, the ISD 22 may offer high fidelity radio channels by allowing the user to select a particular channel and obtaining a digitized radio channel from a remote location and outputting the digital audio, for example, on audio interface 122 , video phone 130 , and/or digital phones 121 . A digital telephone may be connected to the audio interface 122 such that a user may select any one of a number of digital audio service channels by simply having the user push a digital audio service channel button on the telephone and have the speaker phone output particular channels. The telephone may be preprogramed to provide the digital audio channels at a particular time, such as a wake up call for bedroom mounted telephone, or elsewhere in the house. The user may select any number of services on the video phone and/or other user interface such as a cable set-top device. These services may include any number of suitable services such as weather, headlines in the news, stock quotes, neighborhood community services information, ticket information, restaurant information, service directories (e.g., yellow pages), call conferencing, billing systems, mailing systems, coupons, advertisements, maps, classes, Internet, pay-per-view (PPV), and/or other services using any suitable user interface such as the audio interface 122 , the video phone/user interface 130 , digital phones, 121 and/or another suitable device such as a set top device 131 .
In further embodiments, the ISD 22 may be configured as an IP proxy server such that each of the devices connected to the server utilizes transmission control protocol/Internet protocol (TCP/IP) protocol. This configuration allows any device associated with the ISD to access the Internet via an IP connection through the FMP 32 . Where the ISD 22 is configured as an IP proxy server, it may accommodate additional devices that do not support the TCP/IP protocol. In this embodiment, the ISD 22 may have a proprietary or conventional interface connecting the ISD 22 to any associated device such as to the set top box 131 , the personal computer 14 , the video telephone 130 , the digital telephone 18 , and/or some other end user device.
In still further embodiments, the ISD 22 may be compatible with multicast broadcast services where multicast information is broadcast by a central location and/or other server on one of the networks connected to the FMP 32 , e.g., an ATM-switched network. The ISD 22 may download the multicast information via the FMP 32 to any of the devices connected to the ISD 22 . The ISD 22 and/or CPE 10 devices may selectively filter the information in accordance with a specific customer user's preferences. For example, one user may select all country music broadcasts on a particular day while another user may select financial information. The ISD 22 and/or any of the CPE 10 devices may also be programmed to store information representing users' preferences and/or the received uni-cast or multicast information in memory or other storage media for later replay. Thus, for example, video clips or movies may be multicast to all customers in the community with certain users being preconfigured to select the desired video clip/movie in real time for immediate viewing and/or into storage for later viewing.
Referring to FIG. 3A, a videophone 130 may include a touch screen display 141 and soft keys 142 around the perimeter of the display 141 . The display may be responsive to touch, pressure, and/or light input. Some or all of the soft keys 142 may be programmable and may vary in function depending upon, for example, the applet being run by the videophone 130 . The function of each soft key may be displayed next to the key on the display 141 . The functions of the soft keys 142 may also be manually changed by the user by pressing scroll buttons 143 . The videophone 140 may also include a handset 144 (which may be connected via a cord or wireless connection to the rest of the videophone and/or directly to the ISD), a keypad 150 , a video camera 145 , a credit card reader 146 , a smart card slot 147 , a microphone 149 , a motion and/or light detector 148 , built-in speaker(s) 155 , a printer/scanner/facsimile 152 , and/or external speakers 154 (e.g., stereo speakers). A keyboard 153 and/or a postage scale 151 may also be connected to the videophone 130 . Any or all of the above-mentioned items may be integrated with the videophone unit itself or may be physically separate from the videophone unit. A block diagram of the video phone unit is shown in FIG. 3 B. Referring to FIG. 3B, in addition to the items above, the video phone 130 may also include a signal processor 171 , high speed interface circuitry 172 , memory 173 , power supply 174 , all interconnected via a controller 170 .
When the videophone 130 is used as a video telephone, the display 141 may include one or more video window(s) 160 for viewing a person to whom a user is speaking and/or showing the picture seen by the person on the other end of the video phone. The display may also include a dialed-telephone-number window 161 for displaying the phone number dialed, a virtual keypad 162 , virtual buttons 163 for performing various telephone functions, service directory icons 165 , a mail icon 164 , and/or various other service icons 166 which may be used, for example, for obtaining coupons or connecting with an operator. Any or all of these items may be displayed as virtual buttons and/or graphic icons and may be arranged in any combination. Additionally, any number of other display features may be shown on the video phone in accordance with one or more of the applications incorporated by reference below.
Referring to FIG. 4A, the FMP 32 may coordinate the flow of data packets, separate voice signals from other signals, perform line monitoring and switching functions, and/or convert between analog and digital signals. The FMP 32 may process data sent from the CPE 10 to the central or local office 34 by separating and reconstructing analog voice signals, data, and control frames. The FMP 32 may process data sent from the central or local office 34 to the CPE 10 by separating control messages from user information, and configure this information into segments that for transport across the digital subscriber loop. The FMP 32 may also terminate the link layer associated with the digital subscriber loop.
In some embodiments, the FMP 32 may include an access module 70 and a digital loop carrier 87 . The access module 70 may include a line protector 71 , a cross-connector 73 , a plurality of TVRC modems 80 , a plurality of digital filters 82 , a controller multiplexer 84 , and/or a router and facilities interface 86 . The digital loop carrier 87 may include a plurality of line cards 96 , a time domain multiplexing (TDM) multiplexor (MUX) 88 , a TDM bus 90 , a controller 92 , and/or a facilities interface 94 .
During normal operations, digital signals on the customer connection 30 (e.g., twisted-pair lines) containing both voice and data may be received by the TVRC modems 80 via the line protector 71 and the cross-connector 73 . Preferably, the line protector 71 includes lightning blocks for grounding power surges due to lightning or other stray voltage surges. The TVRC modems 80 may send the digital voice and/or data signals to the controller multiplexor 84 and the digital filters 82 . The digital filters 82 may separate the voice signals from the digital data signals, and the controller multiplexor 84 may then multiplex the voice signals and/or data signals received from the digital filters 82 . The controller multiplexor 84 may then send multiplexed voice signals to the TDM MUX 88 and the data signals to the router and facilities interface 86 for transmission to one or more external networks. The TDM MUX 88 may multiplex the voice signals from the controller multiplexor 84 and/or send the voice signals to the TDM bus 90 , which may then send the digital voice signals to the controller 92 and then to the facilities interface 94 for transmission to one or more external networks. Both the router and facilities interface 86 and the facilities interface 94 may convert between electrical signals and optical signals when a fiber optic link is utilized.
When there is a failure of the digital data link (e.g., if there is a failure of the TVRC modems 80 at the FMP 32 or the TVRC modem 114 at the ISD 22 ), only analog voice signals might be sent over the subscriber lines 30 . In such a case, the analog voice signals may be directly routed to the line cards 96 , bypassing the TVRC modems 80 , the digital filters 82 , the controller multiplexor 84 , and the TDM MUX 88 . Thus, voice communication is ensured despite a failure of the digital data link. The line cards 96 may convert the analog voice signals into digital format (e.g., TDM format) and send the digitized voice data onto the TDM bus 90 and eventually through the controller 92 and the facilities interface 94 for transmission to one or more external networks.
Referring to FIG. 4B, the NSP 36 may be variously configured to provide any number of services provided by a server such as information services, Internet services, pay-per-view movie services, database services, commercial services, and/or other suitable services. In the embodiment shown in FIG. 4B, the NSP 36 includes a router 185 having a backbone 180 (e.g., a fiber distributed data interface (FDDI) backbone) that interconnects a management server 182 , an information/database server 183 , and/or one or more application server clusters 184 . The NSP 36 may be connected via the router 185 by a link 181 to one or more external networks, NSPs 36 , and/or an FMPs 32 . The information/data base server 183 may perform storage and/or database functions. The application server cluster 184 may maintain and control the downloading of applets to the ISD 22 . The NSP 36 may also include a voice/call processor 186 configured to handle call and data routing functions, set-up functions, distributed operating system functions, voice recognition functions for spoken commands input from any of the ISD connected devices as well as other functions.
The dynamic bandwidth allocation schemes allow the mixing of voice and data while also dynamically allocating channel bandwidth for each service in real time. The bandwidth can be dynamically allocated in both the upstream and downstream directions. The allocation schemes allow for the addition of new services on the existing twisted pair infrastructure. Many of these services are in copending applications, incorporated by reference in this application.
FIG. 5 illustrates a diagram of the available spectrum of a twisted pair using ADSL technology. The twisted pair is a baseband arrangement excluding a gap between 40 kHz and 100 kHz. Between 0 kHz and 4 kHz, the spectrum is reserved for POTS transmissions and between 0 kHz and 40 kHz, the spectrum is reserved for ISDN transmissions. Between 100 kHz and 1 MHZ, the spectrum is reserved for other transmissions, primarily the transmission of digital data. The gap between 40 kHz and 100 kHz allows for proper separation of the voice and data signals when they are split at the FMP 32 . The bandwidth allocation is flexible and is not required to be operated in the same scheme as traditional POTS line and permits expansion of the entire frequency spectrum to be between 0 kHz and approximately 1 MHz.
Both the ISD 22 and the FMP 32 have the capability to sense and seize the available bandwidth and allocate that bandwidth to the requested service, deciding the optimal bandwidth allocation scheme for managing the requested services. The circuit between the ISD 22 and the FMP 32 may be variously configured by modulating the transmission of signals in either packetized, framed, time slotted data, frequency division or code division multiplexing formats. However, it may be desirable to frame the data from a plurality of devices into a single frame in order to avoid unnecessary overhead cost. Within the single frame, dynamic reconfiguration of the frame is possible so that different devices may be assigned different amounts of time slots within the frame to dynamically vary the bandwidth allocation between the devices.
Four major categories exist for handling congestion. First, in a simplified scheme, the hardware merely detects that system resources have reached capacity and all additional requests for system resources are denied. In a second scheme, flow control involves prioritizing of all services. Telephone calls might have the highest priority while Internet, utility monitoring and metering might have the lowest priority. Lower priority services are dropped. Third, flow control involves prioritizing certain services and allowing system resources to maximize flow control by decreasing the bandwidth allocation for all the services. For voice calls, voice quality degrades. For data transmission, the data transmission rates decrease. These lower transmission rates might affect the quality of service and possibly increase bit error rates. The service quality degradation and bit error rates are monitored and controlled so that service levels are allowed to deteriorate to a predetermined minimal threshold. The fourth flow control scheme, involves a combination of prioritization and reduction in bandwidth for all current services.
When congestion occurs, an added service allows for low priority traffic to be buffered until the congestion no longer exists. Once this occurs, the buffered services are transmitted or received. The dynamic bandwidth allocation schemes also have the ability to disconnect service to devices where a channel is maintained but inactivity of the channel is detected.
Both the ISD 22 and the FMP 32 have limited buffering resources. When the buffer approaches capacity, incoming packets of data are dropped or service is terminated. When data is being sent, many endpoints such as the ISD 22 and the FMP 32 use a process called time out and retransmission. After a particular period of time, if the transmitting interface has not received an acknowledgment, the data packet is sent again. This retransmission of data, contributes to the congestion and can also fill up the limited buffering resources. At some point, the amount of transmissions and retransmissions causes the network to malfunction, creating what is commonly referred to as congestion collapse.
For digital data transmission, the transmission of traffic can be designed based on transmission speed, block length, error rate, number of overhead bits, propagation speed, and the network's routing algorithm. Throughput can be increased by optimizing one or more of these factors.
The dynamic bandwidth allocation schemes seek to unify a high speed information and communication link between the customer services premises 10 and the communications network. The advanced network access strategy offers greater efficiency, improved cost and scaling capabilities and is able to support advanced network services. Asymmetric digital subscriber line (ADSL) technology was designed to operate on two wire, twisted cable pairs having mixed gauges. High speed simplex channels were designed for digital data transport from the network to the customer equipment premises. Low speed duplex channels were designed for digital data transport in either direction. In the original conception of ADSL, the low frequency region of the ADSL spectrum are configured for voice calls, while the high frequency region would be provisioned for digital data.
In the implementation for this invention, framing, multiplexing, and coding were examined. ADSL bearer transport rates are either low or high speed. The low speed bearer transport rates are divided into five segments and are shown in Table 1. The high speed bearer transport rate is divided into four segments and are shown in Table 2.
TABLE 1
Bearer
Rate (Kbps)
L1
16
L2
64
L3
160
L4
384
L5
576
TABLE 2
Bearer
Rate (Mbps)
H1
1.536
H2
3.072
H3
4.608
H4
6.144
Rate of L 1 and L 2 are primarily used for control channel transport. The remaining low bearer transport rates L 3 , L 4 , and L 5 and all of the high data rates H 1 , H 2 , H 3 , and H 4 are used for user data. All the bearer transport rates are multiples of 64 kbps. Therefore, voice channels operating at 64 kbps can be multiplexed on a modified ADSL. The T 1 rate is specified as 1.544 Mbps which is equivalent to 24×64 kbps and 8 kbps of overhead. All four high speed bearer transport rates are multiples of 1.536 Mbps, so T 1 schemes easily interwork with ASDL schemes.
A diversified subchannel structure is defined to support a wide variety of applications. The subchannels operate at the bearer transport rates of LS 0 , LS 1 , and LS 2 and is summarized in Table 3.
TABLE 3
Channel
Rate (kbps)
LS0
16 or 64
LS1
160
LS2
384 or 576
The channel LS 0 , often referred to as the “C” channel carries the control signaling associated with the high speed channels and can also carry signaling information associated with the other low speed channels. The LS 0 channel is mandatory while LS 1 and LS 2 are optional. The LS 0 transports control, selection of services, and call setup signaling. When the LS 1 channel transports the ISDN basic rate access, the signaling for LS 1 is contained in the ISDN “D” channel. If the LS 1 channel is used for non-ISDN transport, the associated signaling will also be contained in the LS 0 channel. The LS 0 channel operates at 16 kbps for ASDL applications operating at a maximum range (transport class 4 in TABLE 5), and 64 kbps otherwise. The LS 2 channel can operate at either 384 kbps or 576 kbps.
The high speed subchannels are designated by AS 0 , AS 1 , AS 2 , and AS 3 . The default data rates for these four subchannels are required to match the rate of the bearer channel that they transport according to TABLE 4.
TABLE 4
High Speed
Subchannel
Designation
Data Rate (Mbps)
Allowed Values of n k
AS0
n0 × 1.536
n0 = 0, 1, 2, 3 or 4
AS1
n1 × 1.536
n1 = 0, 1, 2 or 3
AS2
n2 × 1.536
n2 = 0, 1 or 2
AS3
n3 × 1.536
n3 = 0 or 1
The assignment of low and high speed subchannels configurations depends upon the transport class and are defined during loop initialization. For any transport classes, there is a maximum number of subchannels that can be active. These classes are shown in TABLE 5. Using the variegated subchannel definition of ASDL, tethered virtual radio channel systems may be configured to carry digital voice, data, or both.
TABLE 5
Maximum Active High
Maximum Active Low
Transportation Class
Speed Channels
Speed Channels
1
4: AS0, AS1, AS2,
3: LS0, LS1, LS2
AS3
2
3: AS0, AS1, AS2
2: LS0 and LS1 or
LS0 and LS2
3
2: AS0, AS1
2: LS0 and LS1 or
LS0 and LS2
4
1: AS0
2: LS0 and LS1
ASDL framing uses data frames that carry user information. Superframes are formed by aggregating the user data frames. The data frames consist of fast and slow buffers within which some of the user information bits are reserved for synchronization and control.
The ASDL user data is clocked at a discrete multitone symbol rate of 4000 baud. A superframe consists of 68 ASDL user data frames and is illustrated in FIG. 6 . The superframe boundary is indicated by a synchronization symbol that is sent every 69 frames and is inserted into the data stream by the modulator. No user data or overhead information is included in the superframe synchronization symbol.
The raw symbol rate for ADSL is given by:
S =(69/68)*4000 baud
The ADSL frame has a time duration given by 1/S (68/69*250 μsec). Since there are 69 frames in a superframe, the duration of a superframe is 17 msec (68*250 μsec). Structural information for the superframe is carried within the constituent frames of the superframe. Each frame is made up of a fast and slow buffer and superframe based information for the fast and slow buffers are carried separately.
In every superframe, 8 bits are reserved for transporting the cycle redundancy check (crc) (crc 0 -crc 7 ) for the fast data buffer, and 24 information bits (ib) (ib 0 -ib 23 ) are reserved for fixed overhead for supporting the operations, administration and maintenance functionality. The fixed overhead bits are referenced as indicator bits. These bits are carried in the first byte of the fast buffer, the “fast” byte of frame 0 , 1 , 34 and 35 as shown in TABLE 6.
TABLE 6
Frame
Bit Assignment
0
crc7
crc6
crc5
crc4
crc3
crc2
crc1
crc0
1
ib7
ib6
ib5
ib4
ib3
ib2
ib1
ib0
34
ib15
ib14
ib13
ib12
ib11
ib10
ib9
ib8
35
ib23
ib22
ib21
ib20
ib19
ib18
ib17
ib16
For frames 2 - 33 and 36 - 67 , the fast bytes of consecutive even and odd frames are grouped in pairs for assignment, and are assigned to either the embedded operations channel or for synchronization control of the bearer channels that are assigned to the fast buffer, depending upon whether bit 0 of each byte is 0 or 1 . In these frame pairs, if the embedded operations channel (eoc) is transported, then bit 0 is set to 0 . This is shown in TABLE 7.
TABLE 7
Frames
Even Numbered Frames
Odd Numbered Frames
2-33 &
eoc6
eoc5
eoc4
eoc3
eoc2
eoc1
r1
1
eoc13
eoc12
eoc11
eoc10
eoc9
eoc8
eoc7
1
36-37
sc7
sc6
sc5
sc4
sc3
sc2
sc1
0
sc7
sc6
sc5
sc4
sc3
sc2
sc1
0
The eoc is designed to allow the ADSL modems located at the central or local office to communicate with the remotely located ASDL transmit unit located on the customer premises (ATU-R) and the ADSL transmit unit located on the network side (ATU-C), where the ATU-C act as the link master and the ATU-R as the slave. With the eoc in-service and out-of-service maintenance may be performed, and the status and performance related parameters can be retrieved. Complete protocol specification for the eoc is provided in A.N.S.I. T1.413, Section 11.
TABLE 8
Fast Byte
AS0
AS1
AS2
AS3
LS0
LS1
LS2
ABX
LEX
FEC
Redundancy
TABLE 8 illustrates the format of the fast buffer frame format within each frame at the output of the FED encoder. Both blocks AEX and LEX appear if there is an ASX subchannel assignment to the fast buffer. If there is an LSX assignment, then only the LEX appears. The assigned subchannels are synchronized for to a 32 kbps transmission rate. Therefore, for each subchannel, the length of its associated block will be the number of bytes that will be required to carry the transmission rate in multiples of 32 kbps. This function is defined as B F (X). If LS 2 is assigned to the fast buffer with a bearer rate of 384 kbps, then B F (LS 2 ) is 12.
The first byte of the interleaved buffer of each frame within the superframe is regarded as the “synch” byte. The synch byte of frame 0 carries the crc check bit for the previous superframe. In frames 1 through 67 the synch byte is used for synchronization control of the bearer channels that are assigned to the interleaved buffer or for carrying the ADSL overhead control channel (aoc). A LEX byte appears as the last byte in the interleaved buffer whenever bearers are assigned to the interleaved buffer. In this case, the ADSL overhead control channel data is carried in the LEX byte and the synch byte designates when the LEX byte contains ADSL overhead control channel data and when it contains data from the bearer data streams. If there are no bearer assignments to the interleaved buffer, then the LEX byte does not appear, bit synchronization is not required and the ADSL overhead control channel is carried directly in the synch byte.
The frame structure for the interleaved buffer as input to the FEC encoder is illustrated in TABLE 9.
TABLE 9
Synch
AS0
AS1
AS2
AS3
LS0
LS1
LS2
AEX
LEX
Byte
Depending on the application, the bearer subchannels may be assigned to the fast or interleaved buffer upon initialization. For each subchannel, the two byte combination [B 0 , B 1 ] is transmitted to indicate how the subchannel is allocated to the fast or interleaved buffer. There are seven specifications, one for each subchannel. A subchannel can be allocated to either the fast or interleaved buffer, but not to both.
Using ADSL requirements as specified, it is possible to achieve symmetric low speed residential applications with a bearer capacity of 640 kbps on one twisted pair line. For business applications operating at multiples of T 1 rates, it is possible to develop systems operating at a maximum bearer capacity of 12.288 Mbps on four twisted pair lines. For low speed operations when both voice and data is transported, it will be appropriate to allocate the voice traffic to the fast buffer and the data traffic to the interleaved buffer. This way, the advantages of the higher level of coding will be obtained for the data traffic, while simultaneously minimizing the processing delay associated with interleaving the voice traffic. A similar approach can also occur to voice and data traffic in high speed business applications.
The processor 102 in the ISD 22 may be configured to discriminate between the various forms of traffic and to route this traffic to an appropriate device. Where high priority voice and/or video is distributed across the interface, the ISD may include one or more priority queues disposed in the SRAM and/or DRAM 103 , 104 . There may be different priority queues for each connected device on the premise distribution network (including any attached device described with regard to FIG. 2 or discussed herein). Additionally, there may be different queues for each device in both the transmit and receive direction. Further, control and signaling information may be assigned various levels of priority. A similar queue structure may also be implemented in the FMP. In one exemplary embodiment, the queues give priority to signaling information, and voice information for the various attached telephones. If a queue is in danger of overflow, flow control mechanisms may be utilized by the ISD and/or FMP. Voice data is accessed first using an appropriate queuing scheme such as priority fair weighted queuing or another suitable scheme. In addition to queuing, bandwidth may be varied so that more DSL frames are assigned to voice and/or video than data. Further, asymmetric DSL protocols may be dynamically implemented such that more bandwidth may be allocated to one direction or the other as necessary. Where one ISD 22 is serving as the node for, for example, a seven way conference call, the outgoing bandwidth for the node may need to be increased relative to the incoming bandwidth. However, where a PPV movie and/or Internet file is being downloaded, the bandwidth may be reversed such that more bandwidth is available from the network to the CPE equipment. Thus, asymmetric high speed transport of data to the home with the asymmetric character of the link and apportionment of that bandwidth variable depending on the amount of traffic results in a substantially more flexible platform to implement advanced services to the user. Multiple modem protocols may be downloaded into the DSL modem dynamically to chose the best protocol for a particular dynamic bandwidth allocation to maximize the amount of through put.
For example, with reference to FIGS. 6A and 6B, information may be multiplexed into one or more DSL frames in order to dynamically allocate bandwidth. In one exemplary embodiment, where data is being input to one of the connected data devices (e.g., a PC), and a voice call comes in, a dynamic allocation of bandwidth may occur. Assume that 1 Mbps is available for information transfer. Prior to the incoming call, all 1 Mbps may be completely used for the data transmission. However, as soon as a voice call comes in, since voice has a higher priority than data, a 64 Kbps channel is deallocated from data usage and is allocated for voice. If a second voice call comes in, then another data channel will be deallocated from data usage and allocated for voice. As a voice call gets terminated, then the allocated voice slots will be reallocated to use by voice in the next available frame. Hence, the system dynamically allocates on a frame by frame basis bandwidth in real time.
In an alternative embodiment, where individual packets are used to transport voice and data between the ISD 22 and the FMP 32 , an individual channel does not need to be allocated. Voice packets are simply given priority over data slots in the frame. Therefore, silence periods may be used to the advantage and a higher overall bandwidth occurs. Data is simply stored in the buffer and/or slowed in its transfer using standard flow control where voice has priority. Signaling or header data in each packet may be used to establish priority in embodiment.
The dsl modem 114 may be variously configured to supporting transport over 18000 foot loops at following rates exceeding 1 Mbits/second, and may include adapting duplex and downstream bit-rates to the needs of the current traffic such that more bandwidth is provided to the upstream and/or downstream and/or between various devices based on an intelligent bandwidth allocation algorithm. The DSL modem may provide a single-tone DMT mode for low power operation during idle periods to avoid re-synchronization at next service request and enable “always on” functionality. The always on and/or virtually always on functionality allows voice/data calls to be established virtually instantaneously without long delays. The virtually always on functionality allows the channel bandwidth to adapt to the current needs of the system to minimize power consumption, reduce thermal dissipation, and generate less interference. For example, if no device is currently being utilized, only a very low bandwidth channel is required. Accordingly, by reducing the bandwidth available across the loop, it is possible to improve overall performance for other lines. The header HDR supplies the data that maps users (users) with the different data in the frame. It is always present. Note that signaling data may also be supplied and treated with an even higher priority than voice data. Signaling data serves the function of setting up the routes for all data transmitted in the packet.
While exemplary systems and methods embodying the present invention are shown by way of example, it will be understood, of course, that the invention is not limited to these embodiments. Modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. For example, each of the elements of the aforementioned embodiments may be utilized alone or in combination with elements of the other embodiments. | A dynamic bandwidth allocation system is used to optimize the transmission of traffic on the twisted pair connecting the customer premises equipment with the local office. As demand for simultaneous traffic at the customer premises equipment increases, the requirement for multiple twisted pair lines is minimized by dynamically allocating the bandwidth of the channel and sharing that bandwidth with multiple, simultaneous services.
Additional efficiencies for simultaneous transmission of traffic can be achieved by directing all traffic to occupy a smaller channel. This might slightly affect the quality of some services but in many cases the impact will be minimal. Voice signals will be allowed to decrease to a predetermined level and facsimile or other data traffic will transmit at a slower transmission rate. At some predetermined level, traffic quality will degrade to a level such that service will be unacceptable. At this point, a prioritization scheme will buffer certain traffic at the intelligent services director (terminal block) or the facilities management platform (access module). New requests for services are denied until the required bandwidth is free. Once the required bandwidth becomes available, buffered traffic is allowed to transmit or receive will flow again and service availability will resume.
An alternative scheme employs allows all services to maintain their highest quality and ranks all traffic by a priority scheme. Once the allocated bandwidth is occupied, the priority scheme discontinues or buffers lower ranking traffic. Once bandwidth resources are released by the higher ranking traffic, the lower ranking traffic is allowed to proceed if the information was buffered. By optimizing the traffic on the twisted pair, requirements for the installation of multiple twisted pairs is minimized as services are added by the user. | 7 |
TECHNICAL FIELD
The present invention relates to heating object uniformly in a high frequency heating unit by feeding high frequency electric waves from the bottom of the heating chamber and by use of a rotary waveguide.
BACKGROUND ARTS
There are a large number of prior art heating units which relate to making the heating distribution in high frequency heating units uniform. They are largely classified into a stirrer system in which metal vanes are turned in a heating chamber, a turntable system in which the object to be heated is turned and a rotary antenna system in which the antenna, which is the source of radiation of electromagnetic waves, is turned. Among them, the rotary antenna system which has small dimensions and which gives high uniformity of wave distribution is often utilized. The method of radiating electromagnetic waves from the bottom of the heating chamber using the rotary antenna system results in less nonuniform heating due to the standing waves inside the heating chamber, because the electromagnetic waves radiated are directly absorbed by the load, and therefore there is less influence from the dimensions of the heating chamber, which is an advantage, but it is defective in that the center of gyration is heated very intensively. As one of means for solving such a problem, there has been proposed a method comprising adjusting the length of the horizontal part of the rotary strip antenna, as reported in Japanese Laid-Open Patent application No. 15594 of 1981. According to this method, the overheating at the center of gyration is inhibited by adjusting the alignment of impedance between the horizontal rotary strip antenna and the object being heated. Therefore, if the shape and/or size of the load is changed, the radiation from the rotary strip antenna will be altered. Thus this method makes heating uniform for some limited loads, but has only a small effect on different loads.
For whatever load, it seems difficult with a strip antenna to diminish the radiation of electromagnetic waves at the center of gyration and propagate them in the horizontal direction.
As a method of propagating electromagnetic waves from the center of gyration in the horizontal direction, an arrangement for turning a flume shape rotary wave guide has been proposed, as disclosed in Japanese Patent Publication No. 2144 of 1973. In this arrangement, the coupling of the feeding port with the rotary waveguide is difficult. That is to say, because the direction of the electric field at the feeding port is fixed, when the rotary wave guide and the direction of the electric field coincide with each other, the electric wave is propagated through the flume shape rotary wave guide, but when they cross each other at a right angle, the electric waves are barely propagated. Thus in whichever direction the rotary waveguide is turned, the electric waves will in no event be propagated through the rotary wave guide. Accordingly, the heating distribution is differentiated between fore-and-aft and right-and-left.
In Japanese the arrangement disclosed in Utility Model Publication No. 35741 of 1972, with the antenna and the wave guide coupled, the rate of propagation of electric waves through the waveguide is unaltered, even if the turning direction is changed, but since the antenna and the wave guide are not electrically in contact with each other, not all of the electric waves on the antenna are propagated to the waveguide. On this account, it becomes necessary to provide for a labyrinth for the electric waves on the outer circumference of the waveguide, resulting in a complex waveguide.
In addition, a method of turning a waveguide having a plurality of openings with different radii of gyration at the bottom of an oven as disclosed in U.S. Pat. No. 4,314,127 has been contemplated. By this method, parts of the object being heated (food) near the openings are well heated, but its upper parts are only slightly heated like on a frying pan. Since it is impossible to equalize the rates of radiation of electric waves from the plurality of openings in accordance with whatever load is present such as various foods, consequently their distribution on a plane is not favorable.
DISCLOSURE OF THE INVENTION
The present invention, designed to solve such prior art problems, provides a structural arrangement which not only greatly improves the uniformity of electric wave distribution, but which also minimizes the dispersion of the uniformity of distribution by a simple arranging means. In addition, stable performance will be maintained, even if any seepage of liquid from the food inside the heating chamber has occurred.
In the structural arrangement adopted for achieving the aforementioned objects and in which the electric waves are fed from the bottom of the heating chamber, a foldable fan shape antenna coupled by the magnetic field is rotated and low impedance parts are provided outside the arc part, whereby the usual problem of overheating at the central bottom of the chamber is averted, so as to ensure uniform heating of whatever food is present.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a high frequency heating unit according to this invention, showing its appearance;
FIG. 2 is a front sectional view of the unit of FIG. 1;
FIG. 3 is an enlarged view of an essential part of the unit of FIG. 1;
FIG. 4 is a plan view of the part shown in FIG. 3, as seen from the direction indicated by the arrow G in FIG. 3;
FIG. 5 is a sectional view taken along line 4--4 in FIG. 4;
FIG. 6 is a plan view of the essential part of another embodiment of this invention;
FIG. 7 is a perspective view of the essential part of another embodiment of this invention;
FIG. 8 is a perspective view of the essential part of the unit of this invention;
FIG. 9 is a sectional view of a heating unit having the essential part of another embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, an embodiment of this invention is described with reference to FIGS. 1 and 2:
Numeral 1 in the figures denotes a high frequency oscillator which receives the high voltage power fed through a voltage doubler circuit (not shown in these figures) composed of a high tension transformer, high tension capacitor and high tension diode, converts this high voltage power into electric waves and radiates the electric waves into a wave guide 3 through an antenna 2. The electric waves radiated into the wave guide 3 are propagated through the inside of the wave guide 3 and radiated into the heating chamber 4 through the feeding port 5 located roughly at the center of the bottom of the heating chamber 4 composed of thin metal and in the shape of a cube. At this feeding port 5, there is provided a coupling rod 6 made of a metal which couples the heating chamber 4 and the wave guide 3 in a high frequency coupling for facilitating radiation of the electric waves into the heating chamber 4. Further, on one end of this coupling rod 6 is mounted an internal wave guide 8 made of a metal and having a box shape and covering the aforementioned feeding port 5, and which is spaced a certain distance from the bottom of the aforementioned heating chamber 4 and which is provided at its end with an opening 7 which opens toward the heating chamber 4. The other end of the coupling rod 6 is coupled with a motor 9, so that the coupling rod 6 and the internal wave guide 8 are rotatable. Accordingly, the electric waves led to the feeding port 5 of the heating chamber 4 pass along the coupling rod 6, are propagated through the internal waveguide 8 and pass through the opening 7, to be radiated into the heating chamber 4. Above the internal wave guide 8 in the heating chamber 4 is positioned, a table 10 composed of a dielectric, such that the radiated electric waves are absorbed through this table by the object being heated (not shown in these figures) placed on the table 10. The internal wave guide 8 is arranged to be rotatable as above-described, so that the electric waves radiated through the opening 7 are absorbed by the object of heating more efficiently and more uniformly.
Numeral 12 in these figures designates an openable and closeable door for passing the object of heating into and out of the heating chamber 4, and 13 designates a control panel for an ON/OFF the power switch for the high frequency heating unit or for changing the output of the electric waves.
On the bottom of the heating chamber 4, a ridgeshaped protrusion 11 is provided concentrically with the feeding port 5 and outside the opening 7. This prevents oil or water from the food, if the object of heating is a food and if it should seep under the table, from entering between the internal waveguide 8 and the bottom of the heating chamber or entering into the motor 9, causing spark discharge due to high frequency electromagnetic waves or otherwise causing failure of the motor 9. In addition, on the outside of the protrusion 11, small holes 13 which permit oil and water from the food escape from the heating chamber 4 are provided.
FIG. 3 is an enlarged view the heating chamber bottom part of FIG. 2 at about the center of the wall 14 of the heating chamber 4, the feeding port 5 is provided. The part of the heating chamber bottom wall 14 around the feeding port 5 is raised a little, lest any liquid seepage from the food easily flow down into the motor 9. The shaft 15 of the motor 9 is made of a low loss dielectric, so that the high frequency electromagnetic waves inside the waveguide 3 will not leak out to the motor 9 as well as making the transmission of heat inside the heating chamber 4 to the motor 9 difficult. The coupling rod 6 is mounted on the shaft 15 to be turned thereby. The coupling rod 6 leads the high frequency electromagnetic waves in the wave guide 3 into the heating chamber 4. The internal waveguide 8 is caulked onto the tip of the coupling rod 6 inside the heating chamber and, electrically and mechanically locked there. Accordingly, the high frequency electromagnetic waves are propagated between the internal waveguide 8 and the heating chamber bottom wall 14. At one end of the internal waveguide 8, there is provided a low impedance part 16 having a length about one fourth of the wave length of the high frequency electromagnetic wave and spaced from bottom wall 14 a distance F. By this means, the high frequency electromagnetic waves inside the space between the internal waveguide 8 and the heating chamber bottom wall 14 are reflected by this low impedance part 16. The reason can be explained as follows: Since the characteristic impedance of the heating chamber is approx. 300Ω and the low impedance part 16 has approx. 20Ω, the impedance of the opening C is calculated by 20×20÷300 to be about 1Ω, assuming the length of the low impedance part to be one quarter wave length. Accordingly, because the characteristic impedance of the internal waveguide 8 is determined from the dimension I to be approx. 80Ω, the reflection coefficient will be approx. 0.98. Thus 98% of the electric waves inside the internal waveguide 8 are reflected and therefore, hardly any electric waves will come out through the opening D. For this reason, the electric waves in the internal waveguide 8 will be propagated mostly in the direction E. The above-description clearly indicates the paramount importance of the distance F between the low impedance part 16 and the heating chamber bottom wall 14.
FIG. 4 is a view as seen in the direction indicated by an arrow G in FIG. 3. The internal waveguide 8 is roughly in a fan shape with low impedance parts 16 provided outside the angular shaped part and the rear of the internal waveguide 8, to reflect the electric waves, so that the electric waves are radiated from the front end of the internal waveguide 8. Accordingly, the electric wave radiating opening 7 is turned and the electric field in the radiating opening 7 is in the vertical direction and excites the inside of the heating chamber.
In this way, the bottom part of the load such as food, etc., is heated by the electric waves leaking through the low impedance parts 16, but the whole of the food can be heated by the electric waves from the opneing 7. Since the direction of the electric field of the electric waves from the opening 7 is vertical, a vertical electric field is produced inside the heating chamber 4 and therefore, the uniformity is stabilized for so-called planar food having abundant horizontal components. Between the internal waveguide 8 and the heating chamber bottom wall 14, there is provided an arc shaped antenna spacer 17 which is formed of a low loss dielectric for stabilization of the dimension F of FIG. 3.
The internal waveguide 8 and the coupling rod 6 are supported by two contacting points 18 and 18' of the antenna spacer 17 and the low impedance parts 16 and by the shaft 15, thus at three positions in all, and the center of gravity G of the internal waveguide 8 and the coupling rod 6 is designed to be located on the shaft side from the straight line between the contact points 18 and 18', so that the internal waveguide 8 will be stable during turning.
Since the position of the opening 7 is so set as to be farther from the center than the usual radius of the food, the electric waves coming from the bottom do not come directly to the load. Thus this method has no disadvantage of overheating the bottom part of food which is usually present in the method of feeding from the bottom of the heating chamber, the heating of the lower part of food being effected merely by the small amount of the electric waves leaking through the low impedance parts 16.
FIG. 5 is a sectional view an arrow H in FIG. 4. That the antenna spacer 17 has a flat plate shape and is provided with protrusions 19 at several positions, which are inserted in small holes 20 provided in the heating chamber wall, whereby it is held in place. The small holes 20 are each formed at a definite angle θ to the arc, as shown in FIG. 4, so that the protrusions 19 will not come loose and the elasticity of the antenna spacer 17 permits snug insertion of protrusions into the small holes 20, thus enabling ready assembling.
The low impedance part 16 in the aforementioned embodiment is formed of a sheet of stainless steel plate or alumite plate, etc., in a press. As an alternative, however, the low impedance part which is held at the distance of F from the wall can be formed of a dielectric with a higher dielectric constant than that of air, e.g., ceramic, alumina ceramic, etc.
The height of the antenna spacer is chosen to be lh where the electric wave radiation from between the radiator flange part and the heating chamber bottom wall is checked to an appropriate level, but sparks, abnormal heating, etc., will not be induced between the flange part and the heating chamber bottom wall. The thickness lt is designed to be enough smaller than lh, so that not only the electric wave loss due to this rail is minimized, but the slip friction is kept as small as possible by reducing the contact area with the flange of the radiator.
FIG. 6 is a plan view as seen in the direction indicated by an arrow G in FIG. 3 showing another embodiment of this invention.
The internal waveguide 8 has a fan shape with the coupling rod 6 provided at its pivot. In this embodiment, roughly the same effect as in the aforementioned embodiment can be achieved.
FIG. 7 is a view showing another embodiment of the internal waveguide, in which the radiating part is composed of a flat plate having, on each side, a parallel flat plate part 21 between the internal waveguide part 8 and another internal waveguide part 8'.
In the following, the effects obtained by the above-described structure are described:
The electric waves generated by a high frequency oscillator 1 are transmitted through the wave guide 3, excited by the coupling rod 6 and the internal wave guide 8 and then, enters the heating chamber, when they are radiated through the opening 7. Since the entrance portion of the radiating part is composed of a waveguide, the electric wave propagating direction is very well controlled toward the open end of the waveguide. However, at the end edge of the waveguide, where its side walls disappear, exposing the parallel flat plate edges, part of the electric waves having been transmitted up to this position, while being controlled in one direction, are radiated sideways, thereby intensifying the heating at about the central part of the food. The electric waves transmitted along the parallel flat plate line up to the tip of the radiating part are radiated toward the upper part of the heating chamber between the forward end of the radiating part and the wall of the heating chamber, and are reflected by the side wall and the upper wall of the heating chamber, thereby heating mainly the outer circumferential part of the food.
It is possible to adjust the heating balance between the central part and the peripheral part of the food by changing the position of the parallel flat plate part 21, shown in FIG. 7, in the radiating part.
FIG. 8 is a perspective view of the essential part of another embodiment of this invention.
Referring to FIG. 8, 4 designates a heating chamber; 5, a feeding port located at the bottom of the heating chamber 4; 6, a coupling rod for coupling in a high frequency coupling the heating chamber 4 with the waveguide 3; and 8, an internal waveguide having an opening 7 at one end thereof and mounted tip of the coupling rod 6. Reflecting plates 22 are placed in positions nearly equally spaced from the opening 7 as the wall surface of the heating chamber 4, one in each corner of the heating chamber 4.
In the above described structure, observing the wall surface of the heating chamber 4 and the reflecting plate 22 from the opening 7 of the internal waveguide 8, Z 1 and Z 2 may be nearly equal in terms of impedance, because the distances from the opening 7 to the wall surface and to the reflecting plate are nearly equal. Accordingly, the impedance in the heating chamber 4 becomes stabilized with regard to the opening 7 insofar as high frequency is concerned. Thus the operation of the high frequency oscillator is stabilized and breakdown of the high frequency oscillator can be averted. Moreover, because the distances from the wall surface of the heating chamber 4 and the reflecting plates 22 to the opening 7 are equal, the radiating angle of electric waves becomes fixed. This, associated with the turning of the internal waveguide 8, enables uniform heating without irregular absorption by the object.
FIG. 9 is a front sectional view of another embodiment of this invention. Referring to this view, 1 denotes an oscillator for generating microwaves; 3 denotes a waveguide for transmitting the microwaves generated in the aforementioned oscillator 1; 4 denotes the heating chamber for heating the object; 5 denotes the feeding port located on the bottom wall 14 of the aforementioned heating chamber 4 for exciting the aforementioned heating chamber 4 with the microwaves transmitted through the aforementioned waveguide 3; and 6 designates the coupling rod. Numeral 8 designates a rotary waveguide having an opening at its end, which covers the aforementioned feeding port 5 and which turns in a plane parallel to the bottom wall 14 of the aforementioned heating chamber with the feeding port 5 as the center. This internal waveguide 8 is formed of a metal body and fixed to the aforementioned coupling rod 6. It is driven by a motor 9. Numeral 10 designates a table for bearing the object to be heated and which is formed of a dielectric such as glass, etc. The aforementioned heating chamber wall 14 has a circular concavity in the bottom with the center of rotation of the aforementioned internal waveguide 8 as its center.
The microwaves radiated from the aforementioned oscillator 1 pass through the aforementioned waveguide 3 and are radiated through the coupling part composed of the aforementioned feeding port 5 and the aforementioned coupling rod 6 into the space surrounded by the internal waveguide 8 inside the aforementioned heating chamber 4 and the heating chamber wall surface 14. The microwaves radiated from the aforementioned coupling part pass through the opening 7 provided at the end of the aforementioned internal waveguide 8 and the table 10, to heat the object placed in the heating chamber 4. The aforementioned internal waveguide 8 is rotationally driven by the aforementioned motor 9 to turn with the aforementioned coupling part as the center. Accordingly, the opening 7, being the microwave feeding port, is rotated and transferred, so that the microwaves may be fed from various positions at the heating chamber bottom and therefore, relatively uniform heating distribution to the object may be achieved. Since the aforementioned heating chamber wall 14 has a circular concavity with the center of rotation of the aforementioned internal waveguide 8 as its center, the distance between the sloped part 23 of the heating chamber wall facing the opening 7 of the aforementioned waveguide 8 and the aforementioned coupling part located at the center of rotation of the aforementioned internal waveguide 8 does not undergo any change during the turning of the aforementioned internal waveguide 8, but is always fixed. The aforementioned heating chamber wall 14 is formed of a metal body for enclosing the microwaves and is a reflector of electric waves, but since, as above described, the distance between the aforementioned sloped part 23 and the aforementioned coupling part is fixed, the phase of the reflecting waves which are reflected by the aforementioned sloped part 23 facing the aforementioned opening part 7 and which then return toward the aforementioned oscillator 1 remain unaltered, without undergoing change with turning of the aforementioned internal waveguide 8. Accordingly, the change in the impedance on the load side, as observed from the aforementioned oscillator 1 is small. On this account, the aforementioned oscillator 1 can operate at an operating level where its efficiency is high, so that the operation of the aforementioned oscillator 1 is stabilized, its durability improved and moreover, unnecessary radiations from the aforementioned oscillator 1 can be reduced. Besides, with the aforementioned concave part formed by drawing the metal, the amount of material for forming the aforementioned heating chamber wall.
The above described structure has the following effects:
(1) Sure propagation of electric waves from the coupling rod to the circumference of the waveguide 8 results in adequate effect of rotation and accordingly, proper heating distribution.
(2) Since the degree of heating at the lower part of the food is freely adjustable by the choice of the length of the low impedance part and the distance F, too strong or too weak heating at the lower part of the food will not occur.
(3) Because the heating chamber is excited with vertical electric waves, even if a planar shaped food undergoes changes in shape, stable uniformity is ensured in the heating.
(4) The low impedance part of the internal waveguide can be formed merely by bending a metal plate, thereby minimizing the raising cost.
(5) Because the part of the heating chamber wall around the feeding port is raised relative the outside part, liquid seepage from the food will not enter into the motor part.
(6) Since the heating is effected mainly by the radiation of electric waves, with the high frequency electromagnetic waves radiated from the bottom, changes in the uniformity of distribution will not result due to a size difference of the heating chamber. Therefore, this unit can be accommodated in heating chambers of various sizes.
(7) Because the distance of the low impedance part from the heating chamber bottom wall is fixed by means of an antenna spacer, dispersion of the products is small.
(8) Because of absence of any protrusions inside the heating chamber, this unit can be readily used and cleaned.
(9) As the protrusion is placed outside the antenna spacer, the resistance at the sliding joint between the antenna spacer and the low impedance part will not increase due to liquid seepage from the food below the table and the sliding part, being placed above the heating chamber bottom wall, is assured of rotation without being affected by a substantial amount of liquid seepage from the food.
(10) By the sliding movement between the low impedance part of the internal waveguide part and the antenna spacer, smooth turning is achieved with very small friction.
(11) By supporting the radiating body at two points of the low impedance part and one point of the coupling part, thus three points in total, very stable supporting and rotation are achieved with a minimum necessary friction.
(12) By placing the contact points between the low impedance parts and the antenna spacer outside the center of gravity of the internal waveguide and the coupling rod, as seen from the center of rotation, stable rotation and output characteristics can be achieved simply by use of a mere inserting structure for the connection between the coupling rod and the motor shaft and thereby, it becomes possible to perform reliable, high quality electric wave feeding with a simple and low cost structure.
(13) By making the thickness lt of the antenna spacer sufficiently smaller than its height lh, electric wave loss can be reduced, and reducing the size of the contact areas of the low impedance parts of the internal waveguide, the rotational friction can be greatly reduced.
(14) By making the internal waveguide a combination of the waveguide parts and the parallel flat plate parts, the heating near the center of the heating chamber can be intensified, and the electric wave heating distribution all over the heating chamber improved.
(15) With a concave part and reflecting plates placed on the heating chamber bottom, the distances from the heating chamber wall surface and from the reflecting plates or the concave part of the heating chamber bottom to the opening of the waveguide can be equalized, so that impedances can be held constant, stable operation of the high frequency oscillator obtained, and breakdown of the high frequency oscillation averted.
(16) The distances from the heating chamber wall surface and from the reflecting plates to the opening can be equalized, making it possible to fix the electric wave radiating angle, to have the electric waves absorbed by the object to be heated in a specified direction, thereby achieving a uniform heating pattern.
FIELD OF INDUSTRIAL APPLICATION
This invention relates to making the heating uniform in high frequency induction heating units generally called electronic ranges in which the high frequency induction heating is applied mainly for heating foods. | This invention is designed to make uniform the heating of the object inside the heating chamber by turning an internal waveguide which is roughly in a foldable fan shape and located at the bottom of the heating chamber in a structure adapted for feeding high frequency electric waves from the bottom of the heating chamber. In order to have stable gyration of the internal waveguide, and annular protrusion made of a low loss dielectric is placed between the low impedance parts provided on the internal waveguide and the heating chamber bottom surface. In this way, a rotary structure which is economical, easy to assemble and reliable can be realized. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of medical and surgical devices and in particular to a long-term or tunnelled Central Venous Catheter (CVC) which can remain in place for long periods of time (months or years).
PRIOR ART
[0002] The Central Venous Catheter (CVC) is a device which is placed into a large vein in order to carry out haemodialysis treatment. It is used when it is not possible to perform a vascular access using the patient's own vessels or prosthetic vessels. It is usually made up of a double-lumen cannula, one used for suction and the other enabling re-entry of blood which has been treated and purified using a dialyser.
[0003] In some cases we see single-lumen cannulas, and in these cases two separate cannulas must be used. The CVC can be manufactured in various polymers: polyurethane, silicone or copolymers such as carbothane. CVCs can be temporary, which remain in place for short periods (2-3 weeks) and have immediate percutaneous access through the skin directly to the central vein, or they can be long-term or tunnelled, which can remain in place for much longer periods (months or years) and provide a passage under the skin (subcutaneous tunnel).
[0004] FIG. 1 reports data concerning the vascular access in use in various DOPPS countries (DOPPS 4 data, 2010). The long-term central venous catheter continues to hold a high percentage (10-30% depending on the country) among patients undergoing chronic haemodialysis, despite guideline recommendations to reduce the use of such a device. So far, prevalence trends over the past few years show a continual increase compared with past periods. In Italy, the prevalence of long-term CVCs in patients undergoing haemodialysis was 15% in 2007 (DOPPS 3) and 23.8% in 2010 (DOPPS 4).
[0005] The most significant and serious catheter-related complications are infections. Infections related to long-term CVCs are expressed as the following clinical conditions:
Bacteriaemia or sepsis Infection of the exit site and the subcutaneous tunnel
[0008] If we compare the various types of vascular access, the relative risk (RR) of access-related bacteraemia with respect to arteriovenous fistula using native veins is 15.5 for patients with a tunnelled CVC and 25.5 for patients with a temporary CVC.
[0009] The incidence of infections from long-term (or tunnelled) CVCs is 1.6-5.5 cases/1000 catheter days, and 3.8-6.6 cases/1000 catheter days for temporary catheters.
[0010] All tunnelled CVCs which have been marketed and used in clinical practice up until now are featured by a single cuff, usually made from Dacron® and positioned in the end section of the CVC (corresponding to the subcutaneous passage). A few days following positioning, a scarring reaction occurs which anchors the CVC to the subcutaneous tissue and closes the opening preventing micro-organisms from the external environment from entering the bloodstream. You can, however, create these scenarios:
if the cuff is positioned close to the exit site it provides an excellent barrier against micro-organisms with a low incidence of bacteremia and infections of the subcutaneous tunnel, but a weak anchoring of the CVC with risk of leakage; if the cuff is positioned deeper in relation to the subcutaneous tunnel, it provides an excellent anchoring system but a greater stretch of tunnel is exposed to micro-organisms, therefore resulting in a greater risk of infection of the tunnel.
[0013] The purpose of this invention is to provide a tunnelled CVC with an improved anchoring system and antibacterial barrier to reduce the incidence of:
1) CVC-related infections 2) subcutaneous tunnel infections 3) displacement of the CVC.
SUMMARY OF THE INVENTION
[0017] The present invention solves the above mentioned problems by way of a non-temporary CVC ( 50 ) for use in haemodialysis treatments characterised in that, in the end section to be positioned in the subcutaneous tunnel, it comprises two cuffs ( 51 ) and ( 52 ) spaced apart by a distance in the range between 3 and 8 cm so that cuff ( 51 ) is positioned within the subcutaneous tunnel in the proximity of the exit site ( 57 ) and cuff ( 52 ) is positioned within the subcutaneous tunnel in the proximity of the access point ( 58 ) to the catheterised central vein.
[0018] Due to the two cuffs, the CVC according to the invention can be implanted for long periods of time equal to months or years and so can be classified among the so-called long-term or tunnelled CVCs.
[0019] Cuff ( 51 ), preferably positioned 1-2 cm from the exit site ( 57 ), provides an excellent antibacterial barrier whilst cuff ( 52 ), preferably positioned 1-2 cm from the point of access ( 58 ) to the central vein into which the catheter is inserted, provides excellent anchoring of the CVC to the subcutaneous tissue.
[0020] Surprisingly, in preliminary data concerning the use of the new CVC with the double-cuff “Bandera modification” on a sample of 11 patients for a total observation period of 3310 catheter days, only two tunnel infections were observed (corresponding to an incidence of infection equal to 0.6 cases/1000 catheter days) and no displacements.
[0021] Therefore, the preliminary results are significant, despite referring to a short observation period and a low number of patients, they show a clear and significant reduction in the incidence of infectious episodes related to the CVC compared to what is reported in the literature (0.6 cases/1000 catheter days vs. 1.6-5.5 cases/1000 catheter days). Such a reduction in the incidence of infections associated with no displacement is an absolutely unexpected result.
[0022] The positioning of the CVC has not resulted in any additional difficulty, neither has its removal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows data concerning the vascular access in use in various DOPPS countries (DOPPS 4 data, 2010);
[0024] FIG. 2(A) shows a bilumen CVC according to the invention equipped with two cuffs ( 51 ) and ( 52 ); (B) shows a cross-section of the CVC according to the invention.
[0025] FIG. 3 shows a CVC according to the invention as inserted into a patient who must undergo frequent haemodialysis treatments.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The cuffs ( 51 ) and ( 52 ) are preferably made of a polyethylene terephthalate fibre (for example DACRON®) or other biocompatible material that causes a fibrotic reaction with the subcutaneous tissue.
[0027] The term cuff refers to a sleeve (cylindrical tube coaxial to the catheter) applied in a non-sliding manner to the outer surface of the catheter.
[0028] The two cuffs ( 51 ) and ( 52 ) have, independently of each other, a length in the range between 5-10 mm and thickness in the range between 0.5 and 2.0 mm. Preferably, the cuffs have a length of 8 mm and thickness of 1.0 mm. Preferably, the two cuffs ( 51 ) and ( 52 ) are identical in size and shape.
[0029] Preferably, cuff ( 52 ) is spaced apart from the tip ( 53 ) of the CVC by a distance (x) in the range between 18 and 26 cm. In particular for the right side CVC the distance (x) is preferably in the range between 19 and 20 cm; for the left side CVC the distance (x) is preferably in the range between 23 and 25 cm.
[0030] The “double cuff system” can be applied to all types of CVC, both double- and single-lumen.
[0031] The material comprising the CVC can be silicone or another material usually used for such medical devices.
[0032] Therefore, for example, the CVC according to the invention has, like other known and commercially available CVCs:
length in the range between 150 and 450 mm, external diameter, preferably oval or circular, of between 3.0 and 6.5 mm, internal diameter, preferably circular, of between 1.5 and 3.0 mm.
[0036] Like other known CVCs, the CVC ( 50 ) according to the invention, with reference to FIG. 2A , can preferably be equipped, in a kit, with suture wings ( 54 ), one or more clamps ( 55 ), one or more luer-lock connectors ( 56 ), one or more luer-lock plugs. Below is a table of the preliminary clinical data relating to the positioning of CVCs according to the invention:
[0000]
PATIENT
DATE CVC
DATE OF
DATE OF
Catheter
NO.
INSERTED
TYPE OF CVC
INFECTION
REMOVAL
days
1
18 Feb. 2010
BILUMEN
No infection
2 Sep. 2010
196
malfunctioning
2
28 Jul. 2009
BILUMEN
5 Jan. 2011
526
deceased CVC
functioning
3
22 Jul. 2009
BILUMEN
Deceased
506
12 Nov. 2010
4
8 Apr. 2010
Deceased
15 Apr. 2010
5
12 Mar. 2010
SINGLE-
1 Jun. 2010
22 Jul. 2010
130
CANNULA
tunnel infection
6
20 Nov. 2009
BILUMEN
19 Jul. 2011
590
due to death
7
29 Jun. 2010
BILUMEN
1 Sep. 2010
60
due to death
8
6 Jul. 2010
TWO SINGLE-
Fully
590
CANNULA
functioning
9
13 Jul. 2010
TWO SINGLE-
21 Sep. 2010
13 Jan. 2011
184
CANNULA
subcutaneous
due to AVF
tunnel infection
puncture
10
10 Aug. 2010
Two single-
No infection
11 Nov. 2010
92
cannula
Showing
above the skin
11
19 Aug. 2010
TWO SINGLE-
No infection
8 Nov. 2011
440
CANNULA
Due to
subcutaneous
passage fissure
[0037] Results of the Preliminary Study:
2 infectious episodes out of a total of 3310 catheter days=0.6 infectious episodes/1000 CVC days no displacements | The present invention describes a long-term central venous catheter (CVC) for use in haemodialysis treatments with two cuffs in the end section to be positioned in the subcutaneous tunnel. | 0 |
RELATED APPLICATION
The current application claims priority to U.S. Provisional Application No. 61/192,779, filed Sep. 20, 2008, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to the generation of video animation and more specifically to the generation of animation using character motion data.
BACKGROUND
Three dimensional (3D) character animation has seen significant growth in terms of use and diffusion in the entertainment industry in the last decade. In most 3D computer animation systems, an animator defines a set of animation variables, or Avars that form a simplified representation of a 3D character's anatomy. The Avars are often organized in a hierarchical model and, therefore, the collection of Avars for a 3D character can be referred to as its hierarchical model. Motion of the 3D character can be defined by changing the values of Avars over time. The value of an Avar over time is referred to as the Avar's motion curve, and a sequence of motion can involve defining the motion curves for hundreds of Avars. The motion curves of all of a 3D character's Avars during a sequence of motion are collectively referred to as motion data.
An animator can directly animate a 3D character by manually defining the motion curves for the 3D character's Avars using an off-line software tool. Motion capture of a human or animal during a desired sequence of motion can also be used to generate motion data. Motion capture is a term used to describe a process of recording movement and translating the movement onto a digital model. A 3D character can be animated using the motion capture process to record the movement of points on the human or animal that correspond to the Avars of the 3D character during the motion. Motion capture has traditionally been performed by applying markers to the human or animal that can be mapped to the Avars of the 3D character. However, markerless techniques have recently been developed that enable the animation of 3D characters using mesh based techniques. Markerless motion capture using mesh based techniques is described in U.S. Patent Publication No. 2008/0031512 entitled “Markerless Motion Capture System” to Mundermann et al., the disclosure of which is incorporated by reference herein in its entirety.
Animating a 3D character manually or using motion capture can be time consuming and cumbersome. As discussed above, the manual definition of a character's motion can involve a Laborious process of defining and modifying hundreds of motion curves until a desired motion sequence is obtained. Motion capture requires the use of complex equipment and actors. In the event that the captured motion is not exactly as desired, the animator is faced with the choice of repeating the motion capture process, which increases cost, or attempting to manually edit the motion curves until the desired motion is obtained, which is difficult. The inability of animators to rapidly and inexpensively obtain complex motion data for a 3D character can represent a bottleneck for the generation of 3D animations.
SUMMARY OF THE INVENTION
Systems and methods in accordance with embodiments of the invention enable the online interactive generation of synthetic motion data for 3D character animation. One embodiment of the invention includes a server system configured to communicate with a database containing motion data including repeated sequences of motion, where the differences between the repeated sequences of motion are described using at least one high level characteristic. In addition, the server system is connected to a communication network, the server system is configured to train a generative model using the motion data, the server system is configured to generate a user interface that is accessible via the communication network, the server system is configured to receive a high level description of a desired sequence of motion via the user interface, the server system is configured to use the generative model to generate synthetic motion data based on the high level description of the desired sequence of motion, and wherein the server system is configured to transmit a stream via the communication network including information that can be used to display a 3D character animated using the synthetic motion data.
In a further embodiment, the server system comprises an application server and a web server that are configured to communicate, the application server is configured to communicate with the database, the web server is connected to the communication network, the application server is configured to train the generative model using the motion data and provide the generative model to the web server, the web server is configured to generate the user interface that is accessible via the communication network, the web server is configured to receive the high level description of the desired sequence of motion via the user interface, the web server is configured to use the generative model to generate the synthetic motion data based on the high level description of the desired sequence of motion, and wherein the web server is configured to transmit the stream via the communication network including the information that can be used to display the 3D character using the synthetic motion data.
In another embodiment, the motion data includes actual motion data obtained via motion capture.
In a still further embodiment, the motion data is obtained via marker based motion capture.
In still another embodiment, the motion data includes meshes obtained using markerless motion capture.
In a yet further embodiment, the motion data includes manually generated motion data.
In yet another embodiment, the high level characteristic specifies the type of motion.
In a further embodiment again, the high level characteristic specifies a physical characteristic of the motion.
In another embodiment again, the high level characteristic specifies an expressive characteristic of the motion.
In a further additional embodiment, the server system is configured to train the generative model using supervised learning.
In another additional embodiment, the user interface provides the ability to describe the desired sequence of motion using the same types of high level characteristics as were used to describe differences between the repeated sequences of motion in the motion data.
In a still yet further embodiment, one of the high Level characteristics is expressed as a value on a continuous scale.
In still yet another embodiment, the server system is configured to use the generative model to generate synthetic motion data from any description within the continuum of the scale of the high level characteristic.
In a still further embodiment again, the high level description of the desired sequence of motion includes at least a motion type, a trajectory for the motion, and at least one motion styling.
In still another embodiment again, the motion styling is a description of a physical characteristic or an expressive characteristic of the motion.
In a still further additional embodiment, the motion system is expressed as one of a number of discrete types of motion.
In still another additional embodiment, the trajectory of the motion is specified including at least a start point and an end point.
In a yet further embodiment again, the motion styling is expressed using a value from a continuous scale that corresponds to a high level characteristic that was used to describe differences between repeated sequences of motion in the motion data during the training of the generative model.
In yet another embodiment again, the server system is configured to receive an updated high level description of the desired sequence of motion over the communication network via the user interface, the server system is configured to use the generative model to generate a second set of synthetic motion data based on the updated high level description of the desired sequence of motion, and the server system is configured to transmit a stream via the communication network including information that can be used to display the 3D character animated using the second set of synthetic motion data.
A yet further additional embodiment also includes a user device connected to the communication network and configured using a browser application to display the user interface and to display the animated 3D character using the stream received from the server system.
In yet another additional embodiment, the motion data is based upon a standard model for a 3D character, the server system is configured to receive a model of a 3D character from the user device via the communication network, the server system is configured to retarget the synthetic motion data generated by the generative model based upon the high level description of the desired sequence of motion to animate the 3D character received from the user device, and the server system is configured to transmit a stream via the communication network including information that can be used to display the 3D character received from the user device animated using the synthetic motion data.
In a further additional embodiment again, the stream of the animated 3D character is generated by streaming the motion data to the user device, and the user device is configured to animate the 3D character using the received motion data.
In another additional embodiment again, the server system animates the 3D character using the synthetic motion data and streams the animated 3D character via the communication network for display.
Another further embodiment includes obtaining motion data from a storage device including sequences of repeated motion, where the motion data includes labels that describe high level characteristics of the repeated sequences of motion, building a generative model based on the motion data using supervised learning, defining initial motion characteristics for a desired motion sequence, generating synthetic motion data using the generative model based upon the initial motion characteristics, animating the 3D character using the synthetic motion data, and displaying the animated 3D character.
Still another further embodiment also includes modifying the initial motion characteristics to provide an edited high level description, generating a second set of synthetic motion data using the generative model based upon the edited high level description, animating the 3D character using the second set of synthetic motion data, and displaying the animated 3D character.
Yet another further embodiment includes filtering of the motion curves and joint angles using a low pass filter, removing the relative motion between the feet and the floor when foot contact is present using a model trained using machine learning techniques to identify situations in which the foot is expected to be locked, applying inverse kinematics correction to the motion of the feet, and reducing the number of keyframes on the motion curves.
Another further embodiment again includes obtaining a user model of the 3D character, determining a mapping from the training model to the user model of the 3D character, defining initial motion characteristics for a desired motion sequence, generating synthetic motion data using the generative model based upon the initial motion characteristics, retargeting the synthetic motion data generated by the generative model to animate the user model of the 3D character, and displaying the animated 3D character.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a semi-schematic diagram of an animation system configured to generate synthetic motion data in accordance with an embodiment of the invention.
FIG. 2 is a flow chart illustrating a process for generating synthetic motion data in accordance with an embodiment of the invention.
FIG. 3 is a flow chart illustrating a process for generating synthetic motion data and retargeting the data to animate a user defined 3D character in accordance with an embodiment of the invention.
FIG. 4 is a conceptual illustration of a user interface for obtaining a high level description of a desired sequence of motion in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, animation systems and methods for real time interactive generation of synthetic motion data for the animation of 3D characters are illustrated. The term synthetic motion data describes motion data that is generated by a machine. Synthetic motion data is distinct from manually generated motion data, where a human animator defines the motion curve of each Avar, and actual motion data obtained via motion capture. Animation systems in accordance with many embodiments of the invention are configured to obtain a high level description of a desired motion sequence from an animator and use the high level description to generate synthetic motion data corresponding to the desired motion sequence. Instead of directly editing the motion data, the animator can edit the high level description until synthetic motion data is generated that meets the animator's needs. In several embodiments, a generative model is used to generate synthetic motion data based upon a high level description of a desired motion sequence. In a number of embodiments, the generative model is a statistical model that is obtained using supervised learning. Supervised learning involves training a statistical model using motion data for a number of sequences of motion, which can be referred to as training sequences. The training is supervised, because each training sequence is described using a high level description. In this way, the statistical model builds relationships between high level descriptions and actual motion data. Once a generative model has been created, synthetic motion data can be generated by providing the generative model with a high level description indicative of a desired sequence of motion. In a number of embodiments, the high level description represents one or more expressive characteristics of the motion as values on a continuous scale and, when provided with a sufficient number of training sequences from throughout the scale, the generative model can produce synthetic motion data anywhere on the continuum and that is potentially unlike any of the motion sequences observed during training.
Animation System
An animation system that can generate synthetic motion data in accordance with an embodiment of the invention is shown in FIG. 1 . The animation system 10 includes a storage device 12 connected to server system, which in the illustrated embodiment includes an application server 14 connected to a web server 16 . The web server is connected to the Internet 18 and a number of user devices 20 can access the web server via the Internet using a browser application.
The storage device contains motion data that is used by the application server to create a generative model. A generative model is a model that can generate synthetic motion data corresponding to a high level description of desired motion characteristics. In a number of embodiments, the generative model is a statistical model that is built by the application server using supervised learning. Supervised learning is a training process where each training sequence is described by a high level description. During training, the statistical model forms associations between the high level characteristics of the motion and the underlying motion data. Therefore, a generative model is obtained that can produce realistic synthetic motion data based upon a high level description of the desired motion. In general, the performance of the generative model in generating desired synthetic motion data is improved by using motion data during training that includes multiple repetitions of the same sequence of motion and using the high level characteristics to explain the differences between each repetition. In several embodiments, supervised learning is used to train a Continuous Restricted BoLtzmann Machine (CRBM) that can then be used as a generative model. Training of a CRBM using motion data is an extension of the method described in the conference paper by Taylor et al. entitled “modeling Human Motion Using Binary Latent Variables” presented at the Twentieth Annual Conference on Neural Information Processing Systems in Whistler, Canada (available at http://www.cs.toronto.edu/˜gwtaylor/), the disclosure of which is incorporated by reference herein in its entirety. In other embodiments, any of a variety of statistical models that can be trained using supervised learning to form a generative model, which can generate synthetic motion data from a high level description of desired motion can be used.
A high level description of motion can take any of a number of different forms appropriate to the application. In many embodiments, each training sequence is described using a common set of arbitrary characteristics. The arbitrary characteristics can relate to any aspect of the motion from a simple descriptor of the type of motion (e.g., running or walking) to a complex expressive quality of the motion (e.g., happiness, tiredness, urgency, or intoxication). The term expressive quality is used herein to describe aspects of motion that communicate information about a character and/or the character's state of being. When a generative model is trained using a sufficiently large number of training sequences labeled to reflect the expressive qualities of the training sequences, the generative model can be used to generate synthetic motion data possessing specific expressive qualities. In a number of embodiments, simple characteristics of motion such as a type of motion are expressed by labeling each training sequence with one of a number of discrete values. In several embodiments, complex characteristics of motion such as the extent of a specific expressive quality (i.e., the extent to which the motion conveys a particular idea or emotion) or a physical characteristic of the motion (e.g., walking speed, height and/or distance of a jump) are expressed by assigning each training sequence with a score on a continuous scale. When a high level characteristic is expressed on a continuous scale, the generative model can be used to generate synthetic motion data anywhere on the continuum.
Once a generative model has been trained, the application server deploys the generative model to the web server, which can use the generative model to create synthetic motion data from a high level description. In the illustrated embodiment, the web server creates a web based user interface that can be accessed via a user device configured with an appropriate browser application. The web based user interface enables an animator to provide a high level description of desired motion, which is typically in terms of the arbitrary characteristics used in the training of the generative model. The web server uses the high level description to generate synthetic motion data in real time that can animate a 3D character. The animation can be streamed to the animator's browser in real time enabling the animator to determine whether the synthetic motion data produces a desired animation sequence. Alternatively, the motion data (e.g., curves and/or joint angles) can be compressed and streamed to the user device and used by a client application on the user device to animate the 3D character. Such client application could be a video game, a browser plug-in, or a third party software application. In the event that the animator wishes to edit the sequence of motion, the animator can modify the high level description originally provided to the web server via the user interface and the application server can generate a new set of synthetic motion data in response to the new high level description. The editing process is analogous to providing modified directions to an actor and reshooting a motion capture sequence. However, the use of a generative model can eliminate the need for an actor and motion capture equipment during the editing process. Use of a generative model can also provide the animator with greater control over the final motion data.
Provision of a generative model in a distributed architecture in accordance with embodiments of the invention enables efficient use of motion capture data. Instead of each animator separately performing motion capture for each 3D character, a large bank of motion capture data can be built over time and then the same motion capture data can be used by multiple animators via generative models. Despite the likelihood that the bank of motion capture data does not contain the specific sequence of motion desired by the animator, the generative model enables the generation of synthetic motion data matching the high level description of the desired motion provided by the animator and unlike any sequence in the bank of motion capture data. Therefore, much of the efficiency is obtained by providing multiple animators with access to the same system for generating synthetic motion and by providing a system that is capable of generating synthetic motion and not simply retrieving motion sequences from a library.
Although a specific architecture is shown in FIG. 1 , a number of animation systems in accordance with embodiments of the invention are implemented using a single server, using additional servers, as off-line software packages that include one or more previously trained generative models and/or provide the ability to download one or more generative model. In addition, the functions performed by different aspects of the system can vary. For example, embodiments of the invention could utilize a web server that generates a user interface and performs the generation of synthetic motion data using a generative model. Furthermore, the specific architecture shown in FIG. 1 is not essential to the delivery of motion data to a remote user. In a number of embodiments, the animation system is implemented using any of a variety of architectures for providing remote access to a system capable of generating synthetic motion data using a generative model including an architecture based around the use of cloud computing.
Generating Synthetic Motion Using a Generative Model
A process for generating synthetic motion data for animating a 3D character using a generative model in accordance with an embodiment of the invention is shown in FIG. 2 . The process 40 includes obtaining ( 42 ) motion data to use in the training of a generative model. The motion data can be actual motion data obtained via motion capture (either marker based or markerless), or can be synthetic motion created manually by an animator using a conventional off-line animation software application. For the motion data to be used in the training of the generative model, each sequence of motion data is described using a set of high level characteristics appropriate to the application. The motion data is then used to build ( 44 ) a generative model using supervised learning. As discussed above, any model appropriate to the application that is capable of generating synthetic motion data from a high level description of a desired motion sequence can be used. An initial set of high level motion characteristics is then defined ( 48 ) and the generative model generates ( 50 ) synthetic motion data based upon the high level motion characteristics. The motion data is presented to the animator and a determination ( 52 ) is made concerning whether the synthetic motion data is satisfactory. In the event that the synthetic motion data does not animate the 3D character in the manner desired by the animator, the high level description of the desired motion can be modified ( 54 ) and the modified description used by the generative model to generate new synthetic motion data. When the animator is satisfied with the manner in which the generated synthetic motion data animates the 3D character, the synthetic motion data can be downloaded for storage by the animator and/or stored in a user account.
Although a specific process for generating synthetic motion data in accordance with an embodiment of the invention is illustrated in FIG. 2 , other embodiments that enable the editing of a high level description of desired motion in order to produce synthetic motion data can also be used.
Building an Animation Sequence
Animation systems in accordance with embodiments of the invention support the animation of user defined models of 3D characters (User Model). The animation typically involves building a generative model using a first model, a so-called Standard Model, and then determining how the Standard Model maps to a User Model. When hierarchical models are used as both the Standard Model and the User Model, the mapping includes determining the relationships between Avars in each hierarchical model. In this way, variations in the proportions and shape of a User Model compared to a Standard Model used during the training of the generative model can be accommodated without the need to train a new generative model using the User Model for which training sequences may not be available.
A process for generating synthetic motion data to animate a user defined 3D character in accordance with an embodiment of the invention is illustrated in FIG. 3 . The process 60 includes obtaining ( 62 ) a User Model. In web based systems, the User Model can be uploaded to a web server in a standard file format. Once the User Model is obtained, the User Model can be compared to the Standard Model used during the training of the generative model. Through careful comparison, mappings of the motion data of the Standard Model to the User Model can be determined. The animator can then provide ( 66 ) an initial high level description of a motion sequence, which the generative model can use to generate synthetic motion data. The generative model generates motion data suitable for animating the Standard Model. Therefore, a retargeting process is applied to the synthetic motion data to provide synthetic motion data that is suitable for animating the User Model. In many embodiments, the animation is displayed to the animator in real time by streaming the animation directly or the motion data to a client application via the Internet. The animator can determine ( 72 ) whether additional modifications ( 74 ) to the high level description are required to obtain the desired motion or whether to save ( 76 ) the final motion data.
Although a specific process is illustrated in FIG. 3 , other processes in accordance with embodiments of the invention can be used that enable the retargeting of synthetic motion data generated by a generative model to animate a User Model.
Specifying Desired Motion
Once a model for a 3D character has been selected (either a User Model or the Standard Model), systems in accordance with embodiments of the invention enable the animation of the model of the 3D character using a high level description of the desired motion. As discussed above, a variety of characteristics of the motion including the physical characteristics of the motion and the expressive characteristics of the motion can be controlled via a user interface. A user interface that can be used to obtain a high level description of a sequence of motion from an animator in accordance with an embodiment of the invention is shown in FIG. 4 . The conceptual illustration of the user interface 100 includes three different panels that enable the definition of the motion in three stages. The first panel 102 enables the user to define a sequence of discrete types of motion. In the illustrated embodiment, the sequence involves “running” followed by “throwing”. The specific motions can be selected using any of a variety of common techniques for building user interfaces. For example, a user can select options from a pull down list or search for a specific motion by entering a search term in a dialog box 108 . In a number of embodiments, a single generative model is capable of multiple different types of motion by providing the type of motion to the generative model. In several embodiments, a different generative model is used to generate synthetic motion data for each type of motion. In many embodiments, additional generative models are used to generate motion data for the transitions between different types of motion. The second panel 104 enables the user to define the trajectory of each different specified type of motion. Where appropriate, a number of embodiments of the invention enable the animator to specify a landscape. The animator can then define the starting point and the ending point of each type of motion. In a number of embodiments, the animator can also define the transition. In the illustrated embodiment, the user interface enables the definition of the starting and end points of each motion using a drag and drop interface. The third panel 106 enables the definition of additional physical and/or expressive characteristics of the motion, which can also be referred to as the motion styling. In the illustrated embodiment, the user interface includes three sliders that enable the description of the desired speed of the motion ( 110 ), a description of the athleticism to be expressed by the motion of the 3D character ( 112 ), and a description of the level of fatigue to be expressed by the motion of the 3D character ( 114 ). In other embodiments, any of a variety of high level characteristics specified during the training of the generative model can be controlled via the user interface. Once the animator has completed describing the characteristics of the motion using the user interface, the animation system uses one or more generative models to generate synthetic motion data corresponding to the described motion. In the illustrated embodiment, the animation of the 3D character using the synthetic motion data is presented in the second panel 104 . The animator can review the animation, modify the sequence of motions, the trajectory of each motion and/or the lengths of transitions and modify the values of the styling characteristics until the sequence is satisfactory. At which point, the animator can obtain the synthetic motion data in a standard format.
Although a specific user interface is illustrated in FIG. 4 , any user interface that enables the specification of the trajectory and styling of motion can be used in accordance with embodiments of the invention to obtain a high level description of desired motion from an animator.
Improving the Quality of Synthetic Character Motion Data
In a number of embodiments, synthetic motion data including motion curves and joint angles can be improved by applying filtering processes and reducing the number of key frames (i.e., complete frames). In several embodiments, motion data is filtered using a low pass filter with a frequency that is appropriate for the desired level of smoothing of the motion curves and joint angles. In addition, relative motion between a character's feet and a surface such as a floor when foot contact is present can be removed. In many embodiments, the relative motion is removed using machine learning techniques (e.g., Support Vector Machines) to learn the situations in which the foot is expected to be locked during motion. The relative motion can be eliminated by applying an inverse kinematics correction to the motion of the feet. The editing of the motion data can be facilitated by reducing the number of keyframes on the motion curves. Although specific processes are outlined above for improving the quality of synthetic motion data, many filters and adjustments can be made in accordance with embodiments of the invention to achieve enhancements to generated character motion data as appropriate to a specific character and/or application.
Although the present invention has been described in certain specific aspects, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that the present invention may be practiced otherwise than specifically described, including various changes in the implementation such as using supervised learning to train a generative model based upon meshes as opposed to markers. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive. | Systems and methods are described for animating 3D characters using synthetic motion data generated by generative models in response to a high level description of a desired sequence of motion provided by an animator. An animation system is accessible via a server system that utilizes the ability of generative models to generate synthetic motion data across a continuum to enable multiple animators to effectively reuse the same set of previously recorded motion capture data to produce a wide variety of desired animation sequences. An animator can upload a custom model of a 3D character and the synthetic motion data generated by the generative model is retargeted to animate the custom 3D character. | 6 |
RELATED APPLICATIONS
[0001] This application is a continuation of co-pending application Ser. No. 12/652,483, filed on Jan. 5, 2010, which claims the benefit of U.S. Provisional Application No. 61/142,423 filed Jan. 5, 2009. Both of these applications are incorporated herein by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates generally to lids adapted for use with trays and containers, and more particularly to lids featuring ease of use and improved release from trays and containers.
BACKGROUND OF THE INVENTION
[0003] Containers with detachable and re-attachable lids, including disposable food containers, trays and platters with compatible lids, are well known and are commonly employed in many industries, including food related industries such as restaurants, caterers, institutional food service establishments, cafeterias, and households.
[0004] A tray, serving platter, or container base for use in catering and other food service applications frequently features a lid or cover that is cooperatively engagable therewith for presenting, handling, transporting, and/or protecting a variety of food items. The tray or base usually has an upwardly projecting sidewall terminating in a rim. The base or tray rim may simply feature a lip area, or may include sealing ridges, channels or other locking mechanisms that are adapted for cooperative engagement with corresponding grooves, inverted channels, or other cooperative features which are integrated with the lid. Note that the terms “tray” and “base” are used generically herein to refer to any type of tray, serving platter, container, or other support base which is attachable to a lid or cover. Note also that the term “lid” is used generically herein to refer to any type of lid or cover that is compatible with and attachable to a “tray” or a “base”.
[0005] Most disposable lids for use with food containers and platters are usually thermoformed from a sheet of Polyethylene Terephthalate (PET) or Oriented Polystyrene (OPS) although other plastic materials may be employed. The lid is configured to fit the base, and may include an elevated and/or dome-shaped central portion to allow for comfortably accommodating a certain quantity or height of foods or other contents, and will preserve the shape, form, decorative appearance and/or the general presentation of items such as certain food preparations, including desserts, cakes, sandwiches, or other foods. Or the lid may be substantially flat, and may be attachable to a container which has sufficient depth to surround food items or other contents to be contained therein. In some approaches, once a lid has been engaged with a tray to form a first tray-lid assembly, a second tray-lid assembly can be stacked on top of the first tray-lid assembly, and thus a plurality of tray-lid assemblies can be stacked on top of each other for compact storage and for ease of transportation and handling.
[0006] In the case of food containment, it is paramount that food preparations be protected and that inadvertent disengagement or removal of the lid from the tray be avoided. Therefore, in many cases one or more locking features and/or undercuts are provided at the periphery of the tray and/or the lid, resulting in a relatively tight interference fit between the lid and the tray. However, this tight interference fit can make it difficult for a user to disengage and/or remove the lid at the time of use, resulting in an inconvenience to the user at best, and spilling of the food at worst, as the user struggles to remove the lid from the tray. Depending on the material from which the lid is constructed, the lid may even tear or rip during removal, thereby rendering subsequent reengagement of the lid with tray or container ineffective or futile.
[0007] A typical method for disengaging a generic container-lid assembly is by holding the container with one hand and pulling the lid off with the other hand. Sometimes a tab or an indent is provided in either the lid or the container so as to facilitate creating an initial separation or opening between the lid and the container at the location of the tab or indent, and then separating the lid from the container around the entire periphery of the container-lid assembly. However, this method of disengaging or separating a lid from a container can be difficult if the container is shallow, for example if the container is in the form of a tray or plate.
[0008] Typically, a lid having a raised portion, herein referred to generically as a “dome” lid regardless of whether the lid is round, rectangular, or some other shape, features a downwardly projecting peripheral skirt that overhangs beyond the perimeter of the tray or container base. As will be appreciate by those skilled in the art, for a relatively shallow tray the overhang of the peripheral skirt of the lid is typically almost as tall as the tray, making it difficult for a user to slide his or her fingers underneath the peripheral skirt of the lid for lifting the tray-lid assembly. Instead, a user typically has to lift the tray-lid assembly by the peripheral edge of the lid without touching the tray. In this situation, the entire weight of the tray and its contents is thus borne by the locking or engagement mechanism between the tray and the lid, further necessitating that the tray and lid have a tight fit, and making it even more difficult to removal the lid from the tray.
[0009] A particular difficulty for removing lids from tray-lid assemblies of the type described above is encountered due to the fact that in many cases the lid is flexible and the periphery of the tray-lid assembly is relatively large compared to the size of the tab or indent that is provided with the lid or the tray for initiating separation of the lid from the tray. Consequently, when a user exerts an upward or downward force on the tab or indent provided in the lid or tray for pulling the tray-lid assembly apart, the rim of the lid tends to press opposingly inwardly at other locations, causing the lid to grip even more tightly onto the tray at those locations, and thereby rendering removal of the dome from the tray base extremely difficult, or at least cumbersome.
[0010] Thus, there is a need for a lid that is securely engageable with a tray or a container and yet can be conveniently removed from the tray or container with relative ease and without disturbing the contents of the tray or container. These and other needs are met by the lid of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0011] A lid is claimed for a tray that enables secure and reliable engagement between the lid and the tray while enabling easy removal of the lid from the tray without disturbing contents supported by the tray and without applying undue stress to the lid. In particular, the present invention enables removal of the lid from a tray-lid assembly in a reversible manner, i.e. without damaging the lid during removal.
[0012] Note that except where the context requires a more specific definition, the term “tray” is used herein to refer generically to a tray, platter, dish, container, plate, or any other support base compatible with a lid or cover, and the term “lid” is used generically herein to refer to any sort of lid or cover compatible with a “tray,” including flat lids and “dome” lids that include raised portions so as to have cross sectional profiles that are rectangular, rounded, or any other raised shape.
[0013] Note also that while the following discussion is presented in the context of describing feature(s) of a lid, whereby the feature(s) enable removal of the lid from a tray, the roles of the lid and the tray can be reversed without departing from the scope of the invention. In other words, a specific feature or features ascribed herein to the “lid” (or upper element) can be incorporated into the “tray” (or lower element) of the tray-lid combination. Therefore, the invention applies generally to separable halves of a containing assembly comprising a first half and a second half, whereby terms used for convenience to describe one half of the containing assembly, such as “lid” and “cover,” can generally be exchanged herein with terms used to describe the other half of the containing assembly, such as “tray,” “container,” and “support base,” without departing from the meaning or scope of the invention.
[0014] The claimed lid facilitates separation of the lid from the tray-lid assembly by providing at least two tabs or indentations at two separate locations on the outer periphery of the lid, thereby providing at least two distinct locations for initial disengagement of the lid from the tray. By disengaging the lid from the tray at two or more separated locations about the rim, the tendency of the elastic lid to responsively grip the tray is overcome, and the lid is released from the tray without the user applying undue effort, without subjecting the lid to undue stress, and without unduly disturbing the contents of the tray-lid assembly.
[0015] An additional feature of the present invention is to facilitate lifting of a tray-lid assembly securely from a flat surface by utilizing a lid construction with a peripheral skirt that is short enough to allow a user's fingers to reach underneath the skirt and support the sidewalls of the tray when lifting and/or carrying the tray-lid assembly, so that the entire weight of the tray-lid assembly, including any contents supported thereby, is not exclusively borne by the cooperative engagement features.
[0016] Still another feature of the present invention is to provide a lid having a peripheral flange and a peripheral skirt, wherein the peripheral flange has at least a first pressing area and a second pressing area, and wherein the peripheral skirt has a first lifting tab and a second lifting tab. The first pressing area works cooperatively with the first lifting tab and the second pressing area works cooperatively with the second lifting tab. During the process of removing the lid from the tray, a user presses the first pressing area and lifts the first lifting tab with one hand, and concurrently presses the second pressing area and lifts the second lifting tab with the second hand. Once at least a partial separation has been created at the first and second lifting tab locations, the entire lid can be readily removed from the tray.
[0017] One general aspect of the present invention is a method for using and opening a container assembly. The method includes engaging a lid with a container base by cooperatively locking a lid engagement feature provided in the lid proximal to a peripheral boundary of the lid, with a base engagement feature provided in the container base proximal to a peripheral boundary of the container base, said lid including a first graspable member and a second graspable member proximal to the peripheral boundary of the lid in locations that are not directly opposite to each other, each of said graspable members extending beyond the peripheral boundary of the container base, flexing the first graspable member manually via a user's first hand, thereby rotating the first graspable member upward and disengaging a first portion of the lid engagement feature from a corresponding first portion of the base engagement feature, creating a first region of disengagement therebetween, flexing the second graspable member manually via the user's second hand, thereby rotating the second graspable member upward and disengaging a second portion of the lid engagement feature from a corresponding second portion of the base engagement feature, creating a second region of disengagement therebetween, and removing the lid from the container base by lifting said lid away from said container base.
[0018] In embodiments, the first and second regions of disengagement extend peripherally in both directions from the corresponding graspable members. In some embodiments, the first and second regions of disengagement merge to form a single region of disengagement that extends at least from the first graspable member to the second graspable member.
[0019] In other embodiments, said lid and container base engagement features are substantially round. In various embodiments, the lid further includes a first press location cooperative with the first graspable member and a second press location cooperative with the second graspable member.
[0020] In further embodiments, the lid includes visible indications associated with the first and second press locations suggesting that pressure be applied to the first and second press locations, and visible indications associated with the first and second graspable members suggesting that the first and second graspable members be lifted. And in some of these embodiments, the step of flexing the first graspable member manually via a user's first hand is accompanied by pressing on the first press location to facilitate disengagement at said first region, and the step of flexing the second graspable member manually via user's second hand is accompanied by pressing on the second press location to facilitate disengagement at said second region.
[0021] In certain embodiments, the lid includes visible indications associated with the first and second graspable members suggesting that the first and second graspable members be lifted.
[0022] In embodiments, the graspable members are lift tabs. In some embodiments, said lid is dome shaped. In other embodiments, said graspable members are sequentially flexed by at least one of a user's hands.
[0023] In certain embodiments, the first graspable member is flexed by a first hand of the user and the second graspable member is concurrently flexed by a second hand of the user. In further embodiments, the graspable members are located at an angular separation of between 20 degrees and 60 degrees.
[0024] In exemplary embodiments, the graspable members are located at an angular separation of between 25 degrees and 50 degrees. In various embodiments, at least one of the graspable members is located at a vertex of the peripheral boundary of the lid.
[0025] In embodiments, the first and second graspable members are located adjacent to either side of a vertex of the peripheral boundary of the lid. And in some embodiments, the material of construction of the lid is one of: polypropylene (PP), oriented polystyrene (OPS), polyethylene terephthalate (PET), styrene butadiene copolymer, and rubber modified styrene.
[0026] Another general aspect of the present invention is a method for releasing a lid from engagement with a container base. The method includes providing a container assembly that includes said lid engaged with said container base, the lid including a lid engagement feature proximal to a peripheral boundary of the lid, said lid engagement feature being engaged in mutual cooperation with a base engagement feature provided in the container base, a first graspable member and a second graspable member being attached to the lid proximal to the peripheral boundary of the lid in locations that are not directly opposite to each other, each of said graspable members extending beyond the peripheral boundary of the container base, a first press location being cooperative with the first graspable member and a second press location being cooperative with the second graspable member, flexing the first graspable member while pressing on the first press location, said flexing and pressing being performed manually via a user's first hand, thereby rotating the first graspable member upward and disengaging a first portion of the lid engagement feature from a corresponding first portion of the base engagement feature, creating a first region of disengagement therebetween, flexing the second graspable member while pressing on the second press location, said flexing and pressing being performed manually via the user's second hand, thereby rotating the second graspable member upward and disengaging a second portion of the lid engagement feature from a corresponding second portion of the base engagement feature, creating a second region of disengagement therebetween, and removing the lid from the container base by lifting said lid away from said container base.
[0027] In embodiments, the lid further includes a visible indication associated with the first press location suggesting that pressure be applied to the first press location, a visible indication associated with the first graspable member suggesting that the first graspable member be lifted a visible indication associated with the second press location suggesting that pressure be applied to the second press location, and a visible indication associated with the second graspable member suggesting that the second graspable member be lifted.
[0028] In some of these embodiments, the steps of flexing the first graspable member and flexing the second graspable member are conducted concurrently.
[0029] Yet another general aspect of the present invention is a method for using and opening a container assembly. The method includes engaging a lid with a container base by cooperatively locking a lid engagement feature provided in the lid proximal to a peripheral boundary of the lid, with a base engagement feature provided in the container base proximal to a peripheral boundary of the container base, a first graspable member and a second graspable member being attached to the lid proximal to the peripheral boundary of the lid in locations that are not directly opposite to each other, each of said graspable members extending beyond the peripheral boundary of the container base, flexing the first graspable member manually via a user's first hand, thereby rotating the first graspable member upward and disengaging a first portion of the lid engagement feature from a corresponding first portion of the base engagement feature, creating a first region of disengagement therebetween, flexing the second graspable member manually via the user's second hand, thereby rotating the second graspable member upward and disengaging a second portion of the lid engagement feature from a corresponding second portion of the base engagement feature, creating a second region of initial disengagement therebetween; the step of flexing the second graspable member being performed concurrently with the step of flexing first graspable member, and removing the lid from the container base by lifting the lid away from said container base.
[0030] Some embodiments further include the steps of pressing on a first press area of the lid with said first hand while concurrently flexing said first graspable member, and pressing on a second press area of the lid with said second hand while concurrently flexing said second graspable member. And in some of these embodiments, said first and second press areas are located inwardly from said lid engagement feature proximal to said peripheral boundary of the lid.
[0031] The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and examples of claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The invention will be better understood upon reading the following Detailed Description in conjunction with the drawings in which:
[0033] FIG. 1A is a perspective view of a simple lid of the prior art having a single lift tab;
[0034] FIG. 1B is a perspective view of the simple lid of FIG. 1A , illustrating lifting of a single lift tab and consequent opposing inward distortion of the lid that grips the tray and hinders release of the tray from the lid;
[0035] FIG. 2 is a perspective view of a dome lid according to an embodiment of the present invention;
[0036] FIG. 3 is a top view of the lid of FIG. 2 ;
[0037] FIG. 4 is a side view of the lid of FIG. 2 ;
[0038] FIG. 5 is an enlarged view of a press area and lift tab of the lid of FIG. 2 ;
[0039] FIG. 6 is a partial cutaway view of a tray-lid assembly according to an embodiment of the invention wherein the lid displays a short peripheral skirt;
[0040] FIG. 7 is a partial cutaway view of a tray-lid assembly wherein the lid displays a relatively tall peripheral skirt as typically utilized in dome lids of the prior art;
[0041] FIG. 8 is a perspective view of a user removing a dome lid from a tray with both hands according to an embodiment of the present invention;
[0042] FIG. 9A is a perspective view of the dome lid of FIG. 8 having its lift tabs engaged with the tray and prepared for full engagement of the dome lid with the tray;
[0043] FIG. 9B is a perspective view of the dome lid and tray of FIG. 9A showing pressure being applied to the dome lid so as to attach the dome lid to the tray;
[0044] FIG. 10 is a perspective view of a square dome lid with lift tabs at two corners according to an embodiment of the present invention;
[0045] FIG. 11 is a perspective view of a square lid having two lift tabs located on either side of a corner and one additional lift tab located at an adjacent corner, according to an embodiment of the present invention;
DETAILED DESCRIPTION OF THE INVENTION
[0046] The present invention is generally directed towards a lid that can be securely engaged with a tray or container base and yet is readily removable without unduly disturbing the contents of the tray-lid assembly and without applying undue stress to the lid. The following description of one or more embodiments, in conjunction with the accompanying drawings, are offered by way of illustration only, and should not be regarded as restricting the scope of the invention.
[0047] Note that except where the context requires a more specific definition, the term “tray” is used herein to refer generically to a tray, platter, dish, container, plate, or any other support base compatible with a lid or cover, and the term “lid” is used generically herein to refer to any sort of lid or cover compatible with a tray, including flat lids and “dome” lids that are round, rectangular, or any other shape.
[0048] Note also that while the discussion that follows is presented in the context of describing features of a lid that enable removal of the lid from a tray, the roles of the lid and the tray can be reversed without departing from the scope of the invention, so that the features ascribed herein to the “lid” (or upper element) can be incorporated into the “tray” (or lower element) of the tray-lid combination. Therefore, the invention applies generally to separable halves of a containing assembly, whereby terms used for convenience to describe one half of the containing assembly, such as “lid” and “cover,” can generally be exchanged herein with terms used to describe the other half of the containing assembly, such as “tray,” “container,” and “support base,” without departing from the meaning or scope of the invention.
[0049] As will become readily apparent from the foregoing description, a lid that is easy to use and can be readily removed without damaging the lid according to the present invention provides several advantages over prior art lids and tray-lid assemblies. In the case of a food-containing tray-lid assembly, the present invention enables a user to comfortably remove the lid from a tray or other container base with relative ease and without unduly disturbing any of the food items contained within the tray-lid assembly. In particular, the release features or mechanism of the present invention enables lid removal without use of excessive force, which could otherwise result in tearing or damaging of the lid during removal. Being undamaged, the lid can be reattached to the tray and reused as needed.
[0050] FIG. 1A illustrates a simple lid 100 of the prior art. Lid 100 includes a groove 102 into which a lip of a tray (not shown) can be inserted for secure engagement therewith. Lid 100 also includes a skirt 104 that extends downwardly from the groove 102 . A tab 106 is provided in an attempt to facilitate removal of lid 100 from a tray. As illustrated in FIG. 1B , lifting of the tab 106 causes an initial separation between the groove 102 and the rim of the tray in a region 108 immediately proximal to the tab 106 . However, lifting the tab 106 also necessarily leads to an outwardly radial elongation 110 of the groove 102 toward the tab 106 , and consequently orthogonal, inwardly radial forces 112 on opposing sides of the groove 102 . These opposing, inwardly radial forces 112 cause the groove 102 to be tightly pressed toward the rim of the tray as the tab 106 is lifted, thereby causing removal of the lid 100 to be very difficult. In the resulting struggle to overcome this gripping force 112 , food or other contents of the tray-lid assembly can be disturbed, and in extreme cases the lid material can fail and the lid 100 can be damaged.
[0051] A lid designated by reference numeral 10 , according to an embodiment of the present invention, is shown in FIGS. 2 through 6 , wherein like reference numerals represent like parts. Lid 10 is adapted for engaging with a tray or container base, and as particularly shown in FIG. 6 , lid 10 is shown in a superjacent relationship with tray 30 and is engaged therewith.
[0052] In FIGS. 2 through 6 , lid 10 is shown with a plurality of ornamental design features, however, it will be apparent to those skilled in the art that the utilitarian structural features of the present invention can be readily utilized with or without a variety of aesthetic and/or ornamental lid designs, and that the features of the present invention are not limited to a particular lid style or design. Thus, variations in the lid sidewall and top wall are within the scope of the present invention, and do not affect the ease of use and release functionality described herein. Additionally, the height of the lid 10 is shorter or taller in certain embodiments, and/or the lid sidewall in some embodiments includes upright ribs and/or the lid top wall includes a combination of structural features, including a shape other than a flat top, such as a rounded shape.
[0053] As shown in FIG. 2 , the container lid 10 of the illustrated embodiment integrally comprises a generally planar central top wall 11 ; a raised shoulder portion 12 circumscribing or encircling top wall 11 ; a peripheral top portion 13 circumscribing raised shoulder portion 12 ; a sidewall 20 extending circumferentially downward from said peripheral top portion 13 ; a peripheral flange 23 extending outwardly from the bottom end of sidewall 20 ; a peripheral groove portion 24 ; and a downwardly projecting peripheral skirt 25 .
[0054] In the embodiment shown in FIGS. 2-6 , central top wall 11 is generally planar and substantially horizontal as shown, and is adapted to allow a user to view the contents of the tray-lid assembly. In other embodiments, the lid is opaque or translucent, and/or has a rounded or other non-planar shape or appearance.
[0055] In the embodiment shown in FIGS. 2-6 , the raised shoulder portion 12 of lid 10 is adapted for facilitating stacking of another tray-lid assembly on top of lid 10 , whereby nesting of the raised shoulder 12 into a recess provided in the bottom of a second tray stacked above the lid 10 serves to stabilize the stacked assembly (or assemblies) and prevent sliding thereof during transportation or while handling and carrying a plurality of stacked assemblies.
[0056] As shown, peripheral top portion 13 may include a variety of ornamental features which also serve as structural stiffening members that strengthen the lid, so that the peripheral top portion 13 can retain its dimensional stability against a downward force typically applied thereto during assembly of lid 10 with a tray or container (see FIG. 9 ), and when supporting the weight of another tray-lid assembly. In the exemplary embodiment illustrated herein in FIGS. 2-6 , peripheral top portion 13 features a plurality of flutes 14 and a plurality of ribs 15 . In the illustrated embodiment, the flutes 14 and ribs 15 are organized in sections that form an alternately repeating pattern circumferentially arranged around raised shoulder portion 12 . As is best shown in FIGS. 2 and 4 , the flutes 14 have an upwardly raised or convex geometry. However it will be appreciated by those skilled in the art that a variety of designs, geometries, patterns and/or other structural elements may be readily imparted to or included in embodiments of the lid of the present invention so as to provide aesthetic appeal and/or structural reinforcement.
[0057] As is best shown in FIG. 4 , sidewall 20 extends downwardly from peripheral top portion 13 and tapers radially outwardly so as to provide a gradual draft angle for ease of processing and so as to facilitate mold release during the thermoforming process or during any other processing method used for manufacturing lid 10 . Sidewall 20 includes a plurality of panels 21 and flutes 22 that are circumferentially arranged in an alternately repeating pattern therein. The bottom end of sidewall 20 is connected to peripheral flange 23 which is generally horizontal in the embodiment of FIGS. 2-6 .
[0058] Based on the views shown in various figures herein, it should be readily apparent that relative terms such as “horizontal” are used only for illustrative purposes in describing embodiments of the invention, and that more general terms such as “planar” can be substituted without departing from the scope of the invention. Furthermore modifiers such as ‘generally’ and ‘substantially’ are intended to be construed liberally. Thus, for example, ‘generally planar’ and ‘substantially planar’ are intended to allow for irregular deviations from perfectly flat surface and to reasonably broaden terms such as “planar” so as to encompass curved and other non-planar surfaces.
[0059] As is best shown in FIGS. 4 and 6 , peripheral flange 23 rolls downwardly to define a peripheral groove portion 24 . Peripheral groove portion 24 has a C-shaped or U-shaped cross section which is adapted for engaging with a tray by receiving a tray lip therein. Referring to FIG. 6 , there is shown a cross-sectional view of a tray 30 attached to lid 10 . Tray 30 comprises a tray bottom wall 31 resting on a generally horizontal table surface 60 , a tray sidewall 32 which extends upwardly and outwardly from the tray bottom wall 31 , and a peripheral tray lip 33 . In the embodiment of FIG. 6 , the peripheral tray lip 33 has a bead-like configuration. In other embodiments, the tray lip includes other features, such as a turned-down configuration (not shown). As shown in FIG. 6 , peripheral tray lip 33 nests within the peripheral groove portion 24 of lid 10 , and the slight undercut in the groove portion 24 provides a reasonably secure interference fit between the lid 10 and the tray 30 .
[0060] Lid 10 also features a peripheral skirt 25 which extends downwardly from the underside of the peripheral groove portion 24 and flares radially outwardly. Peripheral skirt 25 facilitates a good lid-fit by guiding the tray lip 33 within the peripheral groove portion 24 .
[0061] As mentioned above, the present invention provides ease of use and release functionality. The release functionality is accomplished by means of at least two lift tabs provided in the peripheral skirt. Accordingly, in the embodiment of FIGS. 2-6 , lift tabs 27 and 29 are provided in the tray skirt 25 . Lift tab 27 is adapted to work cooperatively with press area 26 . Lift tab 29 is adapted to work cooperatively with press area 28 . Press areas 27 and 28 lie in the peripheral flange 23 proximate to panels 21 .
[0062] A typical method of removing the lid 10 of the embodiment of FIG. 6 from the tray 30 will now be described. With reference to FIG. 8 , during removal of the lid from the tray, a user presses on press area 26 and lifts lift tab 27 with one hand, and concurrently presses on press area 28 and lifts lift tab 29 with the second hand. The lifting action with both hands serves to rotate the tabs upwardly thereby disengaging a sufficient peripheral portion of lid 10 from the peripheral tray lip of the cooperatively engaged tray or container base to allow removal of the entire lid from the tray. The region of initial disengagement extends peripherally away from each point of lifting action in both directions, and may or may not extend continuously between the two points of lifting action. The removal of the lid of the present invention from a tray by a user is graphically shown in FIG. 9 . As is best shown in FIGS. 1 , 2 , 4 , and 7 , press areas may be indicated by integrally forming or molding the word “PRESS” therein, and lift tabs may be indicated by integrally forming or molding the word “LIFT” therein for the purposes of providing simple lid removal instructions to a user.
[0063] Since lift tabs 27 and 29 lie along the peripheral skirt 25 , the arcuate distance between lift tab 27 and 29 can be optimized for allowing a user to comfortably grip the respective tabs with both hands and for providing a convenient release from the tray. According to some embodiments of the invention, the arc angle between lift tabs 27 and 29 varies from 20 to 60 degrees, and according to some embodiments of the invention the arc angle between the lift tabs is between 25 to 50 degrees. Polygon-shaped trays and lids can have lift tabs located at two or more adjacent corners, as illustrated in FIG. 10 . In other embodiments, two lift tabs are located on either side of one corner, as shown in FIG. 11 . Various embodiments that include more than two lift tabs, for example on larger trays and lids, may require sequentially applied lifting actions by which suitable peripheral portions of the lid are disengaged from the tray. It is will be appreciated by those of ordinary skill that removing the lid of the present invention with one hand by using a single lift tab is significantly more cumbersome compared to utilizing two of the lift tabs concurrently, or more than two sequentially, for removing the lid from the tray.
[0064] FIG. 5 shows an enlarged view of one of the lift tabs, particularly lift tab 27 . Lift tab 27 features a front wall 27 a, an arcuate front end 27 b, and a pair of wedge-shaped side ends 27 c and 27 d. Front wall 27 a may be curved outwardly to allow lifting or flexibly turning or rotating of the tab 27 upward, and thereby locally disengaging the peripheral groove portion 24 from tray 30 . Local disengagement of peripheral groove portion 24 from tray 30 at both tab locations 27 and 29 sufficiently disturbs the lid engagement to allow an easy removal of the lid from the tray or container base. It will be realized that tabs 27 and 29 can feature a variety of shape configurations which are all deemed within the scope of the invention, including rectangular, button-shaped, or other structural shapes and appearances.
[0065] According to an embodiment of the invention, the peripheral groove portion 24 and lift tabs 27 and 29 are adapted for detachably engaging and fitting lid 10 with a tray or container base 30 . Accordingly lid 10 is constructed of suitable materials to allow engagement and subsequent reengagement if desired by the user.
[0066] It will be apparent to those skilled in the art that the lids of the present invention can be made of a suitable thermoplastic material which can be processed by common polymer processing methods known in the art, such as thermoforming or injection molding. The choice of a thermoplastic resin is typically governed by a variety of factors, including cost, resin processability, and other functional requirements of the lid. Accordingly, lids of the present invention can be manufactured by thermoforming and/or injection molding. In some embodiments of the present invention, the lid is thermoformed from a polyethylene terephthalate (PET) sheet material. According to other embodiments of the present invention, the lid is injection molded from a suitable grade of polypropylene resin.
[0067] Certain embodiments of the present invention also include a low profile or short peripheral skirt. As shown in FIG. 6 , arrow segment 40 indicates the vertical spacing between the bottom of peripheral skirt 25 and the table surface 60 , and arrow segment 50 indicates the horizontal spacing between the outer edge of peripheral skirt 25 and tray sidewall 32 . The advantages will be better understood by contrasting the peripheral skirt 25 according to the embodiment of FIG. 5 with the construction of a prior art lid. FIG. 7 illustrates a lid 210 according to the prior art fitted onto tray 230 . The peripheral skirt 225 of lid 210 is appreciably longer than peripheral skirt 25 of lid 10 . The longer length of peripheral skirt 225 results in a much reduced spacing, indicated by arrow segment 240 , between the table surface 260 and peripheral skirt 225 . This poses an inconvenience to the user when lifting the tray-lid assembly represented by tray 230 and lid 210 . Furthermore, the horizontal distance between the outer edge of peripheral skirt 225 and the tray sidewall 232 represented by arrow segment 250 is also too large for a user to conveniently reach the tray with his or her fingers when lifting the tray-lid assembly, thus requiring the fit between the tray and lid to be sufficiently tight for the tray-lid engagement feature to support the entire weight of the assembly and of any items contained therein. However, in some embodiments of the present invention, the distance between the tray sidewall 32 and the outer peripheral skirt 25 represented by arrow segment 50 is sufficiently short to conveniently allow a user to lift the tray-lid assembly while touching and supporting the tray, thereby reducing the stress or weight felt by the tray-lid engagement features. In addition, allowing a user to hold the tray-lid assembly more securely without relying on just the tray-lid engagement and/or interlocking features also provides ease of use and safety.
[0068] The dual tab feature described above is not limited to round lids, but can be implemented on lids of any shape, including rectangular and square lids. A square lid 10 with two corner tabs 27 , 29 according to an embodiment of the present invention is shown in FIG. 10 . It will be realized that the positions of the two or more tabs can be optimized to provide ease of release on square and rectangular lids. According to another exemplary embodiment of the invention illustrated in FIG. 11 , the two tabs 27 A, 27 B are located in a proximate relationship about a bottom corner of a square or rectangular lid 10 and are disposed in a slightly offset position from that corner on both sides thereof. In addition, FIG. 11 shows a third lift tab 29 at an adjacent corner. Dual or multiple tabs can thus also be implemented on lids having a general shape such as a polygonal shape. Thus, the exemplary embodiments shown in FIG. 10 and FIG. 11 are illustrative of embodiments of the invention for non-round containers and do not limit the scope of the invention with regards to lid shape and locations of tabs.
[0069] The embodiments discussed above all include lids that incorporate lift tab features of the present invention for facilitating separation of a lid from a tray. However, it will be understood by anyone skilled in the art that the same purpose can be accomplished by providing indentation features or recessed locations in the tray for allowing access to a user's hands for grasping and manipulating the lid periphery. Therefore, the graspable tabs can be created by indentations provided in either the tray or the lid. Furthermore, graspable members for manipulating separation of a tray-lid assembly may be configured in the form of lift tabs, push tabs, indentations, or combinations thereof. In addition, it will be understood by those skilled in the art that the features of the present invention can be included in the lower, or “tray” portion of a tray-lid assembly, rather than in the lid.
[0070] 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. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive. Many modifications and variations are possible in light of this disclosure. The advantages of the invention may be further realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended example of claims. | A method for releasing a lid from a base without disturbing contents and without undue lid stress includes flexing two graspable members at separated locations about the lid periphery, thereby providing two distinct initial disengagement locations and overcoming any tendency of the lid to reactively grip the tray when disengagement is initiated. The separated locations are not directly opposite to each other, and can be separations of between 20 and 60 degrees or between 25 and 50 degrees. The lid is then easily removed by lifting the lid upward. The method can include simultaneous and/or sequential flexing of the graspable members by one or both of a user's hands. The graspable members can include lift tabs and/or indentations. In embodiments where the lid further includes press locations, the method includes pressing on the press locations while flexing the graspable members. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of animal husbandry, and more particularly to vehicle-mounted enclosures for catching calves in the field in a manner isolating the calves from protective mother cows for the safety of the farmer or rancher.
BACKGROUND
[0002] In the field of animal husbandry, it has been previously proposed to mount a portable enclosure to an all-terrain vehicle (ATV) or other vehicle and use the same for the purpose of catching calves in the field shortly after birth to enable the farmer or rancher to apply identification tags, perform medical procedures or carry out other processing of the calves. The vehicle and enclosure combination allows the farmer or rancher to capture and process each calf in a manner safely isolated from the mother cow, whose protective instincts may otherwise pose a threat to the farmer or rancher attending to the calf.
[0003] Examples of prior art enclosures of this type are found in U.S. Pat. No. 6,964,245, U.S. Pat. No. 7,389,746 and U.S. Pat. No. 8,061,303, and U.K. Patent Application GB2449900. Other examples of vehicle-carried livestock enclosures or carriers are found in U.S. Pat. No. 5,785,006, U.S. Pat. No. 6,035,808 and U.S. Pat. No. 7,685,970.
[0004] Of the forgoing references, GB2449900 and U.S. Pat. No. 7,389,746 are the most relevant to the present invention, in that they attach to an ATV in a position residing alongside same and feature an openable/closeable door at a leading front end of the enclosure so that a calf can be captured by driving the vehicle up alongside the animal with the door in the open position in order to receive the calf through the open door into the interior of pen, at which point the door is promptly closed by the ATV operator. An operator opening in the vehicle-facing side of the enclosure allows the farmer or rancher to enter the enclosure for access to the captured calf in a manner safely isolated from the surrounding field, where the protective mother cow is likely to be nearby.
[0005] Applicant has designed a new calf catching enclosure of this general type in which unique mechanisms for controlling operation of the openable and closeable doors are employed.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the invention there is provided a portable enclosure for attachment to a ground vehicle for capturing and retaining an animal, the portable enclosure comprising:
[0007] a pen arranged for attachment to the ground vehicle in a working position residing thereaside;
[0008] an front opening in the pen at a front end thereof that faces forwardly of the ground vehicle when the pen is attached thereto in the working position;
[0009] at least one door movably mounted to the pen and movable between a closed position obstructing the front opening of the pen and an open position revealing the front opening of the pen;
[0010] at least one lock member movably carried on the pen at a position overlying the front opening therein, the lock member being displaceable upwardly and downwardly between a locking position engaging the at least one door and a releasing position withdrawn from engagement with the at least one door; and
[0011] at least one rotatable actuation member rotatably carried on the pen in a position overhead of the lock member and linked to the lock member such that rotation of the at least one actuation member in an unlocking direction draws the at least one lock member upwardly out of the locking position into the releasing position to allow movement of the at least one door between the open and closed positions.
[0012] Preferably the at least one lock member is arranged to be engagable with the at least one door in both the open and closed positions thereof.
[0013] Preferably the at least one door comprises:
[0014] at least one door panel that resides in the front opening of the pen the closed position and, in said closed position, is engaged by the locking position of the at least one locking member to lock the at least one door in the closed position; and
[0015] at least one extension member that extends out from the at least one door panel for engagement by the at least one locking member in the open position of the at least one door to lock the at least one door in the open position.
[0016] Preferably the at least one door comprises a latching point at which the at least one door is engagable by downward movement of a respective locking member into the locking position, and an inclined ramp surface approaching the latching point in a manner increasing in elevation theretoward to lift the respective locking member out of the locking position during movement of the at least one door into a position aligning said respective locking member with the latching point, whereupon the locking member falls into the locking position and into engagement with the latching point.
[0017] Preferably the latching point is carried on the at least one door panel and is engagable by downward movement a respective locking member into the locking position with the at least one door in the closed position, and a second latching point is carried on the at least one extension member and is engagable by downward movement of the respective locking member into the locking position with the at least one door in the open position.
[0018] Preferably the at least one door comprises a strike plate mounted atop at least one door panel of said at least one door and defining the inclined ramp surface, and the first latching point comprises a hole in the strike plate for engagement by a respective locking member in the closed and locking positions of the at least one door and the respective locking member
[0019] Preferably there is a second inclined ramp surface carried on the at least one extension member and approaching the second latching point in a manner increasing in elevation theretoward to lift the respective locking member out of the locking position during movement of the at least one door into the open position, whereupon the locking member falls into the locking position and into engagement with the second latching point.
[0020] Preferably the at least one locking member is biased into the locking position.
[0021] Preferably at least one spring biases the at least one locking member into the locking position.
[0022] Preferably the at least one door is biased into the closed position.
[0023] Preferably at least one gas spring is coupled between the pen and the at least one door and biases the at least one door into the closed position.
[0024] Preferably a foot pedal is movably mounted on the pen at a position adjacent a bottom end thereof at a side thereof that resides adjacent to the ground vehicle in the working position, and a linking device is coupled between the foot pedal and the rotatable actuation member so as to drive rotation thereof under actuation of the foot pedal.
[0025] Preferably the linking device comprises a link having a first end coupled to the foot pedal at a position eccentrically offset from a pivot axis of the foot pedal and a second end coupled to the rotatable actuation member at a position eccentrically offset from a rotational axis thereof such that pivoting of the foot pedal about its pivot axis drives rotation of the rotatable actuation member.
[0026] Preferably the foot pedal is arranged to drive rotation of the rotatable actuation member in the unlocking direction under depression of the foot pedal.
[0027] Preferably the rotatable actuation member is linked to the at least one lock member by at least one flexible member.
[0028] Preferably the at least one flexible member is a flexible chain.
[0029] Preferably the at least one door comprises two doors, and the at least one locking member comprises two locking members, one for each of the two doors.
[0030] According to a second aspect of the invention there is provided a portable enclosure for attachment to a ground vehicle for capturing and retaining an animal, the portable enclosure comprising:
[0031] a pen arranged for attachment to the ground vehicle in a working position residing thereaside;
[0032] an front opening in the pen at a front end thereof that faces forwardly of the ground vehicle when the pen is attached thereto in the working position;
[0033] at least one door movably mounted to the pen and movable between a closed position obstructing the front opening of the pen and an open position revealing the front opening of the pen; and
[0034] a locking mechanism having at least one locking member arranged to engage with the at least one door in both the open and closed positions thereof, whereby the same at least one locking member locks the at least one door in both the open and closed positions.
[0035] Preferably the locking mechanism is arranged to automatically engage the at least one locking member with the at least one door in both the open and closed positions thereof.
[0036] Preferably the at least one door comprises:
[0037] at least one door panel that resides in the front opening of the pen the closed position and, in said closed position, is engaged by the at least one locking member to lock the at least one door in the closed position; and
[0038] at least one extension member that extends out from the at least one door panel for engagement by the at least one locking member in the open position of the at least one door to lock the at least one door in the open position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
[0040] FIG. 1 is a front side perspective view of a vehicle-carried calf-catching enclosure according to the present invention.
[0041] FIG. 2 is an overhead plan view of the vehicle-carried calf-catching enclosure.
[0042] FIG. 3 is a partial closeup view of the vehicle-carried calf catching enclosure, showing a spring loaded locking member at the front end thereof for automatically locking doors of the enclosure in both open and closed positions.
[0043] FIG. 4 schematically illustrates use of a foot-pedal lock release mechanism, as would be seen from the left side of FIG. 1 , to release the spring loaded locking member of FIG. 3 and enable automatic closing of the doors from their open positions.
[0044] FIGS. 5A, 5B and 5C are overhead views of one of the doors of the vehicle-carried calf catching enclosure in closed, open and intermediate positions, respectively, as would be viewed along cross-sectional line A-A of FIG. 1 .
[0045] FIGS. 6A through 6D illustrate use of an inclined ramp surface of a strike plate on a door panel of one of the doors of the vehicle-carried calf catching enclosure during closing of the door in order to raise the spring loaded locking member to a ready state for subsequent automatic re-deployment thereof once the door is fully closed.
[0046] FIGS. 7A and 7B another a strike plate on an extension member of one of the doors, which features another ramp surface that is inclined in two directions relative to an axis of the extension member in order to similarly ready the spring-loaded locking member for automatic re-deployment thereof once the door is fully opened.
[0047] In the drawings, like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0048] FIG. 1 illustrates a calf-catching enclosure 10 of the present invention for mounting on an ATV or other vehicle 200 in a position residing alongside same, as shown in the overhead plan view of FIG. 2 . The enclosure features a pen 12 having parallel front and rear walls 14 , 16 and parallel inner and outer side walls 18 , 20 extending between the front and rear walls to delimit an interior space of the pen between the four walls. Each wall includes a frame of rectangular metal tubing, and a mesh or grid formed of smaller metal rods perpendicularly crossing one another between members of the frame. The two side walls 18 , 20 consist of an inner wall 18 that faces laterally toward the ATV and an opposing outer wall 20 that faces laterally away therefrom. The outer wall 20 consists of a singular panel whose area is bound on all four sides thereof by respective frame members, and which is overlaid with the respective mesh or grid. The inner wall 18 instead consists of two smaller panels 22 , 24 upstanding from a bottom frame member 26 of the wall on opposite sides of an operator access opening 28 in the wall 18 through which the user of the enclosure 10 can enter and exit the interior space of the pen 12 . Except for a reinforcement member 30 of the frame that lies parallel to a bottom frame member 26 at a short height thereabove to span between upright frame members 32 , 34 of the two panels 22 , 24 , the operator access opening 28 is entirely unobstructed to give the operator convenient access to the interior of the pen. The rear wall 16 features a singular mesh or grid spanning between respective upright frame members 36 , 38 at the rear ends of the two side panels overtop of a bottom frame member 40 of the rear wall 16 .
[0049] A ground wheel 42 is rotatably mounted to a bottom frame member 44 of the outer side wall 20 to rollingly carry the pen on the ground during use. At the inner side of the pen 12 , a pair of lateral arms 46 project perpendicularly from the bottom frame member 26 of the inner side wall 18 at opposing ends thereof that reside at the corners between this side wall 18 and the front and rear walls 14 , 16 . These arms 44 lie in the same plane as the bottom frame member 26 of the inner wall, and each carry a respective hitch coupler 46 at the distal end of the arm furthest from the bottom frame member 26 . The hitch couplers 48 mate with a respective hitch balls at the front and rear ends of the ATV, as shown in FIG. 2 . Each arm is held rigidly by angled reinforcement members 50 , 52 extending from the arm to the bottom and upright frame members 26 , 36 , 56 of the inner side wall. As shown in FIG. 2 , with each hitch coupler 48 mated and locked to the respective hitch ball of the ATV 200 , the ground wheel 42 rollingly supports the pen 12 alongside the ATV for conveyance therewith in a forward working direction F during operation of the ATV. Use of two hitch couplers at the same low elevation in the plane of the of the bottom frame members of the pen to connect to two lower frame-level ball hitches on the ATV provides the enclosure with confident stability during use.
[0050] The front wall 14 features an upper panel 54 bound at its ends by a pair of upright frame members 56 , 58 shared by the front wall with the inner and outer side walls 18 , 20 . Upper and lower cross-bars 60 , 62 spanning perpendicularly between the upright frame members 56 , 58 complete the perimeter of the upper panel 54 . A respective mesh or grid of the panel is fixed in place over the front side or rear of the panel's perimeter. The upper panel 54 spans only a partial elevation of the front wall 14 , for example approximately half of this elevation in the illustrated embodiment. A front opening 64 of the pen 12 resides beneath this fixed upper panel 54 , and has a pair of doors 66 , 68 pivotally mounted therein for movement of the doors 66 , 68 between closed positions obstructing this opening 64 ( FIGS. 1, 2, 5A ) and open positions ( FIG. 5B ) revealing the front opening 64 to enable entrance of a calf to the interior space of the pen through this opening 64 . Each door 66 , 68 features a main door panel 70 having a frame that delimits a generally rectangular area occupied by, or overlaid with, a respective mesh or grid, just like the panels of the pen walls. Each door panel 70 is hinged to a respective one of the upright frame members 56 , 58 at the corners between the front and side walls of the pen 12 for swinging movement of the door between the open and closed positions about the generally vertical pivot axes of the hinges 72 .
[0051] A top frame member 74 of each door panel 70 has a respective strike plate 76 welded or otherwise affixed thereatop. As best shown in the closeup view of FIG. 3 , each strike plate 76 has a bent shape with a horizontal front portion 78 cantilevered forwardly from the horizontally oriented top frame member 74 of the door panel 70 , and an angled rear portion 80 sloping downwardly and rearwardly from the top frame member 74 of the door panel 70 . The terms horizontal and vertical, as used herein, are with particular reference to the illustrated level orientation of the pen 12 in FIGS. 1 and 2 , in which the coplanar bottom frame members of the pen reside in a horizontal plane, and the walls and doors of the pen all reside in vertical planes with the top frame. It will be appreciated that in use, the specific orientation of the pen may vary somewhat and reside in a slightly tilted orientation, for example due to variation in the ground surface on which the ATV and pen are disposed, variation between the hitch to ground measurement of the ATV versus the wheel axis to ground measurement of the pen's ground wheel, and or due to variation between hitch to ground measurement at the front and rear ends of the ATV. The front portion 78 of each strike plate 76 features a respective hole 82 passing vertically therethrough to define a latching point at which the door is engagable by a respective locking member 84 mounted to the upper panel of the front wall for locking the door in the closed position.
[0052] With continued reference to FIG. 3 , each locking member 84 in the illustrated embodiment is an L-shaped latch pin having a vertical leg 84 a for engaging the strike plate 76 of the respective door at the latching point hole 82 therein, and a horizontal leg 84 b projecting laterally from the top end of the vertical leg 84 a. Each locking member 84 is carried by a respective mounting bracket 86 , which features two forward-projecting horizontal flanges 88 , 90 fixed to a backing plate 92 , which in turn is affixed to the front face of the lower cross-bar 62 of the front wall's upper panel 54 above the front opening 64 of the pen 12 . The vertical leg 84 a of the locking member 84 passes through a pair of aligned holes in the two flanges 88 , 90 . A stop collar 94 is affixed to the vertical leg 84 a of the locking member 84 at a position residing between the two flanges 88 , 90 of the mounting bracket 86 , and has a diameter exceeding that of the hole in the lower flange 90 of the mounting bracket 86 . The stop collar 94 limits downward movement of the locking member 84 and defines a default lock-engaging position thereof in which the vertical leg 84 a of the locking member reaches downwardly far enough to penetrate the latch point hole 82 in the strike plate 76 of the door panel 70 , when in the closed position. A compression spring 96 coils around the vertical leg 84 a of the locking member 84 between the stop collar 94 and the upper flange 88 of the mounting bracket 86 in order to bias the locking member downwardly into the default lock-engaging position. In the closed position of each door, the door panel 70 resides within the front opening 64 of the pen beneath the lower cross-member 62 of the front wall's upper panel 54 , and the front portion 78 of the door panel strike plate 76 reaches forwardly out from the front opening 64 of the pen to align the hole 82 of the strike plate 76 with the holes of the two mounting bracket flanges 88 , 90 , thereby enabling engagement of the locking member 84 with the strike plate in order to latch the door in place.
[0053] A respective upright 98 stands vertically upward from the lower cross-bar 62 of the upper panel 54 of the front wall 14 at a position adjacent each one of the mounting brackets 86 , and a rotatable actuation member 100 is provided in the form of a horizontal rod or shaft journaled to the two uprights 98 for rotation about the shaft's longitudinal axis. Beside each upright 98 , a respective flexible member 102 in the form of a flexible chain has an upper end welded or otherwise affixed to the rotatable actuation member 100 , and a lower end welded or otherwise affixed to the horizontal leg 84 b of the respective locking member 84 . The flexible members 102 thereby link the rotatable actuation member 100 to the two locking members 84 such that rotation of the rotatable actuation member 100 in an unlocking direction D acts to wind more of the flexible member 102 around the rotatable actuation member 100 , thereby pulling the two locking members 84 upward.
[0054] A foot pedal 104 is pivotally mounted to the upright member 32 of the front panel 22 of the inner side wall 18 at a short height above the lower frame member 26 thereof. The foot pedal 104 is in the form of a flat plate 104 a affixed to a circular rod 104 b at its forward end. The circular rod 104 reaches horizontally into the interior space of the pen 12 through a hollow sleeve 106 that is affixed to the front side of the upright frame member 32 . A connection lug 108 is affixed to the end of the rod 104 b that resides inside the pen, and projects radially upward from the rod 104 b. A linking device 110 in the form of an elongated tie-rod has one end thereof coupled to the connection lug 108 at a point located eccentrically outward from the rod 104 b. The rotatable actuation member 100 likewise features a respective connection lug 112 projecting radially upward therefrom for connection to the second end of the linking device 110 at a position located eccentrically outward from the rotatable actuation member 100 . A pair of stop tabs 114 , 116 are affixed to the upright frame member 32 on which the foot pedal is carried at the side of the upright frame member 32 facing toward the ATV, and are positioned respectively above and below the foot pedal plate 104 a to limit pivoting of the foot pedal 104 in both upward and downward directions about its horizontal pivot axis, as defined by the rod 104 b. With the linking device 110 connected between the foot pedal 104 and the rotatable actuation member 100 , depression of the foot pedal plate 104 a downward toward the lower stop 116 pulls the actuation member's connection lug 112 rearward to rotate the actuation member 100 in the unlocking direction D that wraps more of the flexible chains 102 rearwardly over the top of the actuation member 100 .
[0055] In addition to the door panel and the respective strike plate 76 mounted thereon, each door features an extension member 118 affixed to the rear facing side of the top frame member 74 of the door panel 70 , as perhaps best shown in FIG. 5A . The extension member of the illustrated embodiment is formed of a bent piece of rectangular metal tubing, which has a first portion 118 a extending generally along the top frame member 74 past the outer end thereof nearest to the side wall of the pen to which the door is hinged. Here, the extension member 118 bends through a curvature of more than 90° but less than 180°, so that a second portion 118 b of the extension member 118 extends rearwardly away from the door panel 70 while angling back toward, without reaching, a vertical plane P that cuts perpendicularly through the door panel 70 at the location of the strike panel 76 thereon. In the door's closed position, the extension member reaches outwardly through an opening in the mesh or grid of the respective side wall 18 , 20 of the pen, as can be seen in FIG. 2 .
[0056] The distal end of each extension member carries a respective strike plate 120 , which like the strike plate 76 of each door panel 70 features a hole 122 passing perpendicularly therethrough. A cross-member 124 spans between the two portions 118 a, 118 b of the extension member at a distance from the curved bend 118 c that joins these two portions together. A biasing member 126 in the form of a tension gas spring has one end pivotally coupled to the cross-member 124 , and the other end pivotally coupled to the lower cross-bar 62 of the front wall's upper panel 54 near a mid-point thereof, for example at a mounting lug 128 projecting rearwardly from the cross-bar 62 , as shown in FIGS. 2 and 5 .
[0057] The strike plate 120 of each extension member 118 is tilted relative to a longitudinal axis A 1 of the second portion 118 b of the extension member 118 in two different dimensions. Firstly, moving along the longitudinal axis A 1 toward the free end 120 a of the strike plate 120 that is situated furthest from the distal end 118 of the extension member, the strike plate 120 slopes obliquely downward relative to the longitudinal axis A 1 by an acute angle, as shown in FIG. 7B . Secondly, the strike plate 120 is tilted about its own longitudinal axis A 2 so that its side edge 120 b facing toward the door panel 70 is lower than its other side edge 120 c that faces away from the door panel 70 . Accordingly, the strike plate 120 on each extension arm 118 is tilted relative thereto in both the length and width directions of the strike plate 120 .
[0058] In the open position of each door, the extension member 118 thereof positions its strike plate 120 beneath the respective locking member mounting bracket 86 with the strike plate hole 122 in alignment with the holes of the mounting bracket flanges 88 , 90 , thereby enabling receipt of the locking member 84 in a latched state with the strike plate 120 . Accordingly, the strike plate 120 on the extension member acts similar to the strike plate 76 of the door panel 70 , but to lock the door in the open position rather than the closed position. FIGS. 5A and 5B show one of the doors 66 in its closed and open positions respectively, while FIG. 5C shows the door 66 in an intermediate position during movement between the open and closed positions.
[0059] To prepare the calf catching enclosure 10 for use, the two hitch couplers 48 are coupled to the front and rear hitch balls of an ATV. The installation of front and rear frame-height ball hitches on an ATV is already known in the art, and therefore not described herein in further detail. At the front end of the enclosure, at a position inside or outside the pen, the user manually pulls up the locking member 84 of one door (against the downward biasing force of the respective compression spring 96 ) in order to withdraw the vertical leg 84 a of the locking member from the latching point hole 82 in the respective door panel strike plate 76 , thereby unlocking the closed door. With the locking member held in this withdrawn position, the user swings the door outwardly from the closed position in the front opening 64 of the pen into the open position shown in FIG. 5B . With the locking member released 84 , the respective compression spring 96 forces the respective locking member 84 downwardly into engagement with the latching point hole 122 in the extension member strike plate 120 , thereby locking the door in the door in the open position. This process of unlocking, opening and automatically relocking the door is then repeated for the other door, thus putting the enclosure in a ready condition for use.
[0060] The user drives the ATV in the forward working direction F, thus conveying the pen 12 forwardly alongside the ATV with the front doors of the pen secured in the open positions. The user drives up alongside a calf, thereby transitioning the calf from the open environment into the interior of the pen via the front opening 64 due to the open state of the doors during this process. As soon as the calf is inside the pen, the user, from the operating seat of the ATV, depresses the foot pedal plate 104 a of the foot pedal 104 downwardly, thus withdrawing both locking members 84 upwardly into their lock-releasing positions unlocking the currently open doors of the pen, at which point the two gas springs 126 automatically pull the two doors closed in order to secure the calf inside the pen.
[0061] FIG. 6 schematically illustrates how each locking member 84 and the corresponding door panel strike plate 76 cooperate during the closing of the respective door to achieve automatic re-locking of the door upon arrival thereof in the fully closed position. As the door is being closed, i.e. moving from the fully open position of FIG. 5B through the intermediate position of FIG. 5C and onward toward the fully closed position of FIG. 5A , the inclined ramp portion 80 of the door panel strike plate 76 approaches the locking member's mounted position on the front wall of the pen, as schematically shown in FIG. 6A . The lower end 80 a of the inclined ramp portion 80 is situated at an elevation below that at which the lower end of the locking member's vertical leg 84 a resides when in its lowest spring-biased lock-engaging position. The elevation of the horizontally cantilevered portion 78 of the door panel strike plate 76 , i.e. the elevation at which the inclined ramp portion 80 joins to the horizontal portion 78 , equates to an attainable elevation of the locking member's lower end that occurs prior to full compression of the respective spring 86 . Turning to FIG. 6B , as the inclined ramp portion 80 of the door panel strike plate 76 reaches the mounted position of the locking member 84 , the bottom end of the locking member comes into contact with the ramp portion 80 and rides upwardly therealong as the door panel continues toward the closed position, whereby the locking member 84 is pushed upwardly against the bias of the compression spring 86 . Turning to FIG. 6C , the lower end of the locking member 84 rides up onto the horizontal portion 78 of the strike plate 76 and comes into alignment with the latch hole 82 as the door reaches the fully closed position. At this point, with reference to FIG. 6D , the compression spring 86 forces the bottom end of the locking member 84 downwardly through the latch hole 82 , thereby automatically locking the door in the fully closed position.
[0062] This self-locking closure of the door means that the pedal-initiated closing of the two doors during use of the enclosure to capture a calf will automatically lock the doors in their closed positions to prevent escape of the calf from the interior of the pen. The user can enter the interior of the pen from the operator seat of the ATV through the operator access opening 28 in the inner side wall 18 of the pen, and tend to the calf in a position safely isolated from the mother cow by the walls of the pen and by the ATV, which bocks the mother cow's access to the operator access opening 28 . Once the calf has been tagged, treated or otherwise processed, the user remains safely inside the pen and manually lifts the horizontal leg 84 b of the locking member 84 of one or both of the doors in order to release the locking member from its latched condition with the respective door panel strike plate 76 , and pushes the respective door panel outward from the closed position toward the open position to allow the calf to exit the pen and return to the surrounding field environment.
[0063] When opening the doors during preparation of the enclosure for use, the tilted orientation of each extension member strike plate 120 works in the same manner as the bent shape of the door panel strike plate 76 to force the respective locking member 84 upwardly as the door approaches the position in which it is to be locked. That is, the extension member strike plate 120 slopes upwardly toward the latch point hole 122 therein from the distal end 120 a and from lower side edge 120 b, whereby the area between the latch point hole 122 and distal end 120 a and lower side edge 120 b defines an inclined ramping surface that increases in elevation toward the latch point hole 122 in order to drive the lower end of the locking member 84 upwardly against the bias of the respective compression spring 86 as the respective door approaches the fully open position of FIG. 5B from the closed and intermediate positions of FIGS. 5A and 5C . As the door reaches the fully opened position aligning the latch point hole 122 with the raised lower end of the locking member 84 , the compression spring 86 forces the lower end of the locking member 84 downwardly through the latch point hole 122 in order to automatically lock the door in the fully opened position.
[0064] The forgoing embodiment of the present solution includes a number of novel, inventive and potentially advantageous features, including the unique arrangement of a rotatable actuation member for raising the downwardly biased locking members up into released positions allowing movement of the doors, foot pedal operation of the actuation member for convenient unlocking of the doors from the operator seat of the ATV, the use of the same members 84 to secure each doors in both the open and closed positions, and the use of inclined strike plate ramp surfaces to automatically lift the locking members into ready positions for subsequent deployment during an automatic locking action.
[0065] While the illustrated embodiment features two doors, each having a respective locking member and pair of strike plates, it will be appreciated that an alternate embodiment may feature a singular door spanning the width of the front opening from one hinged side while employing similar use of a the same lock member to lock the door in the open and closed positions. It will also be appreciated that the unique overhead actuation member for releasing the locked condition of the door(s) may rely on an input other than a foot operated pedal to initiate its rotational action. Additionally, the overhead actuation member and/or the use a sloped strike plate to control the locking member(s) may be used regardless of whether that locking member is used to lock the door in both open and closed positions, or to lock the door in only one of those positions. While the illustrated embodiment uses gas springs to bias the doors toward the closed position, and compression springs to bias the locking members toward the locking position, it will be appreciated that other biasing means may be employed. For example, in one embodiment, gravitational biasing of the locking member(s) downwardly toward their lock-engaging positions may be sufficient without an additional resilient such as the disclosed compression spring. It will also be appreciated that the particular shape of the pen and its interior space may be varied.
[0066] For example, in one embodiment (not shown) the rear wall may be built out over a partial span of its width to accommodate a smaller floor-equipped cage inside the larger pen for transporting a calf from its captured position in the field, whereby the built-out area of the rear wall would change the shape of the overall interior space of the pen from the rectangular volume of the illustrated embodiment.
[0067] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the scope of the claims without departure from such scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A portable enclosure for capturing and retaining an animal features a pen carried alongside an ATV, a front opening in the pen, and at least one door movable between open and closed positions at the front opening. A lock member is carried above the front opening, and is displaceable into and out of a locking position engaging the door. A rotatable actuation member resides overhead of the lock member and is operable by a foot pedal to draw the at least one lock member upwardly out of the locking position to unlock the door. The same lock member acts in both the open and closed positions of the door by way of cooperation with strike plates on the door panel and an extension member projecting therefrom. The strike plates are shaped to return the lock member to a ready state for automatic locking during opening and closing of the door. | 4 |
BACKGROUND OF THE INVENTION
Motorcycles have been conventionally designed for use on roadways, trails and race tracks which are relatively free from bumps, ruts, and other obstacles. However, in recent years, off-road use of motorcycles has become increasingly popular, particularly in competitive events such as motocross and desert racing, and motorcycles have been designed specifically for these off road activities, incorporate many improvements over conventional roadway cycle design, including improvements in rear wheel suspension systems. However, these improvements are for the most part modifications of conventional rear suspension units which are comprised of a swinging arm or fork pivoted from the main frame and carrying the rear wheel, and a pair of shock absorbing units connected between the swinging arm and upper members of the main frame.
These suspension systems have proven quite adequate for normal roadway or graded racetrack use. When used at high speeds in rough terrain, they have proven to have many desirable characteristics needed for this use such as high lateral rigidity, low unsprung weight, maintain load on front wheel for steering in turns, and simplicity in construction and servicing. However, they have one major shortcoming in that the sudden vertical shock loads delivered to the rear wheel upon striking an obstacle are absorbed and reacted into the rear of the frame either as a direct vertical force, or a force that has a significant vertical component. This vertical reaction on the rear of the frame causes it to rise suddenly in a rotational motion about the front wheel point of contact with the ground. The result of this motion is loss of traction, and reduced control of the motorcycle, and in severe cases causes loss of rear wheel contact with the ground which may throw the cycle end-over-end into a bad crash. Such accidents are normally avoided by reducing speeds prior to encountering large obstacles when seen sufficiently in advance, but some are not foreseeable, and the desire to achieve competitive racing positions encourages maintaining high speeds when mode rate obstacles are foreseen. Therefore an improvement in rear suspensions for motorcycles used in off-road racing is definitely needed, but must be accomplished in a manner that does not diminish the desirable characteristics inherent in current designs.
SUMMARY OF THE INVENTION
The invention is an improved rear wheel suspension system primarily intended for off-road motorcycle application which reduces the above mentioned problems by permitting higher speed operation over rough terrain without sacrificing control. The system is capable of absorbing large shocks and vertical rear wheel motion and reacting these forces as torsion in the main frame with a minimum delivery of vertical force of moment coupling, so that the rotational tendency of the motorcycle upon rear wheel impact is greatly reduced.
Structurally the suspension system comprises a spring means mounted between the swing arm that carries the rear wheel and the frame such that vertical displacement of the rear wheel results in horizontal forces being reacted on a portion of the frame which is preferably well below the center of gravity of the motorcycle and rider. The spring means may be provided as a tension, compression, or torsion coil spring, or the equivalent. The suspension on system can be incorporated in traditional off-road motorcycles without reducing the advantageous elements of design such as lateral rigidity, low unsprung and overall weight and positive front wheel steering. A preliminary dynamic analysis of the invention as part of a motorcycle both confirms the theoretical reaction of vertical forces into torsion on the frame with mimimum vertical forces, and assures that the dynamic aspects of natural frequencies of the cycle compared to excitation frequencies induced by rough terrain produce a dynamically stable condition in operation. Extensive testing of the system incorporated in motorcycle of current design and operated by several different riders in off-road races has proven it to be considerably superior to conventional systems in terms of speed and control.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a motorcycle shown in phantom with the suspension assembly installed;
FIG. 2 is a view of the suspension assembly as seen from below;
FIG. 3 is a section view taken along the lines 3--3 of FIG. 2;
FIG. 4 is a side elevation view of a modified form of the spring arrangement;
FIG. 5 is a sectional view taken on line 5--5 of FIG. 4;
FIG. 6 is a side elevation view of an alternative spring arrangement;
FIG. 7 is a side elevation view of another spring arrangement; and
FIG. 8 is a side elevation of a further spring arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The suspension system of the invention as incorporated in a motorcycle is best shown in FIG. 1, wherein 10 represents diagrammatically illustrated motorcycle frame having a pair of vertical support members 12. jointed at their bottoms and rigidly connected at their bottoms to a pair of longitudinal frame members 14 and two diagonal seat supports 16. The rear wheel 18 is journalled at 20 between the rear ends of a swing arm assembly 22 comprising two bars pivoted at 24 to the vertical support 12 of the main frame. The structure as thusfar described is obviously very diagrammatic and subject to extensive modification without defeating the function of the invention.
The rear wheel is carried on the swing arm assembly 22 which is ordinarily suspended beneath an upper frame member by compression springs and shock absorbers in conventional motorcycles. In the instant invention, however, direct spring linkage with an upper frame member is omitted altogether and instead a horizontally reacting spring 26 is used which is connected between an extension arm 28 depending from the spring arm assembly and a bracket 30 which is mounted to a forward portion of the supports 14.
The arm 28 may be actually constructed of two convergent side plates 33 as shown, having integral rearwardly extending fork portions which are preferably welded to the individual side members of the swing arm assembly 22. The convergent ends of the side plates merge into a boss 34 having a longitudinal bore therethrough which receives the threaded shank 36 of a clevis 38 which is secured to the extension arm by a nut 40 which may be spaced from the boss by an alignment washer 42. The nut may be tightened or loosened to vary the static tension on the spring to optimize the tension parameter for riders of different weights.
The spring 26 is retained in the clevis by clevis pin 44, and the bracket 30 to which the other end of the spring is attached comprises a horizontal plate welded to the top of the frame members 14, and two depending parallel arms 48 through which the spring is bolted. This structure is exemplary only, it being clear that the clevis could be attached to the bracket 30 and rather than the arm 28, and other engineering variations are conceivable within the scope of the invention.
The spring action should be damped by one or more shock absorbers which perhaps ideally should parallel the spring. However, practical considerations of exposure to dirt and damage in off-road conditions suggest that, as illustrated at 50, the shock absorbers should be mounted between the swing arm and upper frame members such as seat supports 16. Tests have indicated that the vertical shock forces in the undampened direction coupled to the frame by the shock absorbers, especially when they are forwardly raked as shown in FIG. 1, do not substantially interfere with the dynamic advantages provided by the improved spring means.
In keeping with the overall requirements that the spring means used be substantially horizontally reacting and connected to the frame below the operational center of gravity, several other embodiments of the spring means is replaced by a compression spring 52 which is captured between two retaining caps 54 and 56. As best seen in FIG. 5, cap 54 has welded thereto a pair of bars 58 of which extend through the hollow core of the spring and pass through slots 60 in retaining cap 56 and are pivotally connected at 62 to an arm or bracket 64 which extends downwardly from the lower member of the frame 10. Similarly, a single bar 66 is welded to the forward cap extending through the rear cap and is pivoted to the clevis 38.
This triple bar construction is extremely durable and trouble-free in operation, and permits the utilization of a compression spring in an extension spring capacity. The compression spring is advantageous in that it may be made of lighter guage steel than an extension spring with the same spring strength, and does not require hooked ends which are prone to breakage in use. Also, the problem of pre-loading the spring is lessened, although it is still adviseable to incorporate the means of tension adjustment inherent in the clevis assembly as discussed above. The use of three bars slideable in slots in the end caps virtually eliminates any sloppiness in the spring action as well as investing the spring assembly with tremendous durability. It will be noted that the bars 58 and 66 could be modified or provided in a number other than three and the compression-extension spring action would be substantially preserved.
The angle of the spring 52 will probably decline slightly toward the rear when the motorcycle is not in use, and incline toward the rear under shock conditions. This change of attitude is accomodated by the pivotal mounting of the bars. However, throughout its length of travel, the spring will not deviate from the horizontal by more than a few degrees, so that the horizontal dissipation of shock forces will be generally effective under all conditions.
A modified form of compression-extension spring is shown in FIG 7, in which the coil spring 68 is captured between a brace 70 and an end cap 72 which is compressed against the spring by a draw rod 74 which passes through an opening in the brace and is pivoted to a modified projection 76 mounted on the swing arm. This embodiment is somewhat simpler than the others and may be preferable on certain frame designs.
Finally, a torsion coil or leaf spring, very diagrammatically illustrated at 78 could be used. In this version, substantial horizontal reactance of vertical forces is effected and could undoubtedly be increased somewhat with further engineering development. | The invention comprises a suspension system for a motorcycle or the like wherein the rear wheel suspension spring is connected to the frame in such a manner that upward impacts received by the rear tire are reacted on the frame in a substantially horizontal direction rather than vertically as in conventional motorcycles so that the pitching motion and vertical thrust on the rear end of the motorcycle is considerably reduced over rough terrain, a feature which is particularly advantageous in offroad racing. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a beverage container with a rotatable cover and an automatically extendable drinking straw, and more particularly, to such a container having a straw-bending member and a slot-closing member on a cap.
2. Description of the Prior Art
A beverage container with a rotatable cover and an automatically extendable straw as shown in FIGS. 1 and 2 was well known. This beverage container comprises a body 11, a cap 12, upper and lower straws 13 and 10 and a cover 14. The body 11 is a hollow cylindrical member for containing a beverage such as juice, water, etc.
The cap 12 is screwed onto an outer thread of the open end of the body 11. Upper and lower disk members 121, 122 of different diameters are formed with an annular groove 123 and two symmetric cuts 124. The cap 12 is formed with a through hole 126 to receive the straws 13, 10 through which a user can suck the beverage from the body 11. A member 125 with a flat top surface is also attached on the cap 12.
The cover 14 is disposed above the cap 12 and has an open end. Two symmetrically disposed projections 141 are formed on the inner edge of its open end corresponding to the cuts 124 in the cap 12. An upper wall of the cover 14 is formed with a slot 142 therein to receive the-upper straw 13 which extends therethrough. A stopper 143 is formed on the bottom surface of the upper wall in the vicinity of the slot 142.
When the projections 541 on the cover 14 are aligned with the cuts 124 on the cap 12, the cover 14 fits on the cap 12. The cover 14 can be rotated counterclockwise to move the slot 142 to a position above the upper straw 13 which then extends outwardly through the slot 142 by means of its own resilience to enable a user to suck the beverage from the body 11. Conversely, when the cover 14 is rotated clockwise, the upper straw 13 is acted on by the upper wall of the cover 14 and it is hereby withdrawn back into the cover. The rotation of the cover 14 is stopped when the stopper 143 on the cover 14 abuts against the member 125 which is then just below the slot 142 to block the slot 142 in order to prevent foreign objects from entering into the cover 14.
One drawback of such known container is that the member 125 having a flat top surface fails to effectively shield the slot 142 formed on the slightly arcuate upper wall of the cover member 14. Consequently, dust or other contaminants may pass through the clearance between the slot 142 and the member 125 to contaminate the upper straw 13 and the cap 12.
In the known container, only the cover 14 acts to bend the upper straw 13 causing it to be temporarily pinched off and thus preventing leakage when not in use. It is found, however, that the cover 14 fails to completely clamp off the upper straw 13 to prevent leakage because the bent upper straw 13 will incline upwardly within the cover 14 (FIG. 2).
Furthermore, it is also difficult for a user to recognize whether the cover 14 has been rotated to a position allowing the upper straw 13 to extend outwardly through the slot 142.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide an improved beverage container with an automatically extendable straw of a novel structure such that when the straw is in its folded condition when not in use, leakage is effectively prevented while the slot on the cover is effectively blocked. Moreover, a user can easily recognize when the cover is rotated to either a position closing the slot or a position extending the straw outwardly.
According to the invention, there is thus provided a beverage container comprising an open ended body closed by a removable cap, straw means extending through the cap, a cover member rotatably fitted on the cap for rotational movement relative to the cap between a first position allowing the straw to extend outwardly through a slot of the cover member and a second position folding the straw, means for auxiliarily bending the straw, means for closing the slot to prevent contaminants from passing therethrough when the cover is rotated to the second position, and means for positioning the cover in either the first or second position.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective exploded view of a prior art container;
FIG. 2 is a perspective assembled view of the container shown in FIG. 1;
FIG. 3 is a perspective exploded view of a preferred embodiment of a container of the present invention;
FIG. 4 is a side elevational, partially sectional view of the container of FIG. 3, with the straw extending outwardly for use;
FIG. 5 is a top plan view of the container of FIG. 4, showing the straw extending outwardly for use;
FIG. 6 is a top plan view of the container of FIG. 4, showing the straw in its closed or non-drinking mode; and
FIG. 7 is an enlarged, partially perspective view of the container of the invention, showing a straw in its closed position, with the cover removed for clearer illustration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 3 and 4, the container of the present invention comprises a body 2, a cap 3, first and second straws or tubes 51,52, a cover 4, and a decorative member 48.
The container body 2 is a hollow cylindrical member for holding a beverage such as water, juice, etc. The upper end of the body 2 is formed with outer thread 21.
The cap 3 is screwed on the outer thread 21 of the body 2 to seal the body 2. The cap 3 is formed with a through hole 35 and a fixing seat 351 which projects from the upper side of the hole 35. Upper and lower disk members 31, 32 of different diameters are formed with an annular groove 33. First and second beads 331,332 project radially from the bottom of the groove 33. A shielding member 34 is fixedly mounted on the cap 3 on the edge of its top surface between the first and second beads 331,332. The shielding member 34 has curvature for a purpose to be described. An inverted U-shaped yoke 36 is fixedly mounted on the cap 3 near the edge of its top surface, the ends of the legs of the yoke 36 being provided with enhancing ribs 361,362, respectively.
The first tube or straw 51 is made of relatively soft, resilient material such as silicone and comprises a bent section 513 and a vertical section 511 having two integrally formed separated flanges 512. The first straw 51 is fitted on the through hole 35 in a manner that the fixing seat 351 is sandwiched between the two flanges 512 and that the bent section 513 extends inclinedly through the yoke 36. The second tube or straw 52 is made of rigid material such as polyester and extends downwardly into the interior of the body 2 and contacts the beverage contained therein. More particularly, the second straw 52 has an outer diameter slightly greater than the inner diameter of the first straw 51 such that when the second straw 52 is inserted into the first straw 51 already fitted on the hole 35, the second straw 52 is connected with the first straw 51 and held in position in a coaxial relation due to frictional force.
The straws 51, 52 thus mounted and connected allow a beverage contained in the body 2 to be removed therefrom under a sucking action. The bent section 513 of the first straw 51 is preferably inclined upwardly at 10 degrees with respect to a horizontal plane to facilitate the sucking process and to allow the beverage in the bent section 513 of the first straw 51 to flow back into the body 2 when the sucking process stops.
The cover 4 is disposed above the cap 3 and has a curved side wall 46 and top surface 47. Two symmetrically disposed projections 42 are formed on the inner edge of the open end of the cover 4 for slidably engaging the groove 33 on the cap 3, allowing the cover 4 to be rotated relative to the cap 3 as is known in the art. The cover 4 is preferably made of a rigid yet somewhat flexible material and is of such dimensions as to enable the snapping receipt of the projections 42 onto the groove 33. The side wall 46 of the cover 4 is formed with a slot 41 which can be aligned with the bent section 513 of the first straw 51 and the yoke 36 allowing the first straw 51 to extend outwardly therethrough for a user to use.
The side wall 46 is designed to have an inner surface conforming to the outward surface of the curved shielding member 34 on the cap 3 such that the slot 41 formed on the side wall 46 of the cover 4 can be tightly closed by the curved shielding member 34 on the cap 3 when the container is in its non-drinking mode (see FIG. 6).
A plate 45 projects from the inner surface of the curved side wall 46 of the cover 4 above one of the projections 42. Adjacent another projection 42, a spot 43 is raised on the inner surface of the side wall 46 opposite to the plate 45. A recess 44 is formed on the side wall 46 between the spot 43 and the another projection 42. For achieving a varying and attractive effect, a decorative member 48 can be attached onto the top surface 47 of the cover 4. This may be made, for example, by having legs 481 of the decorative member 48 inserted through holes 471 formed on the top surface 47 and then expanding the end 482 of the legs 481 to mount the decorative member 48 thereon see FIG. 4.
Referring now to FIGS. 4-7, the operation of the container of the invention will now be described. As shown in FIGS. 6 and 7, the first straw 51 is guided a folded through the association of the side wall 46 of the cover 4 with the yoke 36 on the cap 3 and received inside the cover 4, while the slot 41 formed on the side wall 46 of the cover 4 is tightly closed by the curved shielding member 34 on the cap 3.
When a user wishes to drink the beverage contained in the body 2, he or she only needs to rotate the cover 4 clockwise from the position shown in FIG. 6 to a position shown in FIG. 5 where the projection 42 on the cover 4 abuts against the bead 331 on the groove 33 to stop the rotational movement of the cover 4, and the slot 41 faces the yoke 36. Simultaneously, the bent section 513 of the first straw 51 is released and is restored to its extended drinking position by means of its own resilience, extending outwardly through the slot 41.
Conversely, when the first straw 51 needs to be retracted into the cover 4 of the container, the cover 4 is rotated counterclockwise to a position shown in FIGS. 6 and 7, where the projecting bead 332 formed on the groove 33 is positioned in the recess 44 formed on the cover 4, and the projecting plate 45 on the cover 4 presses the bent section 513 against the yoke 36 (FIG. 7). The cover 4 is then well located in a position where the bent section 513 is bent through the association of the yoke 36 and side wall 46 of the cover 4, and the shielding member 34 faces and tightly closes the slot 41.
The results and advantages of the above container constructed according to the present invention become clear when compared to the prior art container. Firstly, the container according to the invention can provide better leakage-proof for the first straw 51, because, besides the cover 4, the yoke 36 on the cap 3 and the plate 45 of the cover 4 also help to close the flow passage in the bent section 513 of the first straw 51. It is insured that there is no beverage remaining in the bent section 513 of the first straw 51 when there is no sucking action due to its upwardly inclined arrangement.
Secondly, since the shielding member 34 on the cap 3 is in a form conformable to the inner surface of the side wall 46, the cover 4 having its slot 41 tightly closed by the shielding member 34 completely isolates the cap 3 and the first straw 51 from the external environment and achieves hygienic purposes. Thirdly, the provision of beads 331,332 on the groove 33 of the cap 3 in association of the projections 42,42 and recess 44 on the cover 4 helps the user to recognize the proper rotational positioning of the cover 4 when he or she wants to either extends the first straw 51 outwardly through the slot 41 or withdraw the first straw 51 back into the cover 4.
It should be noted that the above embodiment is only an example of the present invention and any modification or derivation thereof should fall within the scope of the present invention. | A beverage container includes a rotatable cover and an automatically extendable drinking straw. The container includes an open ended body closed by a removable cap. A cover is fit onto the cap and is rotatable to a drinking position where a first straw section extends in an inclined manner upwardly through a yoke on the cap and a slot on the cover. The cover also may be rotated to a non-drinking position where the first straw section is moved within the cover and is pinched off to prevent leakage. The slot on the cover is closed by a curved member projecting from the top surface of the cap. A second straw section extends downwardly from the cap into the beverage container body. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application relates to and incorporates by reference the entire disclosures of U.S. Application entitled “Wireless Device and Method for Wireless Multiple Access” filed on Mar. 31, 2005 naming Jacob Sharony as inventor, and U.S. Application entitled “System and Method for Wireless Multiple Access” filed on Mar. 31, 2005 naming Jacob Sharony as inventor.
BACKGROUND
[0002] A wireless local area network (WLAN) is a flexible data communications system which may either replace or extend a conventional, wired LAN. The WLAN may provide added functionality and mobility over a distributed environment. That is, the wired LAN transmits data from a first computing device to a further computing device across cables or wires which provide a link to the LAN and any devices connected thereto. The WLAN, however, relies upon radio waves to transfer data between wireless devices. Data is superimposed onto the radio wave through a process called modulation, whereby a carrier wave acts as a transmission medium.
[0003] Exchange of data between the wireless devices over the WLAN has been defined and regulated by standards ratified by the Institute of Electrical and Electronics Engineering (IEEE). These standards include a communication protocol generally known as 802.11, and having several versions, including 802.11a, 802.11b (“Wi-Fi”), 802.11e, 802.11g and 802.11n. Recently, there has been a surge in deployment of 802.11-based wireless infrastructure networks to provide WLAN data sharing and wireless internet access services in public places (e.g., “hot spots”).
[0004] Conventional WLANs utilize a single-in-single-out (“SISO”) cellular sharing architecture, in which data is transferred over a radio channel in a cell. Because the channel is shared by all wireless devices (e.g., mobile units and an access point) within the cell, each device must contend for access to the channel, thus, allowing only one device to transmit on the channel at a given time. Consequently, conventional WLANs present a number of limitations (e.g., delayed transmission times, failed transmission, increased network overhead, limited scalability, etc.).
[0005] In an effort to overcome the limitations of the conventional WLAN, a multiple-in-multiple-out (“MIMO”) shared WLAN architecture has been developed. A MIMO mode uses spatial multiplexing to increase a bit rate and accuracy of data sent between the wireless devices. In the MIMO mode, a single high-speed data stream (e.g., 200 mbps) is divided into several low-speed data streams (e.g., 50 mbps), transmitted to the wireless device (e.g., mobile unit) and recombined into the high-speed data stream for resolving the transmission. However, this high-speed connection is provided only for one-to-one communication (e.g., access point to a single mobile unit) at a given time. In addition, wireless devices operating according to a first version of the 802.11 protocol (e.g., 802.11a, 802.11b, 802.11g, etc.) may not support the high-speed connection without a hardware and/or a software modification(s), which may represent significant costs to operators of the WLAN.
SUMMARY OF THE INVENTION
[0006] The present invention relates to an access point which includes a plurality of antennas, a plurality of transceivers and a processor. Each of the antennas receives a first signal from each of a plurality of wireless devices. The first signal includes a first identifier of a corresponding wireless device. Each of the transceivers is coupled to each of the antennas. The processor is coupled to each of the transceivers. The processor generates a first communication matrix which includes the first identifier from each of a selected number of the wireless devices. The selected number is no greater than a number of the antennas. The processor utilizes the first communication matrix to resolve multiple wireless communications received from the selected number of the wireless devices within a single time slot over a radio channel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows an exemplary embodiment of a system according to the present invention.
[0008] FIG. 2 shows an exemplary embodiment of a downstream protocol according to the present invention.
[0009] FIG. 3 shows an exemplary embodiment of an upstream protocol according to the present invention.
[0010] FIG. 4 shows an exemplary embodiment of a method according to the present invention.
[0011] FIG. 5 shows a schematic view of an exemplary embodiment of wireless communication of the system according to the present invention.
[0012] FIG. 6 shows an exemplary embodiment of a relationship between an aggregate system throughput and a number of antennas of the system according to the present invention.
[0013] FIG. 7 shows a further exemplary embodiment of the relationship between the aggregate system throughput and the number of antennas of the system according to the present invention.
DETAILED DESCRIPTION
[0014] The present invention may be further understood with reference to the following description and the appended drawings, wherein like elements are referred to with the same reference numerals. The exemplary embodiment of the present invention describes a protocol for providing multiple access to a wireless environment for wireless devices therein. In addition, the protocol of the present invention is preferably compatible with legacy 802.11-based wireless devices using conventional access mechanisms.
[0015] FIG. 1 shows a system 100 according to the present invention. The system 100 may include a WLAN 105 deployed within a space 110 . As understood by those skilled in the art, the space 110 may be either an enclosed environment (e.g., a warehouse, office, home, store, etc.), an open-air environment (e.g., park, etc.) or a combination thereof. The space 110 may be one area or partitioned into more than one area (e.g., an area 115 ). The areas 115 are limited neither in number or dimension. As shown in FIG. 1 , the space 110 is divided into the areas 115 ( 1 - 3 ).
[0016] The WLAN 105 may include wireless communication devices, such as, an access point (“AP”) 120 and one or more wireless devices (e.g., mobile units (“MUs”) 125 ) wirelessly communicating therewith. The AP 120 may be connected to a server via the WLAN 105 . Though, FIG. 1 only shows MUs 125 ( 1 - 3 ) within the WLAN 105 , those of skill in the art would understand that the WLAN 105 may include any number and type of MUs (e.g., PDAs, cell phones, scanners, laptops, handheld computers, etc.). Those of skill in the art would further understand that the MU may include a non-mobile unit attached to a wireless device (e.g., a PC with a network interface card).
[0017] Radio frequency (“RF”) signals including data packets may be transmitted between the MUs 125 ( 1 - 3 ) and the AP 120 over a radio channel. As understood by those skilled in the art, the data packets may be transmitted using a modulated RF signal having a common frequency (e.g., 2.4 GHz, 5 GHz). Furthermore, the data packets may include conventional 802.11 packets, such as, authentication, control and data packets. The data packets travel between the AP 120 and the MUs 125 ( 1 - 3 ) along a plurality of paths 130 ( 1 - 6 ) within the space 110 . Though, FIG. 1 only shows six paths 130 ( 1 - 6 ), those of skill in the art would understand that a number of potential paths is essentially infinite.
[0018] Spatial configuration (e.g., length, direction, etc.) of the paths 130 ( 1 - 6 ) may depend upon one or more factors. These factors include, but are not limited to, a location(s) of the AP 120 and/or the MUs 125 ( 1 - 3 ), a configuration of the space 110 and/or the areas 115 ( 1 - 3 ), a location and/or a shape of an obstruction(s) 135 therein. For example, the path 130 ( 1 ) may pass substantially directly from the MU 125 ( 1 ) to the AP 120 , whereas the path 130 ( 2 ) may reflect from a structure (e.g., a wall). The paths 130 ( 3 - 4 ) between the MU 125 ( 2 ) and the AP 120 may pass from the area 115 ( 2 ) to the area 115 ( 1 ) via an opening (e.g., a doorway 140 ( 1 ), a window, etc.), and may then reflect from one or more structures (e.g., wall(s), obstruction 135 , etc.) in area 115 ( 1 ). The paths 130 ( 5 - 6 ) between the MU 125 ( 3 ) and the AP 120 may pass from the area 115 ( 3 ) to the area 115 ( 1 ) via an opening (e.g., a doorway 140 ( 2 ), a window), and may then reflect from one or more structures (e.g., obstruction 135 , wall(s), etc.). Although, not shown in FIG. 1 , those of skill in the art would understand that the paths 130 ( 1 - 6 ) may have varied spatial configurations and pass through any of the structures and/or obstructions described.
[0019] The data packets which are transmitted by the MUs 125 ( 1 - 3 ) and/or the AP 120 may differ from the data packets which are received. That is, changes in a length and/or a number of reflections of each of the paths 130 ( 1 - 6 ) may result in variations in attributes of the RF signal, such as, amplitude, phase, arrival time, frequency distribution, etc. Reflective properties of the structures and/or obstructions may further influence the attributes of the signal and the data contained therein. The changes mentioned above are generally referred to as “multi-path fading.”
[0020] According to the present invention, the AP 120 and the MUs 125 ( 1 - 3 ) may utilize a first mode of communication (e.g., 802.11a, 802.11b, 802.11g) and a second mode of communication (e.g., MIMO, 802.11n). To utilize the MIMO mode, the AP 120 may have an architecture including a processor, two or more antennas, two or more receivers and two or more transmitters. Accordingly, each antenna is capable of transmitting and receiving one or more independent signals concurrently and at a substantially common frequency (e.g., the radio channel). The processor of the AP 120 may resolve the wireless communication of the signals received from the MUs 125 ( 1 - 3 ) or further APs.
[0021] Each MU 125 may utilize the MIMO mode using an architecture including a processor, two or more antennas, two or more receivers and one or more transmitters. The antennas and the receivers allow the MU 125 to receive one or more independent signals concurrently and at a substantially common frequency. The transmitter allows the MU 125 to transmit one or more signals to the AP 120 . The processor of the MU 125 may resolve the wireless communication of the received signals from the AP 120 and/or further MUs.
[0022] In a preferred embodiment, the AP 120 includes four antennas, four receivers and four transmitters, and each MU 125 includes four antennas, four receivers and one transmitter. However, those of skill in the art would understand that the AP 120 may include any number of antennas, receivers and transmitters, but, that the number is changed in a 1:1:1 ratio. That is, for any additional antenna, an additional receiver and an additional transmitter may be included. Similarly, the MU 125 may include any number of antennas and receivers, and any change in the number is done according to a 1:1 ratio. The MU 125 may further include any number of transmitters, which would change the ratio of antennas to receivers to transmitters to 1:1:1. However, in a preferred embodiment of the present invention, the MU 125 maintains a single transmitter. In this manner, the protocol described herein may be utilized by wireless devices employing a legacy-802.11 standard (e.g., 802.11a, 802.11b, 802.11g) without significant hardware and/or software modifications. Architectures of the AP 120 and the MU 125 are described in further detail in U.S. patent application Ser. No. 10/738,167, filed on Dec. 17, 2003, entitled “A Spatial Wireless Local Area Network,” the disclosures of which are incorporated herein by reference.
[0023] FIG. 2 shows an exemplary embodiment of wireless communication from the AP 200 to the MUs 210 ( 1 - 4 ), which is typically referred to as “downstream” communication. In this embodiment, the AP 200 may transmit two or more signals from its two or more antennas. As shown in FIG. 2 , the AP 200 has four antennas, and, correspondingly, transmits four independent signals S 1 -S 4 . The number of signals sent may be directly proportional to the number of antennas (e.g., one independent signal per antenna). Also, in MIMO mode, the AP 200 may transmit the signals S 1 -S 4 concurrently over the radio channel, which will be described in further detail below.
[0024] Due to the multi-path fading and any other factors contributing to signal corruption or degradation, the antennas of each MU 210 receive a signal R 1 -R 4 which differs from the transmitted signals S 1 -S 4 . Those of skill in the art would understand that any or all of the received signals R 1 -R 4 may not differ from the transmitted signals S 1 -S 4 . Accordingly, one or more the received signals R 1 -R 4 may equal one or more of the transmitted signals S 1 -S 4 (e.g., R 1 =S 1 ) In either instance, the received signals R 1 -R 4 may be related to the transmitted signals S 1 -S 4 by a signal-relation equation: R i =Σa ij S j +n i , where a ij are elements of a transmission matrix and n i represents a noise level on a receiving channel i.
[0025] Each MU 210 estimates the transmission matrix a ij using at least a portion of the received signals R 1 -R 4 . In one embodiment, each of the transmitted signals S 1 -S 4 includes a training packet T j , indicative of a transmission channel j used by the AP 200 . The training packet T j may include a pilot sequence p j which may be transmitted as a portion of a preamble signal to the transmitted signals S 1 -S 4 . For example, the AP 200 may send one or more training packets T j in one of a sequence of time slots. Each MU 210 may identify the pilot sequence p j in each training packet and estimate the transmission matrix a ij using a matrix equation: a ij =R i /p j . Each MU 210 may then extract the transmitted signal using the signal-relation equation, above. For example, the MU 210 ( 1 ) may receive signals R 1 -R 4 and use pilot sequence p 1 -p 4 to resolve the transmission matrix a ij . The transmission matrix a ij may then be used in the signal-relation equation to resolve the transmitted signal S 1 . As would be understood by those skilled in the art, the processor of the MU 210 may resolve the transmission matrix a ij and the transmitted signal S 1 using a software application.
[0026] FIG. 3 shows an exemplary embodiment of communication from the MUs 310 ( 1 - 4 ) to the AP 300 , which is typically referred to as “upstream” communication. As described above, in a preferred embodiment, each MU 310 has one or more transmitters. Thus, each MU 310 ( 1 - 4 ) transmits a signal S 1 -S 4 , respectively, to the AP 300 . Signals R 1 -R 4 received by the AP 300 may differ from the transmitted signals S 1 -S 4 due to, for example, multi-path fading. The received signals R 1 -R 4 are used by the AP 300 in the signal-relation equation: R i =Σa ij S j +n i , which may be the same as that used by the MU 210 in the downstream communication. That is, each of the received signals R 1 -R 4 may include the training packet T j indicative of the transmission channel j used by the MU 310 . The training packet T j may further include the pilot sequence p j which may be transmitted as a portion of a preamble to the transmitted signals S 1 -S 4 . The AP 300 uses the received signals R 1 -R 4 and the pilot sequences p j to resolve the transmission matrix a ij with the matrix equation: a ij =R i /p j . The transmitted signals S 1 -S 4 are then resolved using the signal-relation equation.
[0027] FIG. 4 shows an exemplary embodiment of a method 400 according to the present invention. In this embodiment, the method 400 is employed by a receiving station which may be any type of wireless device. For example, in the downstream communication, the MU may employ the method 400 , whereas, in the upstream communication, the AP may employ the method 400 . Thus, the method 400 will be described with respect to a transmitting station and the receiving station. Furthermore, according to the present invention, the receiving station and/or the transmitting station may be operating according to a first mode of communication (e.g., CSMA/CA), but also capable of operating in a second mode of communication (e.g., MIMO). Thus, the method 400 is used by the receiving station as a result of the transmitting station initiating wireless communication in the second mode of communication (e.g., MIMO mode).
[0028] In step 410 , the receiving station receives at least two first signals from the transmitting station. The first signals (e.g., R 1 and R 2 ) are the received versions of at least two second signals (e.g., S 1 and S 2 ) which are transmitted by the transmitting station. As understood by those skilled in the art, the first signals may correspond to a number of transmitting antennas employed by the AP and/or the MU, or a number of MUs transmitting to the AP. The first signals may not contain any data, but may simply include the training packet T j . However, the first signal may be packets (e.g., data packets) which include the training packet T j and/or the pilot sequence p j in a preamble thereof.
[0029] In step 420 , the receiving station identifies the pilot sequence p j included in the training packet T j . Those of skill in the art would understand that the processor in the receiving station or a software application executed thereby may extract the pilot sequence p j from the training packet T j . Furthermore, the training packet T j may only include the pilot sequence p j . Thus, in this embodiment, the first signals (e.g., R 1 and R 2 ) may simply be the pilot sequences p 1 and p 2 .
[0030] In step 430 , the receiving station may resolve the transmission matrix a ij using the matrix equation. As stated above, the transmission matrix a ij may be estimated as a function of the pilot sequence p j and the first signals (e.g., R 1 and R 2 ). As with identification of the pilot sequence p j , the processor and/or a software application executed thereby of the receiving station may utilize the matrix equation to resolve the transmission matrix a ij .
[0031] In step 440 , the receiving station may resolve the second signal using the signal-relation equation. As stated above, the second signal is estimated as a function of the transmission matrix a ij , the first signals and the noise n i on the receiving channel i. Again, the second signal may be resolved by the processor and/or a software application executed thereby of the receiving station.
[0032] In step 450 , the receiving station can begin operating in the second mode of communication. Accordingly, the stations may now transmit and receive signals simultaneously over the share channel. The second mode of communication may increase overall system throughput, reduce corruption and degradation of the data, and allow operators and user of the system to maintain use of legacy 802.11 devices.
[0033] FIG. 5 shows an exemplary embodiment of a system 500 according to the present invention. The system 500 is shown as a schematic timing diagram with phases I-XII representing periods of communication over the channel. In this exemplary embodiment, an AP 505 may be equipped with four antennas 506 - 509 , four receivers and four transmitters. Any number of MUs 510 - n may be within a communication range of the AP 505 . As shown in FIG. 5 , each of the MUs may have one or more transmitters, along with four antennas and four receivers. As noted above, those of skill in the art would understand that there is no limitation on the number of antennas, transmitters and receivers on both the AP 505 and the MUs 510 - n . However, it is preferable that the number of antennas, transmitters and receivers of the AP 505 match the number of antennas and receivers of the MUs 510 - n . Furthermore, as noted above, the system 500 may be scaled based on the number of antennas on the AP 505 and/or the number of MUs within the coverage area thereof. Though, the system 500 will be described with respect to the MUs 510 - n having a single transmitter, those skilled in the art would understand that more than one transmitter may be utilized by the MUs 510 - n.
[0034] In FIG. 5 , phases I-XII depict an exemplary embodiment of a refresh period (e.g., every 50 ms) with phase I signifying a beginning of the refresh period. Those of skill in the art would understand that the refresh period may have a duration that is inversely proportional to mobility of the MUs 510 - n . For example, an increased mobility of the MUs (e.g., more likely to move in and out of the coverage area of the AP 505 ), may result in a shorter duration of the refresh period. Thus, at an end of the refresh period or at the beginning of a subsequent refresh period, the AP 505 may redetermine which MUs are within the coverage area thereof.
[0035] In phase I, the AP 505 transmits a training packet 535 from each antenna 506 - 509 . As shown in FIG. 5 , a total of four of the training packets 535 are transmitted in successive predetermined time slots. That is, the AP 505 accesses the channel in a conventional manner according to the first mode communication (e.g., CSMA/CA), and then transmits (e.g., broadcasts) the training packets 535 thereon. In this manner, the AP 505 may guarantee itself the ability to transmit each of the four training packets 535 successively by waiting for a short inter frame space (“SIFS”) between each transmission. As understood by those of skill in the art, the training packets 535 may be received by any MU 510 - n within the coverage area of the AP 505 . That is, the four training packets 535 are broadcast to all MUs within the coverage area of the AP 505 .
[0036] As described above with reference to the “downstream” communication, each training packet 535 may contain the pilot sequence p j . In an exemplary embodiment, each pilot sequence p j contains a predetermined set of numbers which corresponds to a number and location of transmitting antennas on the AP 505 . That is, in the embodiment shown in FIG. 5 , each pilot sequence p j may contain four numbers. Thus, receipt of the four pilot sequences p j allows each MU 510 - n to construct its own transmission matrix a ij , which will be described further below. As shown in FIG. 5 , each MU 510 - n within the coverage area of the AP 505 may receive four pilot sequences p 1 -p 4 , each having the predetermined set of four numbers.
[0037] In phase II, each MU 510 - n receives four of the training packets 535 from the AP 505 . The MUs 510 - n may then identify the pilot sequence p j in each training packet 535 and use the predetermined set of numbers contained therein to resolve the transmission matrix a ij . In the embodiment shown in FIG. 5 , the transmission matrix a ij may be a four by four matrix. This allows the MUs 510 - n to estimate the channel for resolving transmissions from the AP 505 . That is, the four numbers in each pilot sequence may be modified (e.g., in amplitude and/or phase) as a result of attenuation and/or multipath fading during transmission of the training packets 535 . Thus, the matrix a constructed by each MU 510 - n may be different, and will allow each MU 510 - n to resolve transmissions from the AP 505 addressed for it. As understood by those skilled in the art, every MU 510 - n does not have to resolve the transmission matrix a ij . For example, if an MU does not desire to transmit on the channel (e.g., no data packets for the AP 505 ), the MU may wait for the subsequent refresh period. However, in a preferred embodiment, each MU 510 - n which receives the training packets 535 resolves its own transmission matrix a ij .
[0038] After the MUs 510 - n have resolved the transmission matrix a ij , each of the MUs 510 - n may decide whether it wants to communicate with the AP 505 according to the second mode of communication (e.g., MIMO mode). As shown in FIG. 5 , MUs 510 , 520 , 525 and 530 desire to communicate in the MIMO mode. Thus, each of the MUs 510 , 520 , 525 and 530 transmits a control frame to the AP 505 . As understood by those skilled in the art, the control frame may be a request-to-send (“RTS”) frame which is modified to indicate that each of the MUs 510 , 520 , 525 and 530 desires to communicate in the MIMO mode (e.g., MIMO RTS (“MRTS”) 540 ). The MRTS 540 may include a vector with a predetermined set of numbers (e.g., in FIG. 5 , four numbers). Furthermore, those skilled in the art would understand that the MUs 510 , 520 , 525 and 530 transmit the MRTSs 540 to the AP 505 by gaining access to the channel using the first mode of communication (e.g., CSMA/CA), because the AP 505 has not granted the requests to transmit in the MIMO mode. Furthermore, the AP 505 , at this point, has not received any transmissions from the MUs 510 - n through which it may estimate the channel (e.g., construct a transmission matrix a ij for itself).
[0039] One or more the MUs 510 - n may not desire to transmit in the MIMO mode, but simply intend to communicate according to the first mode. For example, the MU 515 does not transmit the MRTS 540 to the AP 505 , because, for example, it does not have any data packets for the AP 505 . Alternatively, the MU 515 may wish to wait until it has accumulated a predetermined number of data packets before transmitting in the MIMO mode.
[0040] In phase III, the AP 505 receives the MRTS 540 from the MUs 510 , 520 , 535 and 540 , which is similar to the “upstream” communication described above. Although, FIG. 5 only shows that four of the MUs 510 - n have requested to communicate in the MIMO mode, those of skill in the art would understand that any number of the MUs 510 - n may transmit the MRTS 540 to the AP 505 . For example, as shown in FIG. 5 , if more than four of the MUs 510 - n had requested to communicate in MIMO mode, the AP 505 may have to determine which of the MUs 510 - n would be cleared to communicate in the MIMO mode. The AP 505 may invoke a priority scheme based on, for example, bandwidth required and/or application type (e.g., voice, scans, email, etc.). In this manner, the AP 505 may choose four of the MUs 510 - n with the highest priority to communicate in the MIMO mode. The AP 505 may respond to any number (e.g., 2, 3 . . . n) of requests to communicate in the MIMO mode. Thus, the remaining MUs may communicate in the first mode (e.g., CSMA/CA) when the channel is free, or wait until a subsequent refresh period or MIMO phase.
[0041] Upon receipt of the MRTSs 540 , the AP 505 may use the vectors contained in each to resolve its transmission matrix a ij . That is, the AP 505 has received communications from the MUs which allow it to estimate the channel. Thus, in this embodiment, the AP 505 can now communicate with the four MUs at a first bit rate (e.g., 54 mbps). Alternatively, the AP 505 may communicate with three MUs at a second bit rate (e.g., 72 mbps). In either of these embodiments, each transmitting antenna of the AP 505 may allow for communication at a predefined bit rate. Thus, this bit rate can be varied/divided in any fashion (e.g., based on data type, application, etc.) to partition a bandwidth for the channel.
[0042] Utilizing the transmission matrix a ij to resolve concurrent transmissions from the MUs, the AP 505 can begin to communicate in the MIMO mode. That is, the AP 505 may transmit control frames 545 concurrently and on the same frequency to each of the MUs 510 , 520 , 525 and 530 . As understood by those skilled in the art, the control frame may be a clear-to-send (“CTS”) frame which is modified to indicate that each of the MUs 510 , 520 , 525 and 530 may begin communicating in the MIMO mode (e.g., MIMO CTS (“MCTS”) 545 ). In a further exemplary embodiment, the MCTS may be broadcast to the MUs 510 - n . However, the broadcast may define which of the MUs 510 - n is cleared to send in the MIMO mode.
[0043] As shown in FIG. 5 , the AP 505 is responding to the MRTSs 540 from the MUs 510 , 520 , 525 and 530 to communicate in the MIMO mode. However, the AP 505 may initiate communication in the MIMO mode at the start of the refresh period. That is, the AP 505 may transmit the MCTSs 545 in the phase I to any four of the MUs 510 - n . This may happen if, for example, each of the four MUs receiving the MCTSs 545 in the start of the refresh period maintained its transmission matrix a ij . The four of the MUs 510 - n may be determined by the AP 505 using, for example, the priority scheme described above. Thus, according to the present invention, one or more of the MUs 510 - n or the AP 505 may initiate and/or request communication in the MIMO mode.
[0044] In phase IV, the MUs 510 , 520 , 525 and 530 have been cleared to transmit data packets 550 in the MIMO mode. Each of the MUs 510 , 520 , 525 and 530 , may transmit the data packets 550 concurrently to the AP 505 . Using the transmission matrix a ij , the AP 505 can resolve the data packets, as described above with reference to the “upstream” communication.
[0045] In phase V, the AP 505 , communicating in the MIMO mode, may transmit acknowledgment signals (“ACKs”) 555 concurrently to each of the MUs 510 , 520 , 525 and 530 which transmitted the data packets 550 . As understood by those skilled in the art, the MUs 510 , 520 , 525 and 530 may continue transmitting data packets 550 and receiving the ACKS 555 in the MIMO mode for a predetermined amount of time and/or according to a defined protocol.
[0046] In phase VI, the AP 505 transmits data packets 560 , which may have been buffered at, or presently received by, the AP 505 to the MUs 510 , 515 , 520 and n. As shown in FIG. 5 , the AP 505 is transmitting the data packets 560 in the MIMO mode to the MUs 515 and n which had not requested to transmit in the MIMO mode in phase II or been cleared to transmit in the MIMO mode in phase III. However, as noted above, each MU 510 - n within the coverage area of the AP 505 receives the training packets 535 and the pilot sequences p j contained therein. Thus, the MUs 515 and n may resolve the signals from the AP 505 to extract the data packets 560 addressed therefor.
[0047] In phase VII, the MUs 510 , 515 , 520 and n which received the data packets 560 transmit ACKS 565 to the AP 505 , confirming receipt of the data packets 560 . In this embodiment, the MU 515 did not previously request to communicate in the MIMO mode in the phase II. The MU 515 may receive the data packet 560 from the AP 505 transmitting in the MIMO mode, but it may not transmit in the MIMO mode without being cleared to do so by the AP 505 . Thus, as shown in FIG. 5 , the MU 515 transmits the ACK 565 and an MRTS according to the first mode (e.g., CSMA/CA) requesting that it be allowed to communicate in the MIMO mode. As understood by those skilled in the art, the ACK 565 may be sent separately from the MRTS, or the MRTS may be piggybacked thereon.
[0048] Furthermore, as shown in FIG. 5 , the MU 530 did not receive the data packet 560 from the AP 505 in phase VI. However, the MU 530 desires to retain the capability to communicate in the MIMO mode. Those of skill in the art would understand that the MU 530 may desire retention of MIMO-capability if, for example, the MU 530 has further data packets to transmit to the AP 505 . In this case, the MU 530 transmits a control frame (e.g., MRTS 570 ) to the AP 505 . The MU 530 may transmit the MRTS 570 in a time slot in which the MUs 510 , 520 and n are transmitting their respective ACKS 565 , because the MU 530 had received the MCTS 545 in phase III.
[0049] In phase VIII, after receiving the ACKs 565 and/or the MRTSs 570 , the AP 505 may transmit further data packets 575 , which may have been buffered at, or presently received by, the AP 505 . As shown in FIG. 5 , the data packets 575 are transmitted to the MUs 510 , 520 , 525 and 530 . As stated above, the data packets 575 are transmitted concurrently from the AP 505 in a time slot. In phase IX, the MUs 510 , 520 , 525 and 530 which received the data packets 575 concurrently transmit ACKS 580 to the AP 505 , confirming receipt of the data packets 575 .
[0050] In phase X, the AP 505 transmits a control frame (e.g., MCTS 585 ) to each of the MUs 515 , 525 , 530 and n which requested communication in the MIMO mode in phase VII. Also, the MU 525 which may not have requested communication in MIMO mode in phase VII, may have piggybacked a MRTS on the ACK 580 in phase IX. Similarly, the MU n in phase VII may have piggybacked an MRTS on the ACK 565 . Thus, the MUs 515 , 525 , 530 and n are cleared to communicated in the MIMO mode by the AP 505 . In phase XI, the MUs 515 , 525 , 530 and n transmit data packets 590 to the AP 505 concurrently, and, in phase XII, the AP 505 responds with ACKS 595 .
[0051] As understood by those of skill in the art, the AP 505 and the MUs 510 - n may continue communicating over the channel past the phase XII until and/or after a subsequent refresh period. As discussed above, after the subsequent refresh period is initiated, the AP 505 may again broadcast the training packets in the first mode of communication or in the MIMO mode.
[0052] Furthermore, those skilled in the art would understand that the present invention provides certain advantages over conventional systems. For example, in a conventional MIMO system, an AP communicates only with a single MU, but at an increased bit rate (e.g., 216 mbps). In contrast, the present invention provides for an AP which communicates with two or more MUs at a lower bit rate (e.g., 54 mbps), allowing for compatibility with legacy 802.11 systems which may not be capable of handling the increased bit rate without significant hardware and software modifications. Furthermore, the present invention provides for increased system throughput with minimized overhead, by allowing the AP to communicate with at least two MUs concurrently, and vice-versa.
[0053] As noted above, the AP and/or the MUs may have two or more antennas and receivers. FIG. 6 shows a graph representing an exemplary relationship between an aggregate throughput and a number of antennas on the AP and the MUs for a system utilizing the present invention. As shown in FIG. 6 , the aggregate throughput increases in a hyperbolic manner until a saturation point (e.g., 250 antennas, 225 mbps), in which the channel may not be able to support any further transmissions thereon. FIG. 7 shows a enlarged view of a portion of the graph of FIG. 6 . In FIG. 7 , a first ray 700 indicates the exemplary relationship of the graph in FIG. 6 . A second ray 705 indicates a practical relationship due to anticipated overhead created as a result of the present invention. As the number of antennas is increased, so does the anticipated overhead. However, the anticipated overhead is relatively low considering that, for example, eight MUs may be communicating at the same time and on the same frequency at 54 mbps.
[0054] It will be apparent to those skilled in the art that various modifications may be made in the present invention, without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | Described is an access point a plurality of antennas, a plurality of transceivers and a processor. Each of the antennas receives a first signal from each of a plurality of wireless devices. The first signal includes a first identifier of a corresponding wireless device. Each of the transceivers is coupled to each of the antennas. The processor is coupled to each of the transceivers. The processor generates a first communication matrix which includes the first identifier from each of a selected number of the wireless devices. The selected number is no greater than a number of the antennas. The processor utilizes the first communication matrix to resolve multiple wireless communications received from the selected number of the wireless devices within a single time slot over a radio channel. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a power drive system for motor vehicle closures such as windows. It is particularly directed to an automatic reverse feature for power driven closures in which closing motion continues automatically even after a user switch has been released.
Some motor vehicles are available with a power window system having an auto-up mode of operation. In these systems, a window will continue to move up even after the user switch has been released. A government mandated motor vehicle standard requires that a window operating in the auto-up mode must reverse direction before it exerts a 100N force on a 10N per mm compliant cylindrical rod between the window and window frame.
A wide variety of approaches are taken to make power window system comply with the government standard. Known approaches include: monitoring the magnitude of current being drawn by the motor for an increase indicating the presence of an obstacle, placing pressure sensing devices, such as electrically responsive pressure sensitive tape, inside the window frame to sense an obstacle being pressed thereagainst, and monitoring the velocity of the window for a decrease as it moves along its path. However, all of these approaches have drawbacks, as each presents one or more of the following concerns: false obstacle detection preventing window from closing; a need for excessive computing power; and excessive cost.
It is desired to provide a highly reliable auto reverse feature for use with windows having an auto-up mode of operation requiring a minimum of computing power, enabling the use of an inexpensive microprocessor to reliably control window movement.
SUMMARY OF THE INVENTION
In accordance with the present invention, a closure system for a motor vehicle includes a closure, a closure frame, an electric motor, a first displacement sensor and a microprocessor. The electric motor has an output shaft. The closure frame defines a seated position of the closure. The displacement sensors both indicate rotation of the drive motor output shaft, with the second sensor being offset from the first sensor. The microprocessor includes means for measuring a second time for the output shaft of the motor to rotate a predetermined amount using signals from the first sensor. The microprocessor also includes means for measuring a first time for the output shaft of the motor to rotate a predetermined amount using signals from the second sensor. As well, the microprocessor includes means for establishing a reference, or limiting, time signal for the second time signal using the first time signal. The microprocessor has means for comparing the second signal to the reference or limit signal. The microprocessor additionally includes means for reversing the motor if the second signal is greater than the reference signal for a predetermined period of time.
Other objects and features of the invention will become apparent by reference to the following specification and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of an auto reverse power window system of the present invention.
FIG. 2 is a schematic representation of a magnet ring and associated hall effect sensors.
FIG. 3 is a plot of motor rotational speed as a function of torque for a power window system.
FIG. 4 is a plot of motor deceleration as a function of motor velocity for a power window system.
FIG. 5 is a plot of polarity as sensed by the magnetic field sensors as a function of time.
FIG. 6 is a plot of a limiting value of T 2 as a function of T 1 .
FIG. 7 is a plot of (T 1 -T 2 ) limit as a function of T1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A window lift system 10 is shown in schematic form in FIG. 1. An electric motor 12 with an output shaft 14 is electrically connected to a microprocessor 16. A magnetic ring 18, best shown in FIG. 2, has eight poles with north poles 20 and south poles 22 alternating. A first hall effect sensor 24 is located proximate to the magnetic ring 18 and is electrically connected to the microprocessor 16. A second hall effect sensor 26 is circumferentially offset from the first hall effect sensor 24 at approximately 90° thereto and is also proximate to the magnetic ring 18 and electrically connected to the microprocessor 16.
A window 28 is disposed for slidable movement within a window frame 30 in an axial direction 29. A window lift mechanism 32 is connected to both the window 28 and the electric motor 12 and translates the rotary motion of the output shaft 14 into the axial motion needed to move the window 28.
An electrical power source, such as a battery 34, is connected to the microprocessor 16. Both the battery 34 and the microprocessor 16 are connected to an electrical ground 36. Input switches 38 for controlling actuation of the electric motor 12 are also connected to the microprocessor 16.
The electric motor 12 can be any fractional horsepower electric motor, whether a brushless motor or a brush type motor. An exemplary motor is available from ITT Automotive as part of a "Phase III Windowlift Actuator."
The microprocessor 16 is a relatively inexpensive eight bit microprocessor such as a Motorola 6805 microprocessor or an equivalent. It is somewhat limited in capability in that it can only process and store whole numbers. The microprocessor 16 is also not suited for easily calculating the instantaneous velocity and acceleration of the output shaft 14.
The system 10 operates in the following manner. An operator presses the input switch 30 to close the window. The microprocessor 16, responsive to the condition of the switch 30, electrically connects the motor 12 with the battery 34 causing the motor output shaft 14 to rotate. Rotation of the output shaft 14 drives the window lift mechanism 32 which moves the window 28 upward into the window frame 30. With a constant voltage from the battery 34, and no obstructions in the path of the window 28, the motor output shaft 14 rotates at a near constant velocity until the window 28 seats in the frame 30. The microprocessor continually monitors signals from the first hall effect sensor 24, or alternatively from the second hall effect sensor 26, to determine whether the window has impinged against an obstacle. When the time for the output shaft 14 to complete one full revolution as indicated by the first hall effect sensor 24 is greater than a concurrently established target level, and is sustained for a predetermined period of time the microprocessor 16 responsively reverses the direction of rotation of the motor output shaft 14 to lower the window 28. How the target level and the predetermined period of time are established, and how the comparison of the measurement with the target level is made are key factors in enabling the use of such a limited microprocessor to provide the desired window reversing function.
FIG. 3 shows a plot of the angular velocity of the motor output shaft 14 as a function of motor output torque. Lines, A1, A2 and A3 are constant load curves, showing the change in torque with the increase in output shaft rotational speed ω for three different operating load conditions. A1 is the load curve for rotating the electric motor 12 with no load on the motor. A2 is the load curve for rotating the electric motor to drive a window lift mechanism 32 and lift a window 28. A3 is the load curve for rotating the motor 12 to lift the window 28 and also overcome a 100N safety limit load. Suitable curves for lines A1, A2 and A3 can be found in nearly any handbook or text book on electrical motors.
The safety limit load of 100N is established by a government mandated standard requiring that the window reverse direction before it exerts a 100N force on a 10N per mm compliant cylindrical rod 40 for which varies in diameter from 4 mm to 200 mm placed between the window and the frame.
Lines B1 and B2 are constant voltage lines (voltage applied to the motor) and show the change in angular velocity ω of the output shaft 14 as a linear function of torque for two different voltage levels, V1 and V2. The lines B1 and B2 are essentially parallel and have a negative slope. Thus, as torque on the motor 12 operating at a constant voltage is increased, the speed ω decreases.
A motor operating under normal conditions (at constant voltage V1 and displacing a window upward) would operate at torque TQ1 and speed ω1 (point 0P1 where line B1 intersects line A2). If, at time t1, the window 28 impinges against the compressible impediment 40, the torque required to displace the window 28 increases and the speed ω decreases. At time t2, the load induced by the impediment 40 equals 100N, and the operating conditions are characterized by the intersection of line B1 with line A3 (torque TQ2 and speed ω2, point 0P2).
Similarly, line B2 intersects line A2 at torque TQ3 and speed ω3, point 0P3, with a motor 12 operating at constant voltage V2. When the window 28 impinges against the impediment at time t3, the torque required to move the window increases, and the speed ω consequently decreases. At time t4 when the load induced by the impediment equals 100N, B2 intersects A3 at torque TQ4 and speed ω4, defining point 0P4.
The data needed to generate the plot of FIG. 4 is produced by using a motor instrumented to provide a recording of output shaft speed ω as a function of time. Recordings of output shaft speed ω are made with the instrumented motor displacing a representative window against the government standard compliant rod 40 using a representative window drive unit. The operating speed ω of the motor output shaft 14 as the window 28 is moved upward tends to remain equal to a constant initial speed ω 1 until the window 28 impinges against the complaint rod 40. With impingement of the window 28 against the compliant rod 40, the output shaft decelerates at a rate of α, with α equalling the slope of ω as a function of time. Each initial speed ω 1 has an associated value of α induced when the window 28 engages the compliant rod 40. As ω 1 is increased, so is the resultant α. By repeating this test (recording the angular velocity of the motor output shaft as a function of time as the window crushes the compliant rod) for several different initial speeds ω 1 , sufficient data is obtained to plot the curve of FIG. 4.
FIG. 4 is a plot of the absolute value of rotational acceleration α of the output shaft 14 as a function of the initial speed ω 1 after the window 28 has impinged against the compliant rod 40.
Conceivably, the plot of FIG. 4 could be used to generate a look up table establishing limiting rates of deceleration α for a range of initial velocities ω 1 which could be used to determine when an obstacle has been encountered by the moving window as indicated by an instantaneous measured deceleration greater than the limit deceleration established by the plot. However, as already noted, it is not possible to calculate velocities or decelerations instantaneously using the relatively inexpensive microprocessor described. The microprocessor is able to measure the time between revolutions in small increment counts. In this example, one count equals a 2 μs increment of time. The measured time between revolutions is proportional to inverse rotational velocity (1/ω, or ω -1 ), not rotational velocity ω. Because the relationship between velocity and inverse velocity is nonlinear, any attempt to directly calculate deceleration based on time, or microprocessor counts, would be incorrect. What is needed, and what has been done in this invention, is to establish a characteristic limiting function which can be compared with microprocessor counts of the time between revolutions, indicative of inverse velocity, which are readily available.
The wave form of FIG. 5 shows periods T1 and T2, respectively corresponding first and second measurements of the time for one revolution using the first hall effect sensor 24. The second hall effect sensor 26 is used by the microprocessor 16, in combination with the first sensor 24, to establish the direction of rotation, and the position of the window 28, but could alternatively be used to determine periods T1 and T2. The smallest period over which the change in velocity, and therefore acceleration or deceleration, can be estimated is At. A close approximation of Δτ is provided by T2/4 with little error. This allows acceleration α to be derived in terms of ω 1 , the angular velocity corresponding to period T1, and ω 2 , the angular velocity, corresponding to period T2, as indicated below. If T1 and T2 are in units of minutes, then ω 1 =(1 revolution/T1 minutes), and ω 2 =(1 revolution/T2 minutes). Therefore,
α=(ω.sub.2 -ω.sub.1)/Δτ
Given Δτ≈1/(ω 2 revolutions per minute×(1 minute/60 seconds)×(4 edges/rev.))) and substituting:
-α=(ω.sub.1 -ω.sub.2)/(15/ω.sub.2)
ω.sub.2 2-ω.sub.1 ×ω.sub.2 -α×15=0
Solving for ω 2 :
ω.sub.2 =(ω.sub.1 +(ω.sub.1.sup.2 -4×α×15).sup.1/2)/2
A limiting value of ω 2 corresponding to a known value of α can therefore be calculated using the above equation. A table of limiting values for ω 2 can be established for values of ω 1 using values of α from FIG. 4.
After producing the table, the values of ω 1 and ω 2 in the table are then inverted to produce a table of inverse velocities ω 1 -1 and ω 2 -2 . The inverse velocities are then converted to counts and plotted or mapped as shown in FIG. 6. To convert 1/ωrpm to counts, given 2 μs counts, multiply 1/ωrpm by 60s/minute, and then divide by 0.000002 s/count. For example, for ω=4000 rpm, time T in counts per revolution equals 7500. Given this conversion, time (in counts) T 1 is equivalent to ω 1 -1 and time T 2 (in counts) is equivalent to ω 2 -1 .
T 1 equals the number of counts accumulated between, for example, a first rising edge signal from the first sensor 24 and a fifth rising edge signal from the first sensor. T 2 equals the number of counts accumulated between a second rising edge signal and a sixth rising edge signal from the first sensor 24. Rising edge signals occur when the sensor detects a predetermined shift in the magnetic field in a predetermined direction (e.g., from South pole to North pole). Since each revolution of the output shaft 14 produces four rising edge signals, the first signal marks the initiation of a revolution and the fifth signal marks its termination. Similarly, the second and sixth rising edge signals are used to mark initiation and termination of one revolution of the motor 12, offset from the first revolution by approximately 1/4 revolution.
A limiting value of T 2 (T 2 Limit) can be calculated for any measured value of T 1 in counts from the table of inverse velocities. FIG. 6 is a plot of T 2 Limit as a function of T 1 . T 2 Limit is potentially able to serve as the desired characteristic limiting function employing the time counts of the microprocessor. The measured value of T 2 (T 2 Measured) can be compared with T 2 Limit. If T 2 Measured is greater than T 2 Limit, it is an indication that the system is decelerating at a rate greater than a limiting value of α corresponding to T 2 Limit and ω 2 . If T 2 Measured is sustained at a value greater than T 2 Limit for a predetermined period of time, then the microprocessor reverses the direction of the motor. Determination of the predetermined period of time is described later in this Description of the Preferred Embodiment.
The microprocessor stores a discrete number of values of T 1 and corresponding T 2 Limit values. When T 1 Measured equals one of the stored values of T1, then T 2 Limit equals the corresponding stored value of T 2 Limit. When T 1 Measured falls between the stored values of T 1 , the microprocessor interpolates an approximation of T 2 Limit. Interpolation of T 2 Limit is performed using the standard formula for a line, with T 2 Limit=T 1 ×m+b, where m is the slope and b is the ordinate intercept. The adjacent stored values of T 1 and T 2 Limit are used to develop the values of m and b.
However, in this example, which is typical, the slope of the line of T 2 as a function of T 1 is nearly equal to 1. For example, with a ω 1 equal to 4,000 rpm, and an acceleration α equal to 6,000 rpm per second, the value of ω 2 is calculated as 3,977 rpm. Inverting and converting to counts yields a T 1 equal to 7500 and T 2 equal to 7543. Because the microprocessor is only able to operate in whole numbers, even a relatively small deviation in slope from 1-0, such as 1.4, would result in significant errors in the interpolated value of T 2 limit.
To reduce the potential error significantly, the difference between T 1 and T 2 , (T 1 -T 2 ), is calculated as a function of T 1 with the equation (T 1 -T 2 )=T 1 ×m+b, as plotted in FIG. 7.
As is readily apparent in FIG. 7, the slope of the resultant line, although not a constant, is a very small fraction of 1. Since the microprocessor can only work with whole numbers, it is necessary to divide T 1 by 1 over m to provide m with a value greater than zero. The fraction 1/m can be reasonably approximated by a whole number.
The method by which one interpolates an output value from the table determines the quantization error, program time and program space. To optimize all three, 21 values of T 1 -T 2 limit and T 1 are stored in the microprocessor, opening 20 straight lines approximations of the curve of FIG. 7. Each straight line approximation has its own slope m and ordinate intercept b. T 2 limit can now be readily calculated given any value of T 1 and compared to the actual counts for T 2 measured. If T 2 measured is less than T 2 Limit, then the system has a constant velocity, is accelerating, or is decelerating at a rate less than would indicate the presence of an obstacle. However, when T 2 measured is greater than T 2 Limit, it indicates that the resultant deceleration meets or exceeds that produced by a 10 n/mm obstacle.
When a deceleration above the limit is detected, it is desirable to perform some debounce, or filter, to avoid false window reversals. This is most easily done by initiating a timer and assuring that the deceleration continues for the predetermined period of time before reversing the window. For a window system operating with an initial steady state speed of ω 1 , the predetermined period of time must not be greater than (t 2 -t 1 ) of FIG. 3. If appropriate filtering can be done in less than the lowest (t 2 -t 1 ), a lower pinch force less than 100N will result.
By thus monitoring the time to complete a rotation of the output shaft, an inexpensive highly reliable power window system is provided which consistently reverses window direction in response to window impingement against an impediment.
While one embodiment of the invention has been described in detail, it will be apparent to those skilled in the art that the disclosed embodiment may be modified. For example, this same control system could be used with a sun roof or a sliding door instead of a window. Also, the magnet ring 18 could alternatively be fixed to a secondary shaft rotated by the output shaft 14. Therefore, the foregoing description is to be considered exemplary rather than limiting, and the true scope of the invention is that defined in the following claims. | A power closure system for a motor vehicle includes a closure, a closure frame, an electric motor, a first displacement sensor and a microprocessor. The electric motor has an output shaft. The closure frame defines a seated position of the closure. The displacement sensors both indicate rotation of the drive motor output shaft, with the second sensor being offset from the first sensor. The microprocessor includes means for measuring a first time for the output shaft of the motor to rotate a predetermined amount using signals from the first sensor. The microprocessor also includes means for measuring a second time for the output shaft of the motor to rotate a predetermined amount using signals from the first sensor. As well, the microprocessor includes means for establishing a reference, or limiting, time signal for the second time signal using the first time signal. The microprocessor has means for comparing the second signal to the reference or limit signal. The microprocessor additionally includes means for reversing the motor if the second signal is greater than the reference signal for a predetermined period of time. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates in general to the field of molding devices for blow-molding or stretch-blow-molding containers from heated thermoplastic preforms.
[0002] More specifically, the invention relates to improvements made to those of these devices that comprise at least one mold comprising at least two half-molds that can be moved with respect to each other between an open position in which they are parted from one another and a closed position in which they are firmly pressed against one another via collaborating respective bearing faces defining a parting line, locking means being provided to lock the two half-molds in the closed position, which locking means comprising on at least one side of the mold, a first lock element in the form of a hook secured fixedly to the first half-mold along the edge of the bearing face thereof, a second lock element in the form of a hook inverted with respect to the previous one and mounted such that it can move on the second half-mold, and actuating means functionally associated with said second lock element in such a way as to move the latter transversely between a locked position in which it is engaged with the first lock element to lock the two half-molds in the closed position and an unlocked position in which it is disengaged from the first lock element to release the two half-molds that can then be parted from one another.
DESCRIPTION OF THE PRIOR ART
[0003] Document FR-A-2 646 802 discloses means for locking two half-molds in the closed position which means comprise a plurality of coupling fingers supported one above the other, coaxially, by a first half-mold and able to be moved parallel to the axis of the mold to engage in a plurality of respective accommodating slots supported by the second half-mold.
[0004] Such locking means are satisfactory and are currently in commonplace use in molding devices of the “hinged” mold type.
[0005] However, these locking means do have several significant disadvantages.
[0006] One disadvantage lies in the fact that the fingers and accommodating slots are supported in cantilever fashion by the first and second half-molds respectively. As the blowing pressure (for example typically of the order of 40×10 5 Pa) is applied, the supports of these fingers and accommodating slots, which project radially, are subjected to a force substantially tangential to the periphery of the mold. To prevent them from deforming or pulling out, these supports need to be solidly formed, and this increases the weight of the half-molds and also their cost.
[0007] Another disadvantage lies in the cantilevered structure of each finger, the base of which is set into a radially projecting support secured to one half-mold whereas, in the locked position, the free end of the finger is held in a corresponding accommodating slot of a radially projecting support secured to the other half-mold. Under the blowing force, each finger is subjected to a bending/shear stress which, once again, entails that each finger be solidly formed, making it heavy and expensive.
[0008] All these requirements lead to locking means that project appreciably from the periphery of the mold whereas, in installations comprising a great many molds and operating at high speed (rotary molding devices of the carousel type), the space available is very restricted. Furthermore, these locking means are heavy and increase the inertia of the half-molds, something which is detrimental to installations operating at high speed.
[0009] Finally, it must be emphasized that the method of locking/unlocking through the axial movement of a plurality of superposed (“in line”) fingers entails relatively long travels so that the portion of each finger engaged in its corresponding slot is long enough and affords appropriate mechanical strength: it is therefore possible to provide only a restricted number of fingers and slots, spaced axially apart by an appreciable distance. This then finally results in a non-uniform distribution of the forces over the height of the mold.
[0010] There is therefore a remaining need for molds with a simplified, less bulky, less heavy, simpler and less expensive structure, this need being felt all the more keenly as higher production rates are being sought, entailing mechanisms that work more quickly with lower inertia.
SUMMARY OF THE INVENTION
[0011] For these reasons, the invention proposes a molding device as mentioned in the preamble which, being arranged in accordance with the invention, is characterized by the following combination of arrangements:
the locking means comprise two lock elements mounted respectively on the two half-molds along the edges of the respective bearing faces and extending substantially over the entire height of said half-molds, each lock element comprises a multiplicity of hook-shaped projecting fingers distributed over the entire height of the lock element and which, on one lock element face away front the bearing face of the corresponding half-mold and, on the other lock element face toward the bearing face of the corresponding half-mold, said fingers of each lock element being substantially parallel and separated from one another by spacings the individual heights of which are slightly greater than the individual heights of the fingers, one of the lock elements being mounted fixedly on the corresponding half-mold and the other lock element being mounted, on the other half-mold, such that it can move so that it can be slid parallel to the axis of the mold, and actuating means functionally associated with said moving lock element in order to move the latter between two positions, namely:
a first position or unlocked position in which the fingers of the moving lock element are positioned respectively level with the spacings between the fingers of the fixed lock element, in which position the two half-molds are not locked together, and a second position or locked position in which, with the two half-molds pressed firmly together in the closed position, the moving lock element is moved parallel to the axis of the mold so that its fingers engage respectively with the fingers of the fixed lock element, in which position the two half-molds are locked together in their closed position.
[0018] In order to obtain a uniform distribution of the catching force over the entire height of the mold, it is desirable for the number of fingers to be as high as possible in relation to the mechanical strength of said fingers, whereby the height of the spacings between the fingers and therefore the travel of the moving lock element between its locked and unlocked positions are as low as possible, which allows for more rapid closure than can be obtained with the conventional mechanisms when the blowing device is a rotary one.
[0019] In one practical embodiment, the moving lock element is supported, on the corresponding half-mold, by a guide member substantially parallel to the axis of the mold, on which member said lock element is slidably mounted. It is then advantageous for the guide member to be a rod secured to the half-mold, on which rod the moving lock element is slidably mounted, but prevented from rotating.
[0020] For preference, the actuating means for actuating the moving lock element comprise:
a return spring able to return said lock element to its aforesaid first position, and a positive actuating member secured to said moving lock element and able to act positively thereon in order to move it, against the return force of the spring, toward its second position.
[0023] One simple solution then consists in contriving for the positive actuating member to be able to be controlled, when the two half-molds are in the closed position, by the other half-mold.
[0024] In practical terms, many embodiment variants may be anticipated: the fixed lock element may form an integral part of the corresponding half-mold or alternatively may be produced in the form of a part secured fixedly to the corresponding half-mold; likewise, the guide member that guides the moving lock element may be supported directly by the corresponding half-mold, or alternatively may be fixed to an intermediate plate, itself fixed to the half-mold.
[0025] In an embodiment which is very commonplace in practice, the arrangements according to the invention find an application in molds of the hinged type with the two half-molds articulated to one another in terms of rotation on a shaft substantially parallel to one side of the parting line, said locking means then being provided on the opposite side of said shaft about which the two half-molds rotate relative to one another.
[0026] It is also commonplace for each half-mold to comprise a shell holder to which there is internally fixed a shell equipped with a molding half-cavity the parting line being defined by the two shells pressed together when the mold is in the closed position, in which case, according to the invention, the locking means are supported by the two shell-holders.
[0027] By virtue of the provisions according to the invention, a blow-molding or stretch-blow-molding mold is produced in which locking is obtained by a single moving part with a relatively short travel; this travel is linear and parallel to the axis of the mold; finally, the moving part, which is greatly notched in many places to define the locking fingers, has a low mass and therefore a low inertia.
[0028] The result of this is that no angular movement of the locking parts is superposed on the rotational movement of the half-molds during closure or opening and these half-molds are subjected to no parasitic acceleration as they rotate. The vertical movement component of the moving lock element has no appreciable influence over the behavior of the corresponding half-mold. This then finally yields more uniform movements of the half-molds and, above all, shorter locking/unlocking times that provide an effective contribution to increasing the operating rate of the molding device; indeed, for the same rotational speed, if the times needed for locking/unlocking are shorter, the time available for blowing can be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will be better understood from reading the detailed description which follows of certain preferred embodiments given solely by way of nonlimiting examples. In this description, reference is made to the attached drawings in which:
[0030] FIGS. 1 to 4 are simplified perspective views of a mold of the hinged type arranged according to the invention, shown in four functionally different positions respectively;
[0031] FIG. 5 is a simplified view from above of the mold shown in FIG. 4 , in the closed and locked position; and
[0032] FIG. 6 is a simplified view from above showing an embodiment variant of the locking means according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The arrangements according to the invention are improvements made to molding devices for the blow-molding or stretch-blow-molding of containers, such as bottles, from heated thermoplastic (for example PET) preforms. Such a molding device comprises at least one mold comprising at least two half-molds (and possibly a third part that forms an axially movable mold bottom) which can be moved relative to one another between an open position in which they are parted from one another and a closed position in which they are pressed firmly against one another by collaborating respective faces defining a parting line, locking means being provided to lock the two half-molds in the closed position and prevent them from parting or gaping when the blowing fluid is introduced under very high pressure (for example typically of the order of 40×10 5 Pa).
[0034] Commonly, such molding devices may comprise a multiplicity of molds and may therefore be arranged in the form of a rotary device or carousel with the molds arranged at the periphery, the various functions of opening/closing, locking/unlocking, etc. the molds possibly being controlled in sequence as the carousel rotates by cam follower rollers borne by the molds and collaborating with guide cams mounted fixedly on the outside of the rotary part.
[0035] Although the arrangements according to the invention can be applied to any type of mold, they are particularly applicable to molds equipped with two half-molds that rotate one with respect to the other, or to hinged molds, which are currently in very widespread use, and it is therefore in the context of a hinged mold that the arrangements of the invention will be set out in detail, without the protection being restricted to this one type of mold.
[0036] FIG. 1 illustrates, in simplified form, in perspective, the general arrangement of a hinged mold, denoted in its entirety by the reference 1 , comprising two half-molds 1 a and 1 b (it also being possible for an axially movable bottom—not shown—to be provided at the base of the mold). The two half-molds respectively have two collaborating faces or bearing faces 2 a , 2 b which, in the closed position, define a parting line 3 ( FIGS. 3, 4 ). The collaborating faces are hollowed out with, respectively, two half-cavities 4 a , 4 b which, when put together, define the molding volume 4 that has the external shape of the container that is to be obtained, or at least a major part of this shape, with the exclusion of its bottom.
[0037] In the example more particularly illustrated in FIG. 1 , each half-mold 1 a , 1 b has a composite structure and comprises an external framework or shell-holder 5 a , 5 b and an interior molding part or shell 6 a , 6 b which is fixed removably into the respective shell holder and comprises the aforesaid respective half-cavity 4 a , 4 b.
[0038] As can best be seen in FIGS. 3, 4 and 5 , the half-molds 1 a , 1 b (in this instance the shell-holders 5 a , 5 b ) comprise, on one side, respective protruding cheeks 7 a , 7 b which are interleaved with one another in a superposed fashion and have passing through them a shaft 8 arranged in the continuation of the parting line.
[0039] Furthermore, two projecting lugs 9 a , 9 b respectively support in rotation, via-spindles 10 a , 10 b distant from one another on each side of the shaft 8 , the ends of two actuating link rods 11 a , 11 b the other two respective ends of which are connected with the ability to rotate freely on a spindle 12 which can be moved in a linear fashion (arrow 13 ) toward the spindle 8 or in the opposite direction, by drive means (not shown).
[0040] On the other side of the parting line 3 and on the opposite side to the shaft 8 there are locking means 14 intended to keep the two half-molds 1 a , 1 b in the closed position as the blowing pressure is applied.
[0041] The locking means 14 comprise:
[0042] a first lock element 15 which is fixedly secured to the first half-mold 1 a (the one on the left in FIG. 1 ) which extends substantially along the edge of the bearing face 2 a thereof, and
[0043] a second lock element 16 which is secured such that it can move to the second half-mold 1 b (the one on the tight in FIG. 1 ) and which extends substantially along the edge of the bearing face 2 b thereof,
[0044] the two lock elements 15 , 16 extending substantially over the entire height of said half-molds 1 a , 1 b.
[0045] Each lock element 15 , 16 comprises a multiplicity of respective hook-shaped projecting fingers 17 , 18 distributed over the entire height of the lock element. The fingers 17 of the first lock element 15 are parallel and face away from the bearing face 2 a of the corresponding half-mold 1 a and the fingers 18 of the second lock element 16 are parallel and face toward the bearing face 2 b of the corresponding half-mold 1 b . The fingers 17 , 18 of each lock element 15 , 16 have in practice approximately the same height and are separated by spacings 19 , 20 respectively, the individual heights of which are slightly greater than the individual heights of the fingers.
[0046] The second lock element 16 is mounted on the half-mold 1 a such that it can slide vertically, that is to say parallel to the axis of the mold. For this purpose, one simple embodiment is, as illustrated, for the half-mold 1 b to be equipped with a guide member substantially parallel to the axis of the mold and arranged along the edge of the bearing face 2 b , it advantageously being possible for this guide member to consist of a rod 21 held in devises 22 projecting from the external face of the half-mold 1 b and on which rod the lock element 16 is mounted such that it can slide but prevented from rotating.
[0047] Actuating means 23 are functionally associated with the lock element 16 to move it between two positions, namely:
a first position or unlocked position ( FIGS. 1, 2 and 3 ) in which the fingers 18 of the moving lock element 16 are positioned respectively level with the spacings 19 separating the fingers 17 of the first lock element 15 and the spacings 20 between the fingers 18 are situated respectively level with the fingers 17 , in other words a position in which the two lock elements are vertically offset from one another such that their respective fingers 17 , 18 do not interfere with each other, and a second position or locked position ( FIG. 4 ) in which the two half-molds 1 a , 1 b are pressed firmly together (closed) and the moving lock element 16 is moved vertically, parallel to the axis of the mold, on the rod 21 so that its fingers 18 fit in behind the fingers 17 of the fixed lock element and engage respectively therewith, so that it becomes impossible to open the mold.
[0050] FIGS. 1 to 4 show four successive positions in the closing of the mold:
in FIG. 1 , the mold 1 is open, the two half-molds 1 a , 1 b are widely parted from one another, particularly with a view to loading a preform; in FIG. 2 , the mold 1 is partially closed, the two half-molds 1 a , 1 b being brought closer together and the respective fingers 17 , 18 being offered up to face the respective opposing spacings 19 , 20 ; in FIG. 3 , the mold 1 is in the closed position, the two half-molds 1 a , 1 b being pressed firmly together via their respective bearing faces 2 a , 2 b defining the parting line 3 , the fingers 17 , 18 being imbricated in one another; and finally, in FIG. 4 , the moving lock element 16 has been moved (in this example raised) along the rod 21 so that the fingers 17 , 18 are hooked together, the mold 1 then being closed and locked.
[0055] In order for the locking force to be distributed approximately uniformly over the entire height of the mold, it is necessary for fingers 17 , 18 to be uniformly distributed over this entire height, defining between them spacings that are as short as possible. It is therefore desirable for the number of fingers to be determined as a compromise, that is to say to be as high as possible in conjunction with their having sufficient individual mechanical strength to allow them, without breaking or deforming, to withstand the force individually applied to them. One advantageous result of this arrangement is that the travel of the moving lock element 16 is short, leading to brief locking/unlocking times. To give a concrete example, the mold illustrated by way of example in FIGS. 1 to 4 , designed for molding 1.5-liter bottles and having a height of approximately 35 cm, is equipped with about ten pairs of fingers 17 , 18 .
[0056] The actuating means 23 for actuating the moving lock element 16 may, in a simple way, comprise:
a return spring 24 , interposed between the half-mold 1 b and the lock element 16 , to return the latter to its aforesaid first position or unlocked position, and a positive actuating member secured to the lock element 16 and able to act positively thereon in order to move it, against the return force of the spring 24 , toward its second position.
[0059] By virtue of this arrangement it can be guaranteed that even unwanted mold closure will always occur with the fingers 17 , 18 offset from one another.
[0060] When the mold forms part of a rotary molding device of the carousel type, the positive actuating member may call upon a simple technical solution functionally associated with mold closure. For this purpose, as shown in FIGS. 1 to 4 , one of the half-molds, for example the one 1 b on the right, is made to support a movement transmission device 25 comprising a moving rod 26 projecting beyond the bearing face 2 b and able to be contacted and pushed back by the other half-mold 1 a as the mold is closed. The device 25 incorporates an appropriate mechanical means (for example inclined surfaces controlled by the rod 26 ) or preferably pneumatic means (the rod 26 controls a pneumatic piston) acting on a thrust rod (inside the spring 24 and not visible) able to raise the lock element 16 .
[0061] The way in which the locking means 14 are embodied may give rise to many variants. In particular, in the example illustrated in FIGS. 1 to 5 , the two lock elements 15 , 16 form an integral part of the two respective half-molds 1 a , 1 b , that is to say that the projecting fingers 17 of the first lock element 15 form an integral part of the first half-mold 1 a (for example are cast with this half-mold or with the shell-holder 5 a in the example illustrated), while the devises 22 supporting the guide rod 21 of the second lock element 16 form an integral part of the second half-mold 1 b (or of the shell-holder 5 b in the example illustrated).
[0062] However, it is possible to envisage forming the locking means in the form of separate elements attached to the half-molds, as illustrated in FIG. 6 (in which the mold has a different, quadrilateral, shape, only the shell-holders 5 a , 5 b being drawn, and the shells being omitted). As visible in this FIG. 6 , the first lock element 15 is produced in the form of a plate 27 which is provided with the fingers 17 along one of its edges; the plate 27 is fixed, for example by bolting at 28 , to the corresponding shell-holder 5 a . In the same way, the shaft 21 that acts as a guide for the second lock element 16 may be supported by a plate 29 attached, for example by bolting at 30 , to the second shell-holder 5 b . Such an arrangement of the first and/or second lock elements 15 , 16 in the form of attached parts may allow the manufacture of the half-molds or shell-holders to be simplified and/or may allow the half-molds or shell-holders and the parts incorporating the hook-shaped fingers 17 , 18 to be made of different metals (for example aluminum casting and steel, respectively). | A moulding device for the production of containers in thermoplastic material, by blowing or blow-drawing, including a mould with two mould halves mutually mobile and provided with a locking device with two lock elements extending over the total height of the respective mould halves and provided with a number of projecting fingers in catches spaced at intervals, one lock element being fixed on one mould half and the other lock element sliding on the other mould half under the action of an actuator device. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates broadly to methods and apparatus for napping a traveling fabric web and, more particularly, to a novel method and apparatus by which such napping operations may be repeatably controlled to achieve consistent napping results.
It is known to provide a textile fabric with a raised surface effect by brushing the fabric surface, commonly referred to as napping. A common type of conventional napping machine has a rotating cylinder with a plurality of rotating toothed rollers at the periphery of the cylinder. Typically, card clothing covers the periphery of the rollers. The card teeth may be arranged selectively to project in the same direction as, or counter to, the direction of roller rotation or alternating and intermediate rollers may be provided with oppositely projecting card teeth. In napping operation, a textile fabric web is directed to travel peripherally with respect to the rotating cylinder for napping engagement of the fabric surface by the teeth of the rotating rollers.
The napping effect of cylinder-type napping machines of this type may be varied by adjustment of a number of operating parameters, including the type of card clothing selected for the rotating rollers, the sequence of nap rollers having oppositely projecting card teeth, pretreatment of the fabric web such as by emerizing or chemical treatment, the traveling speed of the fabric web selected, the tension in the fabric web, adjustment of the rotational speed of the rollers, adjustment of the degree of slippage of the napping rollers with respect to their belt drive arrangement, the number of napping passes to which the fabric web is subjected, and lifting devices provided on the periphery of the cylinder. Normally, it is optimally desirable to perform a napping operation with the fabric web traveling at as high a speed as practical and with as few a number of napping passes of the fabric web as necessary to achieve the desired napping effect.
It is, of course, possible to preset or control all of the aforementioned operating parameters of a napping operation in order to provide optimal results. West German Patent No. 11 45 573 discloses a method for controlling various such operating parameters. However, no accepted standards and no known devices exist for precisely measuring the napping effect achieved in any given napping operation. Accordingly, the adjustment of operating parameters in a napping operation generally can be effectively accomplished only by an experienced technician and, even then, uniform napping results are only conditionally reproducible from one napping operation to another.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a method and apparatus by which a precise physical measurement may be taken of a given napping effect to provide a basis for controlling the napping operation of a napping machine to enable the napping effect to be subsequently reproducible.
It has been discovered that each adjustment of the aforementioned operating parameters of a napping operation utilizing a napping machine of the rotating cylinder type produces a characteristic radially inward drawing of the traveling fabric web with respect to the cylinder under the peripheral napping engagement of the toothed rollers. This results because the mechanical inter-relationship between the toothed rollers and the traveling fabric web varies as a function of the adjustable operating parameters. As will be understood, napping of the traveling fabric web occurs only along the arcuate extent of the periphery of the rotating toothed rollers which actually contacts the fabric web, the raising of the fabric surface being specifically a result of the entry of the teeth into and withdrawal of the teeth from the body of the fabric. Accordingly, the radially inward drawing of the fabric web with respect to the rotating cylinder plays a crucial roll in the effect of the napping operation in raising the fabric surface.
Therefore, according to the process and apparatus of the present invention, the napping operation of a napping machine of the rotating cylinder type is repeatably controlled by measuring the degree to which the fabric web is drawn radially inwardly of the cylinder under the peripheral napping engagement of the rollers as a characteristic of an adjustment of a variable operating parameter of the napping operation. Then, the measurement may be later utilized as a reference value for subsequent adjustment of the operating parameter for repeating the napping operation. By way of example, the variable operating parameter represented by the measurement taken according to the present invention may be any one of the following: the tension in the fabric web, the traveling speed of the fabric web, the rotational speed of the toothed rollers, and the amount of drive slippage of the rollers. Advantageously, the measurement need be the only reference value utilized for adjustment of all of the operating parameters of the napping operation.
Accordingly, the present invention contemplates that all adjustable operating parameters of the napping operation which affect the results achieved are to monitored simply by measurement of the degree of radially inward drawing of the fabric web. Conversely, the nature of the napping results achieved by the napping operation may be modified simply by regulating this measurement. For example, the measure of the radially inward drawing of the fabric web may be changed or regulated, even during operation of the napping machine, by changing the tension of the fabric web and/or its traveling speed, by selectively changing the rotational speeds of the napping rollers, and/or by adjusting the amount of drive slippage of the napping rollers. If the optimum measurement of the radially inward drawing of the fabric is not achieved by such means, this may indicate that the card clothing has become dull or is otherwise unsuitable for the fabric web being processed. Further changes may be made in the napping operation through pre-selection of the card clothing, pretreatment of the fabric web and other similar steps.
The degree to which the fabric web is drawn radially inwardly with respect to the rotating cylinder may be determined according to the present invention in various manners using various detection instruments. Preferably, the instrumentation utilized is operable without requiring mechanical contact with the traveling fabric web and, as desired, the data obtained by the instrumentation may be fed directly to a means for automatic control of the napping operation. It is further advantageous that the instrumentation permit a visual display of the degree of radially inward drawing of the fabric web so that the effect of an adjustment in one or more of the various operating parameters may be observed and optimized. Further, a visual display allows the maximum permissible degree of radially inward drawing of the fabric web to be monitored, without affecting the results of the napping operation, to avoid undesirable winding of the fabric web about the napping rollers during operation.
In accordance with the foregoing considerations, measurements may be taken according to the present invention utilizing a sensing device arranged out of contact with the fabric web, preferably at a fixed location relative to the periphery of the rotating cylinder (e.g. at a fixed disposition radially outwardly of the cylinder), for detecting displacement of the fabric web from a reference path extending tangentially with respect to the napping rollers. Preferably, the sensor is capable of determining the cycle of such displacement of the fabric web between successive rollers in relation to the increment in operating time required for each displacement cycle. Ultrasonic sensing devices, devices adapted for reflecting light off the fabric web, or devices for stroboscopic illumination of the fabric web are particularly suitable for use as displacement sensors for the foregoing purpose. Alternatively, the pattern or cycle in which the traveling fabric web is radially inwardly drawn or displaced with respect to the periphery of the rotating cylinder may also be detected photographically and displayed on a monitor by a suitable camera directed from a fixed disposition at a lateral edge of the fabric web on the periphery of the rotating cylinder. In all cases, a stationary pattern of the cyclical displacement of the fabric web may be displayed on a screen by synchronizing the detector with the frequency with which the successive napping rollers pass by the detector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a napping machine of the rotating cylinder type, representatively illustrating the effect of two successive napping rollers in drawing a fabric web radially inwardly with respect to the cylinder;
FIG. 2 schematically illustrates in side elevation an embodiment of the present invention utilizing a displacement sensor arranged at a radial spacing from the periphery of the rotating cylinder;
FIG. 3 is schematic perspective view illustrating an embodiment of the present invention utilizing a camera directed at a lateral edge of a fabric web on the periphery of the rotating cylinder; and
FIG. 4 is a graph depicting the cycle of displacement of a fabric web between successive napping rollers on the rotating cylinder in relation to operating time of the napping machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings, FIG. 1 schematically illustrates in side elevation the napping operation of a napping machine of the type having a cylinder which rotates about an axis 1 and which has a plurality of rotating napping rollers arranged axially about the periphery of the cylinder, only two successive napping rollers 2,3 being shown for simplicity of illustration. A web of textile fabric 8 is directed to travel in open width contact with the periphery of the rotating cylinder in a direction indicated by the arrows 7, the cylinder being rotated so that its peripheral surface and its napping rollers 2,3 move in essentially the same direction as the fabric web 8, as indicated by the directional arrows 4. The napping rollers 2,3, however, are rotated in the opposite direction, as indicated by directional arrows 5,6, so that their respective peripheries move in a direction opposite to the fabric web 8. The periphery of each of the napping rollers 2,3 is covered by a plurality of angular wire teeth, e.g. card clothing, the napping roller 2 having its teeth extending angularly in the direction of travel of the fabric web 8 (i.e. opposite the roller's own rotational direction) and the napping roller 3 having its teeth extending angularly opposite to the direction of travel of the fabric web 8 (i.e. in the same direction as the roller's own rotation).
As illustrated, the fabric web 8 does not follow a tangential path of travel with respect to the napping rollers 2,3, as indicated by the broken line 9, but instead the action of the teeth of the napping rollers 2,3 in engaging the facing surface of the traveling fabric web 8, as indicated by the lines of force 10,11, maintains engagement with the traveling web 8 over an effective arcuate extent of each roller 2,3 between points A and E, which as will be appreciated is a considerably greater area of effective fabric engagement than achieved by travel of the fabric web 8 in a tangential path 9. As a result, as the fabric web 8 travels from the point E at which it leaves engagement with one napping roller (e.g. roller 2) to the point A at which the web 8 first engages the next succeeding napping roller (e.g. roller 3), the fabric web 8 is progressively drawn radially inwardly with respect to the rotating cylinder, i.e., the web 8 is progressively displaced radially inwardly from the tangential path 9. By way of example and for purposes of illustration only, the measures of the degree of radially inward drawing of the fabric web 8 by the napping rollers 2,3 are indicated, respectively, by the angles W1 and W2.
As aforementioned, the degree of radially inward drawing or displacement of the fabric web is uniquely characteristic of the particular settings of the adjustable operating parameters of a napping machine for any given napping operation. Accordingly, the present invention contemplates the measurement of the radial displacement of the fabric web resulting from the peripheral napping engagement of the rollers for use as a reference value by which adjustment of one or more operating parameters of the napping operation may later be precisely controlled to enable the napping operation to be reliably repeated. More specifically, the measurement obtained by the present invention should represent the cycle of fabric web displacement, i.e., the amount of progressive increase in radially inward web displacement from one napping roller to the next succeeding napping roller in relation to the incremental operating time required for fabric travel between the successive rollers.
FIG. 2 illustrates one embodiment of the present invention wherein a deflection sensing device 13 is mounted at a fixed location radially outwardly from the periphery of a napping machine of the rotating cylinder type provided with a plurality of napping rollers 2,3 mounted at the cylinder periphery. The sensor 13 may be of any suitable conventional type of device capable of detecting and measuring the distance a radially between the sensor 13 and the lengthwise traveling extent of the fabric web 8 at a point along the arcuate extent of the fabric's contact with the cylinder, thereby to determine the deflection pattern of the fabric web 8 as the web travels over the rotating cylinder. For this purpose, the sensor 13 may be an ultrasonic sensor of a type adapted to reflect ultrasonic sound waves off the surface of the fabric web 8 facing radially outwardly of the cylinder 12 to measure the distance a. Alternatively, the sensor 13 may similarly be of a conventional type adapted to reflect light waves off the outward surface of the fabric web. As a still further possibility, the sensor 13 may be a stroboscope for intermittent illumination of the outward surface of the fabric web 8 to provide for visual detection of the degree of radially inward fabric deflection. Of course, those persons skilled in the art will readily recognize that other detection devices may be of equal utility for measuring the fabric web deflection pattern. In each case, the sensor 13 is advantageously out of physical contact with the traveling fabric web and the napping machine.
As will be understood, the distance a changes in a repeating pattern as a result of the rotation of the napping cylinder. By means of the sensor 13 of FIG. 2, the cyclical pattern of progressive fabric web displacement between successive napping rollers 2,3 may be determined by plotting the measurements taken of the distance a against the time interval of the measurements, as represented by the line 17 of FIG. 4, and the displacement cycle thusly determined may be recorded, as desired, and stored in a central computer. More specifically, the saw-tooth wave line 17 of FIG. 4 represents the progressive degree of radially inward displacement of the fabric web 8 from the point at which it leaves contact with one napping roller (e.g. point E in FIG. 1) to the point at which it first contacts the next successive napping roller (e.g. point A in FIG. 1) as related to the operational time interval required for the fabric web 8 to travel such distance, as more fully explained with respect to FIG. 1 above, this saw-tooth pattern of progressive web displacement being the result of the napping energy imparted by rotation of the individual napping rollers 2,3 simultaneously with the rotation of their supporting cylinder. In contrast, the line 16 represents the generally symmetrical degree of increasing and decreasing fabric web deflection which would result if the individual napping rollers were not rotated, whereby the napping rollers would not themselves impart any napping energy to the fabric web. The curve 16 is shown to be symmetrical for sake of simplicity, it being recognized that the differing web deflection angles W1,W2 created by the oppositely oriented teeth of the napping rollers 2,3 would actually cause the deflection pattern to be somewhat asymmetrical.
FIG. 3 illustrates an alternate embodiment of the present invention wherein a camera 14 is mounted in a fixed disposition at an axial spacing from the periphery of a rotating napping cylinder 12 having a plurality of peripheral napping rollers 2,3, with the camera 14 being directed toward the facing lengthwise lateral edge 15 of a fabric web 8 traveling along the cylinder periphery. In this manner, the camera 14 is enabled to photograph the radially inward deflection of the fabric web 8 between successive napping rollers 2,3 and, by triggering the photographic operation of the camera 14 in synchronism with the frequency of movement of the napping rollers 2,3 past the camera 14, a stationary representation of the cycle of web displacement in relation to operating time, such as the cycle line 17 of FIG. 4, may be displayed on an associated monitor or like display screen.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | The napping operation of a napping machine of the type having a rotating cylinder with a plurality of toothed rotating napping rollers at its periphery for napping engagement with a traveling fabric web is controlled for repeatable napping results by measuring the cyclical pattern of a radially inward deflection of the fabric web under the napping engagement of the rollers as a characteristic of an adjustment of a variable operating parameter which may be later utilized as a reference value for subsequent adjustment of the operating parameter to repeat the results of the napping operation. | 3 |
CONTINUING APPLICATION DATA
[0001] This application is a divisional of Ser. No. 09/641,555, filed Aug. 17, 2000, which is a divisional of Ser. No. 09/277,584, filed Mar. 26, 1999, which is a continuation of Ser. No. 08/454,037, filed May 30, 1995, issued as U.S. Pat. No. 5,959,603, which is a continuation of Ser. No. 08/178,949, filed Jan. 7, 1994, issued as U.S. Pat. No. 5,877,738, which is a continuation-in-part of International Application No. PCT/JP93/00604, filed on May 10, 1993 and a continuation-in-part of U.S. patent application Ser. No. 08/148,083, filed Nov. 4, 1993, issued as U.S. Pat. No. 6,084,563, which is a continuation-in-part of International Application No. PCT/JP93/00279, filed Mar. 4, 1993, the contents of each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present invention generally relates to a driving apparatus and a driving method for a liquid crystal display having a plurality of row electrodes and column electrodes. More particularly, the invention relates to such an apparatus and a method in which the row electrodes are divided into groups, each of the electrodes in each group being simultaneously selected each group being sequentially selected for achieving a gray scale display.
[0004] Matrix liquid crystal displays such as, twisted nematic (TN) and super twisted nematic (STN), are known in the art. Reference is made to FIG. 49 in which a conventional matrix liquid crystal display is provided. A liquid crystal panel generally indicated as 1 is composed of a liquid crystal layer 5 , a first substrate 2 and a second substrate 3 for sandwiching the liquid crystal layer 5 therebetween. A group of column electrodes Y 1 -Y m are oriented on substrate 2 in the vertical direction and a plurality of row electrodes X 1 -X n are formed on substrate 3 in substantially the horizontal direction to form a matrix. Each intersection of column electrodes Y 1 -Y m and row electrodes X 1 -X n forms a display element or pixel 7 . Display pixels 7 having the open circle indicate an ON state and those pixels having a blank indicate an OFF state.
[0005] A conventional multiplex driving based on the amplitude selective addressing scheme is known to one of ordinary skill in the art as one method of driving the liquid crystal panel mentioned above. In such a method, a selected voltage or non-selected voltage is sequentially applied to each of row electrodes X 1 -X n individually. That is, a selection voltage is applied to only one row electrode at a time. In the conventional driving method, the time period required to apply the successive selected or non-selected voltage to all the row electrodes X 1 -X n is known as one frame period, indicated in FIGS. 43 A-E as time period F. Typically the frame period is approximate {fraction (1/60)}th of a second or 16.66 milliseconds.
[0006] Simultaneously to the successive application of the selected voltage or the non-selected voltage to each of the row electrodes X 1 -X n , a data signal representing an ON or OFF voltage is applied to column electrodes Y 1 -Y m . Accordingly, to turn a pixel 7 , e.g. the area in which the row electrode intersects the column electrode, to the ON state, an ON voltage is applied to a desired column electrode when the row electrode is selected.
[0007] Referring specifically to FIGS. 43 A-E, a conventional multiplex drive method of a simple matrix type liquid crystal and more specifically the amplitude selective addressing scheme is shown therein. Such a conventional drive method is not intended to provide the features of achieving a gray scale display. FIGS. 43 A-C show the row selection voltage waveforms that are applied in sequence to row electrodes X 1 , X 2 . . . X n , respectively. More particularly, in time period t 1 , a voltage pulse having a magnitude of V 1 is applied to row electrode X 1 , and a voltage of zero is applied to electrodes X 2 -X n ; in time period t 2 , a voltage pulse having a magnitude of V 1 is applied to row electrode X 2 and a voltage of zero is applied to electrodes X 1 and X 3 -X n and in time period t n , V 1 is applied to row electrode X n and a voltage of zero is to electrodes X 1 -X n - 1 . In other words, a voltage pulse having a magnitude of V 1 is applied to only one row electrode X i in time t i . Typically, t i is approximately 69 μ seconds and V 1 is approximately 25 volts. As will be apparent to one who has read this description, all of the row electrodes are sequentially selected in time periods t 1 -t n or one frame period F.
[0008] [0008]FIG. 43D shows the waveform applied to column electrode Y 1 , and FIG. 43E shows the synthesized voltage waveform applied to the pixel 7 1,1 formed at the intersection of the column electrode Y 1 and the row electrode X 1 . As shown therein, during time period t 1 , a voltage pulse having a magnitude of V 1 is applied to row X 1 and a voltage pulse of −V 2 is applied to column electrode Y 1 . Typically, V 2 is approximately 1.6 volts. The resultant voltage at pixel 7 1,1 is (V 1 -V 2 ). This synthesized voltage is sufficient to turn pixel 7 1,1 to its ON state.
[0009] As noted above this conventional driving method does not display an image having a gray scale. Furthermore, another known problem with this method is that in order to select and drive the one line of the row electrodes, a relatively high voltage is required to provide good display characteristics, such as, contrast and low distortion. These conventional displays, requiring such a high voltage, also consume relatively more energy. When such displays are used in portable devices, they are supplied with electrical energy by, for example, batteries. As a result of the higher energy consumption, the portable devices have relatively shorter times of operation before the batteries require replacement and/or recharging.
[0010] Various attempts have been made to overcome this problem. For example parent patent application Ser. No. 08/148,083, filed Nov. 4, 1993, is directed to a method driving a liquid crystal panel comprising the steps of sequentially selecting a group of a plurality of row electrodes during a selection period, simultaneously selecting the row electrodes comprising the group, and dividing and separating the selection period into a plurality of intervals within one frame period.
[0011] In another example, it has been suggested in “A Generalized Addressing Technique for RMS Responding Matrix LCDs,” 1988 International Display Research Conference, pp. 80-85. to simultaneously apply a row selection voltage to more than one row electrode.
[0012] As shown in FIG. 45A-D, a conventional method for driving a liquid crystal display is provided by simultaneously selecting a group of more than one row electrode. As shown therein, the n row electrodes are divided in j groups of row electrodes, each group comprising, for example, two row electrodes. In this example, row electrodes X 1 , X 2 and X 3 and X 4 , X 5 and X 6 form first and second groups of row electrodes, respectively.
[0013] Referring again to FIG. 45A, that figure illustrates row selection voltage waveforms applied simultaneously to row electrodes X 1 , X 2 and X 3 in time periods t 11 -t 18 and a voltage of zero is applied to row electrodes X 1 , X 2 and X 3 in the remaining time periods of frame period F. Similarly, FIG. 45B indicates the row selection voltage waveforms applied to row electrodes X 4 , X 5 and X 6 , during time periods t 21 -t 28 and a voltage of zero is applied to row electrodes X 4 , X 5 and X 6 in the other time periods of frame period F. FIG. 45C illustrates the voltage waveform applied to column electrode Y 1 , and FIG. 45D indicates the synthesized voltage waveform applied to the pixel 7 1,1 . Generally, t 1,1, t 1,2 . . . t j,n =34.5 μ seconds, V 1 is approximately 17.6 volts and V 2 is approximately 2.3 volts.
[0014] As shown in the example of FIGS. 45 A-D, every three row electrodes are selected in sequence. In the first selection sequence, three row electrodes, X 1 , X 2 and X 3 , are selected and row selection voltage waveforms such as that shown in FIG. 45A are applied to each row electrode. At the same time, the designated column voltage, which is described below, is applied to each column electrode, Y 1 to Y m . Next, row electrodes X 4 , X 5 and X 6 are simultaneously selected with substantially the same type of waveform voltages as that described above. At the same time, the column voltages Y 1 to Y m are applied to each column electrode. One frame period represents the selection of all row electrodes, X 1 to X n . In other words, a complete image is displayed during one frame.
[0015] As will be explained hereinbelow, when h row electrodes are simultaneously selected, the voltage waveforms that apply the row electrodes described above use 2 h row-select patterns. In the example illustrated in FIGS. 45 A-D, the number of row electrodes simultaneously selected is three, thus the number of row select patterns is 2 3 or 8.
[0016] Moreover, the column voltages applied to each column electrode Y 1 to Y m provide the same number of pulse patterns as that of the row select pulse patterns. That is, there are 2 h pulse patterns. These pulse patterns are determined by comparing the states of pixels on the simultaneously selected row electrodes i.e., whether the pixels are ON or OFF, with the polarities of the voltage pulses applied to row electrode.
[0017] In this example, as shown in the previously described FIGS. 45 A-D, when row electrodes X 1 , X 2 and X 3 are selected and row voltages such as those in FIG. 45A are applied thereto and when the pixels on row electrodes X 1 , X 2 and X 3 are ON, ON and OFF, respectively, as shown in FIG. 44, the voltage waveform applied the column electrode is voltage waveform Y 1 shown in FIG. 45C.
[0018] The above-mentioned column voltage waveform Y 1 is determined as follows. At first, each pixel simultaneously selected is defined to have a first value of 1 when the voltage applied by the row electrode to the corresponding selected pixel is positive or a first value of 0 when the row electrode is negative. In the example shown in FIG. 46A, the voltage ON/OFF patterns applied to the three simultaneously selected row electrodes X 1 , X 2 , and X 3 are shown in the following table using values of 1 and 0 for ON and OFF pixel states, respectively.
TABLE A X 1 0 0 0 0 1 1 1 1 X 2 0 0 1 1 0 0 1 1 X 3 0 1 0 1 0 1 0 1
[0019] Each of the selected pixels is defined to have a second value of 1 when the display state is ON or a second value of 0 when display state is OFF. The first value is compared to the second value bit-by-bit, the number of mismatches, i.e., when the first value does not equal the second value, is calculated. When the number of mismatches for the simultaneously selected rows is zero, −V Y2 is applied; when 1, −V Y1 is applied; when 2, V Y1 is applied; and when 3, V Y2 is applied. In this example the ratio of V Y1 to V Y2 is 1:3.
[0020] For example, when the pulse waveforms shown in FIG. 45A are applied to row electrodes X 1 , X 2 and X 3 , a column voltage having the waveform of Y 1 is applied. For time period t 11 , the column voltage is determined as follows. The pixels formed at the intersections of column electrode Y 1 and rows electrodes X 1 , X 2 and X 3 are in the ON, ON and OFF states, respectively. For the purposes of this discussion, these pixels will be referred to as the first, second and third pixels, respectively. In other words, the first pixel has a second value of 1, the second pixel has a second value of 1 and the third pixel has a second value of 0 (zero) Those pixels assume the first values, as shown in Table A. Referring to the first pixel, since the first value is 0 and the second value is 1, there is a mismatch. With regard to the second pixel, the first value is 0 and the second value is 1, thereby also forming a mismatch. Finally, referring to the third pixel, the first value is 0 and the second value is also 0, thereby forming a match. Accordingly, the number of mismatches is determined to be 2. Therefore, a voltage of V Y1 is applied to the column electrode in time t 11 .
[0021] The row select pattern of the voltage applied to the row electrodes X 1 , X 2 , and X 3 in time t 12 is OFF-OFF-ON. The number of mismatches during this time period is three. Therefore, voltage V Y2 is applied as the second pulse to column electrode Y 1 . Similarly, V Y1 is applied as the third pulse, −V Y1 as the fourth pulse. Thus the following pulses are, in sequence, −V Y2 , V Y1 , −V Y1 , −V Y1 applied to the column electrode in the fifth to eighth pulses.
[0022] The next three row electrodes X 4 -X 6 are then selected, and when the voltage shown in FIG. 45B is applied to these row electrodes X 4 -X 6 , a column voltage of the voltage level corresponding to the number of mismatches between the on/off states of the pixels shown in FIG. 44 at the intersections of row electrodes X 4 -X 6 and the column electrode Y 1 and the on/off states of the voltage row select patterns applied to the row electrodes X 4 -X 6 as shown in FIG. 45C is applied.
[0023] The voltage waveforms generated based on these values for application to the row electrodes are shown in FIG. 46A. The waveform shown in FIG. 46A, however, contains dispersions in the frequency component, which can result in display non-uniformity when applied. In other words, the applied voltage waveforms, include the following different frequency components:
[0024] X1: 4·Δt, 4·Δt
[0025] X2: 2·Δt, 4·Δt, 2·Δt
[0026] X3: 2·Δt, 2·Δt, 2·Δt, 2·Δt
[0027] Such differences in frequency appear to cause distortion of the displayed image.
[0028] The waveforms modified by reordering the array to eliminate the bias in the frequency component is shown in FIG. 46B. The prior art example shown in FIG. 45A-D can also utilize these waveforms.
[0029] However, when a driving method, such as shown in FIG. 48A or B is used to drive a liquid crystal display panel, the pulse width of each pulse becomes narrower. That is particularly true when the number of simultaneously selected row electrodes increases. In other words, there is an exponential increase in the number of bit word patterns with each pulse width becoming narrower. The narrower pulse width leads to possible rounding when the waveform is applied to pixel and/or crosstalk may occur. These distortions are particularly apparent when a gray scale display is attempted.
[0030] In another example, values 1 and −1 are used for the positive and negative selection pulses of the row voltage waveform, and −1 and 1 are used for the ON and OFF display data states of pixel, respectively, and the column voltage waveform is set according to the difference between the number of matches and the number of mismatches, values of 1 or −1 can be used for either, and the column voltage waveform can be set using only the number of matches or the number of mismatches without calculating the difference between the number of matches or the number of mismatches.
[0031] FIGS. 47 A, A′, B and C depict another example of a conventional method for driving a liquid crystal display by simultaneously selecting a group of more than one row electrode. As shown therein, the n row electrodes are divided in j groups of row electrodes, each group comprising, for example, two row electrodes. In this example, row electrodes X 1 , X 2 ; X 3 , X 4 ; and X n−1 , X n , each form a group of row electrodes.
[0032] Referring again to FIG. 47A, that figure illustrates row selection voltage waveforms applied simultaneously to both row electrodes X 1 and X 2 in time periods t 1 and t 2 and a voltage of zero is applied to row electrodes X 1 and X 2 in the remaining time periods of frame period F. Similarly, FIG. 47A′ indicates the row selection voltage waveforms applied to row electrodes X 3 and X 4 , during time periods t 3 and t 4 and a voltage of zero is applied to row electrodes X 3 and X 4 in the other time periods of frame period F. FIG. 47B illustrates the voltage waveform applied to column electrode Y 1 , and FIG. 47C indicates the synthesized voltage waveform applied to the pixel 7 1,1 . Generally, t 1 , t 2 , . . . t n =69 μ seconds, V 1 is approximately 17.6 volts and V 2 is approximately 2.3 volts.
[0033] As shown in the example of FIGS. 47 A, A′ B and C every two row electrodes are selected in sequence. In the first selection sequence, two row electrodes, X 1 and X 2 , are selected and row selection voltage waveforms such as that shown in FIG. 47A are applied to each row electrode. At the same time, the designated column voltage, which is described below, is applied to each column electrode, Y 1 to Y m . Next, row electrodes X 3 and X 4 are simultaneously selected with substantially the same type of waveform voltages as that described above. At the same time, the column voltages Y 1 to Y m are applied to each column electrode. As explained above, one frame period represents the selection of all row electrodes, X 1 to X n .
[0034] As will be explained hereinbelow, when h row electrodes are simultaneously selected, the voltage waveforms that apply the row electrodes described above use 2 h row-select patterns. In the example illustrated in FIGS. 47 A, A′, B and C the number of row electrodes simultaneously selected is two, thus the number of row select patterns is 2 2 or 4.
[0035] Moreover, the column voltages applied to each column electrode Y 1 to Y m provide the same number of pulse patterns as that of the row select pulse patterns. That is, there are 2 h pulse patterns. These pulse patterns are determined by comparing the states of pixels on the simultaneously selected row electrodes i.e., whether the pixels are ON or OFF, with the polarities of the voltage pulses applied to row electrode.
[0036] In this example, as shown in the previously described FIGS. 47 A, A′ B and C when row electrodes X 1 and X 2 are selected and row voltages such as those in FIG. 47A and FIG. 48A are applied thereto and when the pixels on row electrodes X 1 and X 2 are ON and OFF, respectively, the voltage waveform applied the column electrode is voltage waveform Y a shown in FIG. 48B. When the pixels are OFF and ON, respectively, the column voltage waveform Y b is applied to the column electrode. In another example, when the pixels are both ON, a voltage waveform Y c is applied to the column electrode. Finally, when both pixels are OFF, the a column voltage waveform Y d is applied to the column electrode.
[0037] The above-mentioned column voltage waveforms Y a -Y d are determined as follows. At first, each pixel simultaneously selected is defined to have a first value of 1 when the voltage applied by the row electrode to the corresponding selected pixel is positive or a first value of −1 when the row electrode is negative. Each of the selected pixels is defined to have a second value of −1 when the display state is ON or a second value of 1 when display state is OFF. The first value is compared to the second value bit-by-bit, the difference between the number of matches, i.e., when the first value equals the second value, and the number of mismatches, i.e., when the first value does not equal the second value, is calculated. When the difference between the number of matches and mismatches for the simultaneously selected rows is two, V 2 is applied; when 0, V 0 is applied; and when −2, −V 2 is applied.
[0038] For example, when the pulse waveforms shown in FIG. 47A are applied to row electrodes X 1 and X 2 , a column voltage having the waveform of Y a is applied. This column voltage is determined as follows. The pixels formed at the intersections of column electrode Y 1 and rows electrodes X 1 and X 2 are in the ON and OFF states, respectively. For the purposes of this discussion, these pixels will be referred to as the first and second pixels, respectively. In other words, the first pixel has a second value of −1 and the second pixel has a second value of 1. During the period t a , the first pixel has a first value of −1 and the second pixel has a first value of −1, since the row voltages X 1 and X 2 are both −V 1 . Referring to the first pixel, since the first value is −1 and the second value is −1, there is a match. With regard to the second pixel, the first value is −1 and the second value is 1, thereby forming a mismatch. The difference between the number of matches and mismatches is 1-1 or zero. Therefore, a voltage of 0 (zero) is applied to the column electrode in time t a . Next, concerning the pulse waveforms of the time interval t b , the applied voltage of row electrode X 1 is positive and the applied voltage of row electrode pulse X 2 is negative. Using a similar analysis as described above, the number of matches is zero and the number of mismatches is 2. Thus, −V 2 volts will be applied to the second half of time interval t 1 .
[0039] As should now be apparent, the first values in time interval t c in FIG. 47A are −1 and 1 because the applied voltage of row electrode X 1 is negative and the applied voltage of row electrode X 2 is positive. When these are compared with the second values of the first and second pixels of −1 and 1, the number of matches is two and the number of mismatches is zero. The difference between the number of matches and the number of mismatches is 2. Thus, the column voltage of V 2 volts will be applied in time interval t c .
[0040] In time interval t d , the applied voltage of row electrodes X 1 and X 2 are both positive. Thus, the first values are 1 and 1. When compared to the pixel states of −1 and 1, the number of matches is 1 and the number of mismatches is 1, thus the difference between the number of matches and the number of mismatches is zero. Accordingly, zero volts will be applied to Y a for the time interval t d .
[0041] A summary of this analysis for time periods t a , t b , t c and t d , is shown in Table B below:
TABLE B t a t b t c t d pixel 1-ON first value −1 1 −1 1 second value −1 −1 −1 −1 match yes no yes no mismatch no yes no yes 2-OFF first value −1 −1 1 1 second value 1 1 1 1 match no no yes yes mismatch yes yes no no no. of matches 1 0 2 1 no. of mismatches 1 2 0 1 difference 0 −2 2 0 column voltage 0 −V 2 V 2 0
[0042] As is readily apparent, the column voltage Y a corresponds to the column voltage pattern and is applied to the column to place the first pixel in its ON state and the second pixel in its OFF state.
[0043] As for the other column voltage waveforms, Y b to Y d , the voltages are selected under the same criteria as described above and are summarized in Tables C, D and E hereinbelow:
TABLE C t a t b t c t d pixel 1-OFF first value −1 1 −1 1 second value 1 1 1 1 match no yes no yes mismatch yes no yes no 2-ON first value −1 −1 1 1 second value −1 −1 −1 −1 match yes yes no no mismatch no no yes yes no. of matches 1 2 0 1 no. of mismatches 1 0 2 1 difference 0 −2 2 0 column voltage 0 −V 2 V 2 0 Column Voltage Applied = Y b
[0044] [0044] TABLE D t a t b t c t d pixel 1-ON first value −1 1 −1 1 second value −1 −1 −1 −1 match yes no yes no mismatch no yes no yes 2-ON first value −1 −1 1 1 second value −1 −1 −1 −1 match yes yes no no mismatch no yes yes no. of matches 2 1 1 0 no. of mismatches 0 1 1 2 difference 2 0 0 −2 column voltage V 2 0 0 −V 2 Column Voltage Applied = Y c
[0045] [0045] TABLE E t a t b t c t d pixel 1-OFF first value −1 1 −1 1 second value 1 1 1 1 match no yes no yes mismatch yes no yes no 2-OFF first value −1 −1 1 1 second value 1 1 1 1 match no no yes yes mismatch yes yes no no no. of matches 0 1 1 2 no. of mismatches 2 1 1 0 difference −2 0 0 2 column voltage −V 2 0 0 V 2 Column Voltage Applied = Yd
[0046] In the examples above, the first value is 1 when the row-select voltage has a positive polarity or the first value when the row-select voltage has a negative polarity. Additionally, the second value is −1 when the display state of the pixel is ON, or 1 when the display state is OFF. The column voltage waveforms were selected by means of the difference between the number of matches and the number of mismatches
[0047] As described above, these methods of simultaneously selecting and driving plural sequential row electrodes can suppress the drive voltage while achieving the same on/off ratio as the single line selection method shown in FIG. 43A-E.
[0048] The following is a general discussion regarding the conventional method for simultaneously selecting multiple row electrodes.
[0049] A. Requirements
[0050] A The N number of row electrodes to be displayed are divided up into N/h non-intersecting subgroups.
[0051] B Each subgroup has h number of address lines.
[0052] C At a particular time, the display data on each column electrode is composed of an h-bit words, e.g.:
[0053] d k*h+1 , d k*h+2 . . . d k*h+h ; d k*h+j =0 or 1
[0054] Where 0·k·(N/h)−1 (k: subgroup)
[0055] In other words, one column of display data is:
[0056] d 1 , d 2 . . . d h . . . Subgroup 0
[0057] d h+1 , d h+2 . . . d h+h . . . Subgroup 1
[0058] d N−h+1 , d N−h+2 . . . d N−h+h . . . Subgroup N/h−1
[0059] D The row-select pattern has 2 h cycle and is represented by an h-bit words, e.g.:
[0060] a k*h+1 , a k*h+2 . . . a k*h+h ; a k*h+j =0 or 1
[0061] B. Guidelines
[0062] (1) One subgroup is selected simultaneously for addressing.
[0063] (2) One h-bit word is selected as the row-select pattern.
[0064] (3) The row-select voltages are:
[0065] −V r for a logic 0,
[0066] +V r for a logic 1,
[0067] 0 volts or ground for the unselected period.
[0068] (4) The row-select patterns and the display data patterns in the selected subgroup are compared bit by bit such as with digital comparators, viz. exclusive OR logic gates.
[0069] (5) The number of mismatches i between these two patterns is determined by counting the number of exclusive-OR logic gates having a logical 1 output.
[0070] Steps 1-4 are summarized by the following equation:
i = ∑ j = 1 h a k * h + j ⊕ d k * h + j ( 0 ≤ i ≤ h )
[0071] (where ⊕ is an exclusive OR logic operation)
[0072] (6) The column voltage is chosen to be V(i) when the number of mismatches is i.
[0073] (7) The column voltages for each column in the matrix is determined independently by repeating the steps (4)-(6).
[0074] (8) Both the row voltage and column voltage are applied simultaneously to the matrix display for a time duration Δt, where Δt is minimum pulse width.
[0075] (9) A new row-select pattern is chosen and the column voltages are determined using steps (4)-(6). The new row and column voltages are applied to the display for an equal duration of time at the end of Δt.
[0076] (10) A frame or cycle is completed when all of the subgroups (=N/h) are selected with all the 2 h row-select patterns once.
[0077] 1 cycle=Δt·2 h ·N/h
[0078] C. Analysis
[0079] The row select patterns in a case in which there are i number of mismatches will now be considered. The number of h-bit row-select patterns which differ from and h-bit display data pattern by i bits is given by
[0080] hCi=h!/{i! (h−i)!}=Ci
[0081] For example, when the case for h=3 and row electrode selection pattern=(0,0,0) is considered, the results would be as shown in the table below:
Mismatching number Display Data pattern Ci i = 0 (0,0,0) 1 way i = 1 (0,0,1) (0,1,0) (1,0,0) 3 ways i = 2 (1,1,0) (1,0,1) (0,1,1) 3 ways i = 3 (1,1,1,) 1 way
[0082] These are determined by-the number of bits of a word, not the row electrode selection patterns.
[0083] If the amplitude V pixel of the instantaneous voltage that is applied to the pixel had a row voltage of V row and column voltage of V column , the synthesized voltage would be as follows:
[0084] V pixel =(V column −V row ) or (V row −V column )
[0085] Where, if V row =±V r and V column =V(i), then V pixel =+V r −V(i) or −V r −V(i).
[0086] If V row =±V r and V column =±V(i), then V pixel =V r −V(i),V r +V(i), −V r −V(i) or −V r +V(i).
[0087] That is:
[0088] V pixel =|V r −V(i)| or |V r +V(i)|
[0089] As a consequence, the specific amplitude to be applied to the pixel is either −(V r +V(i)) or (V r −V(i)) in the selection row and is V(i) in the non-selection row.
[0090] In general, in order to achieve a high selection ratio, it is desirable that the voltage across a pixel should be as high as possible for an ON pixel and as low as possible for an OFF pixel.
[0091] As a result, when a pixel is in the ON state, the voltage |V r +V(i)| is favorable for the ON pixel, and the voltage |V r −V(i)| is unfavorable for the ON pixel. On the other hand, when a pixel is in the OFF state, the voltage |V r −V(i)| is favorable for the OFF pixel, and the voltage |V r +V(i)| is unfavorable for the OFF pixel.
[0092] Here, it is favorable for the ON pixel to increase the effective, voltage and unfavorable for the ON pixel to decrease the effective voltage. The number of combinations that selects i units from among the h bits is:
[0093] Ci=hCi={h!}/{i! (h−i)!}
[0094] The total number of mismatches provides the number of unfavorable voltages in the selected rows in a column. The total number of mismatches is i·Ci in Ci row select patterns considered are equally distributed over the h pixels in the selected rows. Hence the number of unfavorable voltages per pixel (Bi) when number of mismatches is i can be obtained as given following;
[0095] Bi=i·Ci/h (units/pixel)
[0096] The number of times a pixel gets a favorable voltage during the Ci time intervals considered is:
[0097] Ai={(h−i)/h}·Ci
[0098] In addition:
[0099] {(h−i)/h}·Ci+(i/h)·Ci=(h/h) Ci=Ci
[0100] Accordingly, the following is obtained:
[0101] Ai=Ci−Bi={(h−1)!}/{i!·(h−i−1)!}
[0102] Where: h≦i+1
[0103] To summarize the above:
[0104] V on (rms)={(S 1 +S 2 +S 3 )/S 4 } 1/2
[0105] V off (rms)={(S 5 +S 6 +S 3 )/S 4 } 1/2
S 1 = ∑ i = 0 h A i ( V r + V ( i ) ) 2 ( favorable ) S 2 = ∑ i = 0 h B i ( V r + V ( i ) ) 2 ( un favorable ) S 3 = { ( N / h ) - 1 } ∑ i = 0 h ( A i + B i ) V ( i ) 2 S 4 = 2 h · ( N / h ) S 5 = ∑ i = 0 h A i ( Vr + V ( i ) ) 2 ( favorable ) S 6 = ∑ i = 0 h B i ( Vr + V ( i ) ) 2 ( un favorable )
[0106] In addition:
[0107] V r /V o =N 1/2 /h . . . row selection voltage
[0108] V(i)/V0=(h−2i)/h={1−(2i/h)} . . . column voltage, and
[0109] R=(V on /V off ) max ={(N 1/2 +1)/(N 1/2 −1)} 1/2
[0110] When plural sequentially row electrodes are simultaneously selected and driven as in prior art example described above, however, the pulse width applied to the row electrodes and column electrode also narrows as the number of simultaneously selected row electrodes increases, and picture quality deteriorates as crosstalk increases due to waveform rounding. This problem is particularly noticeable when this drive method is applied to gray scale displays using pulse width modulation.
[0111] Moreover, a liquid crystal display driven according to such a method has poor contrast between its ON and OFF states.
OBJECTS OF THE INVENTION
[0112] It is an object of the present invention to provide an apparatus that obviates the aforementioned problems of the conventional liquid crystal devices.
[0113] It is a further object of the present invention to provide a liquid crystal display for displaying a gray scale image having high image quality, simply and reliably.
[0114] It is still another object of the present invention to provide a gray scale display with a reduced number of column voltage levels.
[0115] It is an additional object of the present invention to provide a drive method, drive circuit, and display apparatus for a liquid crystal panel capable of achieving a good gray scale display even when simultaneously selecting and driving plural sequentially row electrodes.
[0116] It is still yet another object of the present invention to provide a driving method for a liquid crystal panel having reduced crosstalk.
[0117] These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following detailed description of the preferred embodiments of the present invention in conjunction with the accompanying drawings.
[0118] Although the detailed description and annexed drawings describe a number of preferred embodiments of the present invention, it should be appreciated by those skilled in the art that many variations and modifications of the present invention fall within the spirit and scope of the present invention as defined by the appended claims.
SUMMARY OF THE INVENTION
[0119] According to an aspect of the present invention, a multiplex drive method for a liquid crystal panel is provided in which the selection period is divided into plural periods, and a weighted voltage is applied in accordance with the desired display data in the divided selection periods to achieve a gray scale display.
[0120] According to another aspect of the present invention, a drive method for a liquid crystal panel is provided in which selected pulse data generated by the scan data generating circuit and display data pattern for plural simultaneously selected scan lines by means of an operating circuit is calculated. The data based on the calculation result is transferred to a column electrode driver and the scan data is simultaneously transferred to the row electrode driver to achieve a desired gray scale display.
[0121] According to a further aspect of the present invention, a liquid crystal display apparatus comprises a drive circuit for calculating selected pulse data generated by the row-select pattern generating circuit and the display data for plural simultaneously selected scan lines by means of an operating circuit. A means is provided for transferring the data based on the calculation result to the column electrode driver and for simultaneously transferring the scan data to the row electrode driver. This means also divides the selection period into plural parts and applies a weighted column voltage in accordance with the desired display data by the drive circuit to the column electrodes in each of the divided selection periods to achieve a gray scale display.
[0122] Other objects and attainments together with a fuller understanding of the invention will become apparent and appreciated by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0123] In the drawings, wherein like reference characters denote similar elements throughout the several views.
[0124] FIGS. 1 A, A′, B and C show applied voltage waveforms in accordance with the first embodiment of a drive method of a liquid crystal panel in accordance with the present invention;
[0125] [0125]FIG. 2 is a schematic diagram of a liquid crystal display panel depicting the displayed data;
[0126] [0126]FIG. 3A is an example of waveforms applied to row electrodes in accordance with a preferred embodiment of the present invention;
[0127] [0127]FIG. 3B is another example of waveforms applied to row electrodes in accordance with an embodiment of the present invention;
[0128] [0128]FIG. 4 is a block diagram of a driving circuit in accordance with the first embodiment of the present invention;
[0129] [0129]FIG. 4A is a timing diagram of the driving circuit of FIG. 4;
[0130] [0130]FIG. 5 is a block diagram of the row electrode driver of the row driving circuit of FIG. 4;
[0131] [0131]FIG. 6 is a block diagram of the column electrode driver of the column driving circuit of FIG. 4;
[0132] FIGS. 7 A, A′, B and C show the applied voltage waveforms of a second embodiment of a driving method of the liquid crystal display according to the present invention;
[0133] [0133]FIG. 8 illustrates an example of display data of a liquid crystal display panel having at least one virtual electrode;
[0134] FIGS. 9 A, A′, B and C show the applied voltage waveforms of a third embodiment of a driving method of the liquid crystal display according to the present invention;
[0135] [0135]FIG. 10 illustrates the relationship of the time periods used to achieve a gray scale display by means of a pulse width modulation method;
[0136] FIGS. 11 A, A′, B, and C show the applied voltage waveforms of a fourth embodiment of a driving method of the liquid crystal display according to the present invention;
[0137] FIGS. 12 A, A′, B, and C show the applied voltage waveforms of a fifth embodiment of a driving method of the liquid crystal display according to the present invention;
[0138] [0138]FIG. 13 illustrates another example of display data of a liquid crystal display panel having at least one virtual electrode;
[0139] [0139]FIGS. 14A and 14B show the applied voltage waveforms of a sixth embodiment of a driving method of the liquid crystal display according to the present invention;
[0140] FIGS. 15 A, A′, B, and C show the applied voltage waveforms of a seventh embodiment of a driving method of the liquid crystal display according to the present invention;
[0141] [0141]FIG. 16 illustrates another example of display data of a liquid crystal display panel during two frame periods;
[0142] [0142]FIGS. 17A and 17B show the applied voltage waveforms of an eighth embodiment of a driving method of the liquid crystal display according to the present invention;
[0143] [0143]FIG. 18 illustrates another example of display data of a liquid crystal display panel during two frame periods;
[0144] [0144]FIG. 19 shows the applied voltage waveforms of a ninth embodiment of a driving method of the liquid crystal display according to the present invention;
[0145] [0145]FIG. 20 shows the applied voltage waveforms of a tenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0146] FIGS. 21 A, A′, B and C show the applied voltage waveforms of an eleventh embodiment of a driving method of the liquid crystal display according to the present invention;
[0147] [0147]FIG. 22 illustrates another example of display data of a liquid crystal display panel;
[0148] FIGS. 23 A, A′, B and C show the applied voltage waveforms of a twelfth embodiment of a driving method of the liquid crystal display according to the present invention;
[0149] [0149]FIGS. 24A, B and C show another example of the applied voltage waveforms of the twelfth embodiment of a driving method of the liquid crystal display according to the present invention;
[0150] FIGS. 25 A-C show another example of the applied voltage waveforms of the twelfth embodiment of a driving method of the liquid crystal display according to the present invention;
[0151] FIGS. 26 A-C show the applied voltage waveforms of a thirteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0152] FIGS. 27 A-C show the applied voltage waveforms of a fourteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0153] FIGS. 28 A-C show another example of the applied voltage waveforms of the fourteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0154] FIGS. 29 A-C show another example of the applied voltage waveforms of the fourteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0155] FIGS. 30 A-C show the applied voltage waveforms of a fifteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0156] [0156]FIG. 31 illustrates another example of display data of a liquid crystal display panel;
[0157] FIGS. 32 A-C show the applied voltage waveforms of a sixteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0158] FIGS. 33 A-C show the applied voltage waveforms of a seventeenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0159] FIGS. 34 A-C show the applied voltage waveforms of an eighteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0160] FIGS. 35 A-C show another example of the applied voltage waveforms of the eighteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0161] FIGS. 36 A-C show another example of the applied voltage waveforms of the eighteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0162] FIGS. 37 A-C show the applied voltage waveforms of a nineteenth embodiment of a driving method of the liquid crystal display according to the present invention;
[0163] FIGS. 38 A-C show the applied voltage waveforms of a twentieth embodiment of a driving method of the liquid crystal display according to the present invention;
[0164] FIGS. 39 A-C show another example of the applied voltage waveforms of the twentieth embodiment of a driving method of the liquid crystal display according to the present invention;
[0165] FIGS. 40 A-C show another example of the applied voltage waveforms of the twentieth embodiment of a driving method of the liquid crystal display according to the present invention;
[0166] FIGS. 41 A-C show the applied voltage waveforms of a twenty-first embodiment of a driving method of the liquid crystal display according to the present invention;
[0167] FIGS. 42 A-C show the applied voltage waveforms of a twenty-second embodiment of a driving method of the liquid crystal display according to the present invention;
[0168] FIGS. 43 A-E show the applied voltage waveforms of a conventional driving method of a liquid crystal display;
[0169] [0169]FIG. 44 illustrates a liquid crystal display panel;
[0170] FIGS. 45 A-D show the applied voltage waveforms of another conventional driving method of a liquid crystal display;
[0171] [0171]FIGS. 46A and 48B show the applied voltage waveforms of another conventional driving method of a liquid crystal display;
[0172] FIGS. 47 A, A′, B and C show the applied voltage waveforms of another conventional driving method of a liquid crystal display;
[0173] [0173]FIGS. 48A and 48B illustrates the row selection and column voltage waveforms that are applied to the row and column electrodes in accordance with the conventional driving method of FIGS. 47 A, A′, B and C; and
[0174] [0174]FIG. 49 illustrates a liquid crystal display panel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0175] Referring to FIGS. 4 - 6 , a preferred example of a liquid crystal panel driving circuit according to the present invention is illustrated. More specifically, FIG. 4 illustrates a preferred drive circuit, FIG. 5 illustrates a preferred row electrode driver circuit and FIG. 6 illustrates a preferred column electrode driver circuit. Of course, while the circuits of FIGS. 4 - 6 are preferred, persons of ordinary skill in the art who have read this description will recognize that various modifications and changes may be made therein. The driving circuit is for driving a liquid crystal display panel 1 , as shown in FIG. 49. In the preferred embodiment, the liquid crystal display panel comprises m column electrodes, Y 1 -Y m , and n row electrodes, X 1 -X n . The intersections of the m column electrodes and n row electrodes form n x m pixels. In the preferred embodiment the n row electrodes are arranged in j groups of row electrodes, and each of the j groups of row electrodes comprise i row electrodes. In accordance with the invention, each of the j groups of row electrodes are selected sequentially, and each of the i row electrodes within each group are simultaneously selected. A detailed explanation of the driving method is presented hereinbelow.
[0176] Turning to FIG. 4, reference numeral 1 denotes the row electrode driver and reference numeral 2 represents the column electrode driver. Details of the row and column electrode driver circuits will be explained hereinbelow and are shown in FIGS. 5 and 6, respectively. Reference numeral 3 represents the frame memory; reference numeral 4 represents an arithmetic operations circuit; reference numeral 5 represents a row electrode data generation circuit; reference numeral 30 represents a clock circuit; reference numeral 6 represents a first latch and reference numeral 31 represents a second latch circuit.
[0177] [0177]FIG. 5 illustrates a block diagram of the row electrode driver 1 . In this drawing, reference numeral 11 is a first shift register; reference numeral 12 is a third latch circuit; reference numeral 13 is a first decoder circuit; reference numeral 14 is a first level shifter; and reference numeral 15 are first analog switches.
[0178] [0178]FIG. 6 is a block diagram of the column electrode driver 2 . In this drawing, reference numeral 21 is a second shift register; reference numeral 22 is a fourth latch circuit; reference 23 is a second decoder; reference numeral 24 is a second level shifter; and reference numeral 25 are second analog switches.
[0179] The operation of the liquid crystal display panel will now be described with respect to FIGS. 4 - 6 . Initially, a clock circuit 30 provides appropriate timing signals to row electrode generator 5 , signal S 10 , to row driver 1 , signal S 5 , to column driver 2 , signal S 7 , and to second latch circuit 31 , signal S 11 .
[0180] Row electrode generator 5 generates a row-select pattern S 3 for sequentially selecting a group of row electrodes and for simultaneously selecting the row electrodes within each group to row driver 1 . As shown in FIG. 5, the row select pattern is transferred to the first shift register 11 in accordance with clock signal S 3 . After the data for each row electrode in one scanning period has been transferred to the first shift register 11 , each data is latched in the third latch circuit 12 by latch signal S 6 from the second latch circuit 31 . The data is then decoded by decoder 13 and the appropriate voltage level is selected by the first level shifter 14 and the first analog switches 15 . The voltages selected are from among −V 1 , 0 and V 1 . More specifically, when a positive level has been selected, V 1 volts is supplied to the selected row electrodes and when a negative level has been selected, −V 1 volts is supplied to the selected row electrodes. During the unselected period, a voltage of zero is supplied to row electrodes. The selected voltages are applied to the row electrodes in accordance with the methods described below.
[0181] Image data generated by, for example, a CPU (not shown) is stored in frame memory 3 . A display data signal S 1 , which corresponds to each of the row electrodes selected simultaneously, is read from memory 3 for providing each column voltage waveform. As shown in FIG. 4, the row-select pattern signal S 3 is latched by the first latch circuit 6 . The display data signal S 1 and the latched row-select pattern data signal S 4 are converted by arithmetic operations circuit 4 . Data conversion by arithmetic operations circuit 4 is performed in accordance with, for example, embodiments one to twenty-two described hereinbelow. The converted data S 2 is then transferred to column electrode driver 2 .
[0182] As shown in FIG. 6, data signal S 2 from arithmetic operations circuit 4 is transferred to the second shift register 21 in accordance with shift clock signal S 7 . After each row electrode data during one scanning period has been transferred, each data will be latched by fourth latch circuit 22 in accordance with latch signal S 8 . The data is then decoded by the second decoder circuit 23 . An appropriate voltage level is selected by the second level shifter 24 and second analog switches 25 . In other words one of eight voltage levels is selected by analog switches 25 , e.g. V Y4 , V Y3 , V Y2 V Y1 , −V Y1 , −V Y2 ,−V Y3 , AND −V Y4 Timing diagrams of the aforementioned signals are shown in FIG. 4A.
[0183] First Embodiment
[0184] FIGS. 1 A, A′, B and C illustrate a driving method for a liquid crystal display panel according to a first embodiment of the present invention. In this embodiment the selection signal is divided into plural portions during each frame period.
[0185] Referring specifically to FIG. 1A, voltage waveforms applied simultaneously to row electrodes X 1 , X 2 , and X 3 , i.e. during periods t 1 , t 2 , t 3 and t 4 in frame period F are shown therein. During the other times during frame period F, a voltage of zero is applied to those electrodes. Similarly, waveforms applied simultaneously to row electrodes X 4 , X 5 , and X 6 , i.e. during periods t 1 ′, t 2 ′, t 3 ′, and t 4 ′ in frame period F are shown in FIG. 1A′, and a voltage of zero is applied to those electrodes during the remaining times of frame period F. FIG. 1B depicts the voltage waveform applied to column electrode Y 1 . A detailed explanation of the determination of the column electrode waveform is presented hereinbelow. FIG. 1C illustrates the synthesized voltage at the pixel formed at the intersection of row electrode X 1 and column electrode Y 1 .
[0186] In the preferred embodiment, therefore, the voltage waveforms applied to the row electrodes are set as described below so that the pulse width is wider, so as to overcome the problems associated with conventional driving methods.
[0187] The voltage waveforms applied to the row electrodes are decided based on the conditions that:
[0188] (1) each row electrode must be identifiable,
[0189] (2) the frequency components applied to the row electrodes must not differ significantly, and
[0190] (3) the AC characteristic must be maintained for one or plural frames.
[0191] In other words, the pattern of the applied voltage is appropriately determined from a natural binary, Walsh, Hadamard, or other systems of orthogonal functions considering the above conditions.
[0192] Of these conditions, the first is absolute. To satisfy this condition the voltage waveforms applied to each row electrode are generated so that the voltage waveforms applied to each of the row electrodes are orthogonal to each other.
[0193] The applied voltage waveforms shown in FIGS. 3A and B were determined considering the above conditions. The applied voltage waveforms in FIG. 3A contain different frequency components-where
X 1 4 · Δt o X 2 4 · Δt o , 2 · Δt o X 3 2 · Δt o .
[0194] The applied voltage waveforms in FIG. 3B contain three different frequency components where
X 1 4 · Δt o , 2 · Δt o X 2 4 · Δt o , 2 · Δt o X 3 6 · Δt o , 2 · Δt o .
[0195] While the shortest pulse width in the waveforms shown in FIG. 46A and B is Δt o , the narrowest pulse width in the waveforms in FIG. 3A and B is 2Δt o , an increase of two times. It is thus possible to reduce the effects of waveform rounding, decrease crosstalk, and increase the number of simultaneously selected row electrodes by increasing the pulse width.
[0196] It is to be noted that the waveforms shown in FIG. 3A and B are but one example and can be changed as appropriate. In particular, the row electrode selection sequence and sequence of the row select patterns applied to the row electrodes can also be changed using the properties of the systems of orthogonal functions.
[0197] The row voltage waveform shown in FIG. 1A and A′ form the voltage waveforms applied to the three simultaneously selected row electrodes based on the waveforms in FIG. 3B. In addition, in this embodiment, the selection period is divided and driven in four portions i.e., t 1 , t 2 , t 3 , and t 4 in one frame period F. In other words, the first portion is applied sequentially to each group of the row electrodes and simultaneously to each electrode within each group, the second portion is applied sequentially to each group of the row electrodes and simultaneously to each electrode within each group, the third portion is then applied sequentially to each group of the row electrodes and simultaneously to each electrode within each group and, finally, the fourth portion is applied sequentially to each group of the row electrodes and simultaneously to each electrode within each group. The application of the four portions of the waveforms to all the row electrodes is conducted during one frame period.
[0198] More specifically, the first group of row electrode comprising row electrodes X 1 , X 2 , X 3 are simultaneously selected in period t1. Row selection voltage waveforms in that time interval similar to those in FIG. 23A are applied in time interval t 1 . At the same time, a column voltage waveform selected in accordance with the method described above is applied to each column electrode, Y 1 to Y m . In the present embodiment, row electrodes X 4 , X 5 and X 6 are then selected with the row selection voltage waveforms shown in FIG. 1A′. At the same time column voltages are applied in the same manner to each column electrode, Y 1 to Y m . This process is repeated until all of the row electrodes have been selected.
[0199] As is readily apparent, all of the row electrodes are selected four times in one frame period F. That is, an image or one screen is displayed when each row electrode is selected four times.
[0200] Each of the selection periods t 1 , t 2 , t 3 , t 4 as described above is further divided into plural portions as shown in FIG. 1C, and in each of these divided periods weighted voltage data is applied to the column electrodes Y 1 −Y m to obtain a desired display having a gray scale.
[0201] In other words, in this embodiment, period t 1 is divided into two equal parts to form the two periods ta and tb, a column voltage specifically weighted for each bit based on the display data shown in FIG. 2 and expressing a four gray scale display with two bits in a binary format is applied during period a for the high or most significant bit and to period b for the low or least significant bit as shown in FIG. 1C.
[0202] The column voltage waveforms are determined in a similar manner as discussed above. Specifically, if voltage V X1 is applied to the row electrode in each ON state, −V X1 is applied in each OFF state, and the display data value is 0 when OFF and 1 when ON, and the ON/OFF states of the simultaneously selected row electrodes and the ON/OFF state of the display data are compared bit by bit to calculate the number of mismatches. The voltages applied for the high or most significant bit when the number of mismatches is 3, 2, 1, and 0 are V Y4 , V Y2 , −V Y2 , and −V Y4 , the voltages applied for the low or the least significant bit when the number of mismatches is 3, 2, 1, and 0 are V Y3 , V Y1 , −V Y1 , and −V Y3 , respectively. In other words a weighted voltage is applied to the column electrodes. In the presently preferred embodiment the relationship between each of the voltage levels are:
[0203] 2*V Y1 =V Y2
[0204] 2*V Y3 =V Y4
[0205] 2*V Y1 =V Y3 −V Y1
[0206] 2*V Y2 =V Y4 −V Y2.
[0207] For example, during period t 1 in FIG. 1A, the selected pulses applied to row electrodes X 1 , X 2 , and X 3 are ON, ON, OFF, respectively, the display data for the pixels at the intersections of column electrode Y 1 and row electrodes X 1 , X 2 , and X 3 are (00), (01), (10). In particular, the high or most significant bits are OFF, OFF, ON, respectively, the number of mismatches is three, and voltage V Y4 is therefore applied to the column electrode Y 1 in period ta. The low or least significant bits are OFF, ON, OFF, respectively, and the number of mismatches is one. Therefore a voltage of −V Y1 is therefore applied in period tb.
[0208] Thus, the display data on the row electrodes X 1 , X 2 , and X 3 are compared with the selected pulses applied to the row electrodes for each of the column electrodes Y1-Y m , and a column voltage corresponding to the number of mismatches is applied.
[0209] Next, row electrodes X 4 , X 5 , and X 6 are simultaneously selected and the corresponding column electrode waveform is applied to the column electrodes. When the sequence of simultaneously selecting the row electrodes three lines at a time and applying the corresponding column electrode waveform to the column electrodes until all row electrodes X 1 -X n have been scanned is completed, the operation returns to the first group of row electrodes X 1 , X 2 , and X 3 and the specified voltages are sequentially applied following the above sequence in periods t 2 , t 3 , and t 4 . When all row electrodes X 1 -X n have been selected in each of the four periods t 1 -t 4 , the row electrodes are selected in succeeding frames in a similar manner. Note that the polarity of the applied voltage is reversed in each frame in this embodiment for so-called alternating current drive scheme.
[0210] A good gray scale display with minimal crosstalk can thus be achieved by driving as described above.
[0211] It is to be noted that the sequence of the row voltage waveforms applied to the row electrodes in the above periods t 1 -t 4 can be changed for all frames or in single frames, and the waveforms shown in FIG. 3A or other waveforms satisfying the conditions described above can be used as the row voltage waveforms applied to the row electrodes. Moreover, two waveforms can alternately be used for each group of simultaneously selected row electrodes, for example using the waveform shown in FIG. 3A for row electrodes X 1 -X 3 and the waveform shown in FIG. 3B for row electrodes X 4 -X 6 , or a sequence of three or more waveforms can be used alternately. In addition, it is also possible to combine reordering the waveforms in periods t 1 -t 4 with reordering the waveforms for the groups of simultaneously selected row electrodes.
[0212] While the periods t 1 -t 4 can be driven separately in each period as in the above embodiment, or can be driven consecutively in one frame, if the selection period is driven in plural parts within one frame as in the present embodiment, the unselected selection period becomes shorter and contrast can be improved. In this case, while the selection period is divided into four parts t 1 -t 4 in the above embodiment, any number of divisions can be used. For example, periods t 1 -t 4 can be divided and driven in two parts, or can be divided and driven in more than two parts.
[0213] In addition, row electrodes are selected three at a time in sequence of position in the above embodiment, but the number of the selected row elements is an appropriate number and the row electrode do not necessarily need to be selected in sequence of position.
[0214] The above changes can also be applied to the alternative embodiments described below.
[0215] As understood by one of ordinary skill in the art, the method for driving a liquid crystal display panel can be implemented by the circuit illustrated in FIGS. 4 - 6 previously described.
[0216] Second Embodiment
[0217] As described above in the first embodiment, one of four voltage levels is selected according to the display data and applied to the column electrodes for each bit of the display data. However, the number of levels can be reduced by implementing the following method. By reducing the number of voltage levels, a driving circuit can be fabricated which is simpler, less expensive and more reliable.
[0218] Initially, a description will be given based on the general methods of reducing the number of previously mentioned voltage levels.
[0219] In this embodiment, subgroup h comprises a virtual line e. Line e is a virtual electrode and its sole purpose is for determining the voltage levels applied to the column electrodes. There is no requirement that the virtual electrode is to be fabricated on the liquid crystal display panel. However the virtual electrode may be fabricated in a non-display area of the display panel.
[0220] The number of voltage levels may be reduced by controlling the number of matches and mismatches of the virtual row electrode data. As a result, the total number of matches and number of mismatches will be limited, and the number of drive voltage levels for column electrodes will be reduced.
[0221] With Mi representing the number of mismatches and Vc representing the appropriate constant, V column , the applied voltage to the column electrode, is as follows:
V column = V c ∑ j = 1 h a k * h + j ⊕ d k * h + j = V c ( 2 M i - h ) ( V c : c o n s t a nt )
[0222] or, more simply:
[0223] V column =V(i)(0·i·h)
[0224] In either case, V column is the h+1 level.
[0225] Referring to FIGS. 7 A, A′, B and C, a driving method in accordance with the second embodiment is shown therein having voltage waveforms applied to the column electrodes and the row electrodes. As shown in FIG. 8, the row electrodes include virtual electrodes X n+1 , X n+2 , . . . X n+p . At least one virtual electrode is simultaneously selected along with, for example, row electrodes X 1 , X 2 , and X 3 . The number of mismatches is calculated as in the first embodiment described above. As in the first embodiment voltage V X1 is applied to the row electrode in each ON state, −V X1 is applied in each OFF state, and the display data value is 0 when OFF and 1 when ON. Assuming in this embodiment, the number of mismatches is always 1 or 3 which is accomplished by appropriately changing the display state of the virtual electrode.
[0226] In the second embodiment, when the number of mismatches between the display data and the high or most significant bit is 1, −V Y2 is selected, and when the number of mismatches is 3, V Y2 is selected; when the number of mismatches between the display data and the low or least significant bit is 1, −V Y1 selected, and when the number of mismatches is 3, V Y1 is selected. It is preferable that the relationship between each of the voltage levels is 2·V Y1 =V Y2 .
[0227] The display shown in FIG. 8 is achieved by the waveforms in FIGS. 7 A, A′, B and C applying the above principle. Referring specifically to FIG. 7A, during period t 1 , the selected pulses applied to row electrodes X 1 , X 2 , X 3 and virtual electrode X n+1 are ON, ON, OFF, ON, respectively, and as shown in FIG. 8, the display data for the pixels at the intersections of column electrode Y 1 and row electrodes X 1 , X 2 , X 3 and virtual electrode X n+1 are (00), (01), (10), (11). In other words the high bits are OFF, OFF, ON, ON, and the low bits are OFF, ON, OFF, and ON, respectively. Sequential comparison shows the number of mismatches is three; conversion data S 2 is therefore generated according to this number of mismatches, and voltage V Y2 is therefore applied to the column electrode Y 1 in period a.
[0228] As noted above, the low bits are OFF, ON, OFF, ON, and the number of mismatches determined is one. Accordingly, conversion data S 2 is therefore generated according to this number of mismatches, and voltage −V Y1 is therefore applied in period b.
[0229] Thus, the display data on the row electrodes X 1 , X 2 , X 3 and virtual electrode X n+1 is compared with the selected pulses applied to the row electrodes for each of the column electrodes Y1-Y m , and a column voltage corresponding to the number of mismatches is applied.
[0230] Next, row electrodes X 4 , X 5 , X 6 and X n+2 are simultaneously selected and the corresponding column electrode waveform is applied to the column electrodes. The column voltage waveform is determined in a similar manner. When the sequence of simultaneously selecting the row electrodes three lines at a time plus one virtual electrode line and applying the corresponding column electrode waveform to the column electrodes until all row electrodes to X n have been scanned is completed, the operation returns to the first group of row electrodes X 1 , X 2 , and X 3 and sequential scanning using the row select pattern shown in t 2 continues. One frame period is completed by scanning four times with the row select patterns shown in t 1 , t 2 , t 3 , and t 4 , and the same operation is repeated in the next frame.
[0231] By thus providing a virtual electrode as above, the number of voltage levels applied to the column electrodes can be made less than that of the first embodiment.
[0232] It will be apparent to one of ordinary skill in the art, that the technique of reducing the number of voltage levels applied to the column electrodes by means of a virtual electrode, as described above, can also be applied to each of the embodiments described below.
[0233] Moreover, it will appreciated that the same driving circuit used in the first embodiment may be used in the second embodiment and each of the embodiments described below. In the second embodiment, the arithmetic operation circuit 4 in FIG. 4 is designed to execute data processing to drive the liquid crystal display panel in accordance with each of the embodiments. The voltage levels of the row electrode driver in FIG. 5 are selected by analog switch 15 , and the voltage levels of the column electrode driver in FIG. 6 are selected by analog switch 25 .
[0234] In this embodiment, for example, the arithmetic operation circuit 4 in FIG. 4 and the row electrode driver in FIG. 5 are the same as those of the first embodiment, but while eight voltage levels V Y4 , V Y3 , V Y2 , V Y1 , −V Y1 , −V Y2 , −V Y3 , and −V Y4 are provided in the column electrode driver of the first embodiment in FIG. 6, it is sufficient to provide four voltage levels V Y2 , V Y1 , −V Y1 , and −V Y2 in the second embodiment. Accordingly since four fewer voltage levels are required, the driving circuit is simpler, less expensive and more reliable.
[0235] Third Embodiment
[0236] The first and second embodiments, described above, achieve a gray scale display by changing the voltage value or applying a weighted voltage in accordance with the display data. It is also contemplated to achieve a gray scale display by varying the pulse width of either the voltage applied to the column or row electrodes. The technique of varying the pulse width is known as pulse width modulation.
[0237] Referring specifically to FIGS. 9 A, A′, B and C, the third embodiment is shown therein employing a pulse width modulation technique for achieving a gray scale display.
[0238] The general procedure for achieving a gray scale display by means of pulse width modulation is now described with reference to FIG. 10.
[0239] In general, the period Δt of each pulse is divided into f periods of preferably unequal duration to achieve a gray scale display by means of pulse width modulation.
[0240] Δtg=2 g−1 /(2 f −1)
[0241] where f is the bit number of gradations.
[0242] For example, if f=2, there are 2 2 =4 gradations, and the period is divided:
[0243] Δt 1 =(⅓)Δt o
[0244] Δt 2 =(⅔)Δt o
[0245] as shown in FIG. 10.
[0246] The data is then divided into f bits (expressed as f bits).
[0247] d 1 =(d 1,f , d 1,f−1 . . . d 1,1 )
[0248] d 2 =(d 2,f , d 2,f−1 . . . d 2,1 )
[0249] d h =(d h,f , d h,f−1 . . . d h,1 )
[0250] Each bit of the row electrode selection patterns and the data patterns are then compared at an interval of Δtg.
[0251] For example, when f=2,
[0252] d 1 =(d 1,2 , d 1,1 )
[0253] d 2 =(d 2,2 , d 2,1 )
[0254] The low or least significant bit (d 1,1 ) of di and the row electrode selection pattern are first compared, and applied to the display for period Δt 1 in a similar manner described hereinabove. The high or most significant bit, for example, bit d 1,2 and the row electrode selection pattern is then compared and applied to the display for period Δt 2.
[0255] As is apparent to those who have read this description, this procedure is sequentially repeated as above for each bit d.
[0256] The embodiment illustrated in FIGS. 9 A, A′, B and C achieves a four gray scale display of the data shown in FIG. 2 using the pulse width modulation technique as described above.
[0257] In this example, the row voltage applied to the row electrodes X 1 -X n is the same as in the example illustrated in FIG. 45, and the pulse widths of the corresponding column electrodes Y 1 -Y m are modulated according to the gray scale display as above.
[0258] More specifically, the display data has a gray scale defined by four gradations 0-3 using a 2-bit binary display data, e.g. (00), (01), (10), (11). Accordingly, each pulse width Δt is divided into three equal parts, e.g. Δt 1 , Δt 21 and Δt 22 . Furthermore, as shown in FIG. 10, applicants define Δt 2 =Δt 21 +Δt 22 . The column voltage level of two of the three pulse width parts is determined based on the number of mismatches between the on/off state of the simultaneously selected row electrodes and the high bit state of the display data. The signal voltage level of the remaining one part is determined based on the number of mismatches between the ON/OFF state of the row electrodes and the low bit state. Variations in the brightness of the gray scale display can also be corrected by equally reducing the three parts.
[0259] Specifically, if in FIGS. 9 A, A′, B and C an ON state is achieved by applying voltage V X1 to the row electrode and an OFF state by applying voltage −V X1 , the first pulse applied to the row electrodes X 1 , X 2 , and X 3 generates an OFF state for all three row electrodes. Because a low bit value of 0 indicates an OFF state and a low bit value of 1 an ON state in the display data for the row electrodes X 1 , X 2 , and X 3 in FIG. 2, the corresponding states are OFF, ON, OFF. The number of mismatches is therefore one, and the voltage pulse during period Δt 1 is −V Y1 . In this example, the high bit states are OFF, OFF, ON, and, accordingly, the number of mismatches is one, and the voltage pulse during period Δt 2 is −V Y1 . It is thus sufficient to obtain the voltage pulse applied to the column electrodes by a comparison executed each selection period Δt.
[0260] In this embodiment, the voltage for the high bit is applied during the latter two of the three period divisions, and the voltage for the low bit is applied during the first of the three period divisions.
[0261] Fourth Embodiment
[0262] FIGS. 11 A, A′, B and C depict the fourth embodiment of the present invention. The fourth embodiment is similar to the third embodiment, in that width of the column voltage is varied to obtain a gray scale. Another feature of the fourth embodiment is that the selection period is divided into plural portions within each frame period. This feature is similar to the first embodiment described above. While it will be understood, that in this embodiment the selection period is preferably divided into eight portions, for a matter of convenience, only five portions are illustrated in FIGS. 11 A, A′, B and C.
[0263] Referring specifically to FIG. 11A, voltage waveforms applied simultaneously to row electrodes X 1 , X 2 , and X 3 , i.e. during periods t 1 -t 8 (period t 5 -t 8 are not shown) in frame period F are shown therein. During the other times during frame period F, a voltage of zero is applied to those electrodes. Similarly, waveforms applied simultaneously to row electrodes X 4 , X 5 , and X 6 , i.e. during periods t 1 ′-t 8 ′, t 3 ′ and t 4 ′ in frame period F are shown in FIG. 11A′, and a voltage of zero is applied to those electrodes during the remaining times of frame period F. FIG. 11B depicts the voltage waveform applied to column electrode Y 1 . A detailed explanation of the determination of column electrode waveform is presented hereinbelow. FIG. 11C illustrates the synthesized voltage at the pixel formed at the intersection of row electrode X 1 and column electrode Y 1 .
[0264] The column voltages are determined similarly as in the third embodiment. As noted above, the display data has a gray scale defined by four gradations 0-3 using a 2-bit binary display data, e.g. (00), (01), (10), (11). Accordingly, each pulse width Δt is divided into three equal parts, e.g. Δt 1 , Δt 21 and Δt 22 . Furthermore and as shown in FIG. 10, applicants define Δt 2 =Δt 21 +Δt 22 . The column voltage level of two of the three pulse width parts is determined based on the number of mismatches between the on/off state of the simultaneously selected row electrodes and the high bit state of the display data. The signal voltage level of the remaining one part is determined based on the number of mismatches between the ON/OFF state of the row electrodes and the low bit state. Variations in the brightness of the gray scale display can also be corrected by equally reducing the three parts.
[0265] Specifically, if in FIGS. 11 A, A′, B and C an ON state is achieved by applying voltage V X1 to the row electrode and an OFF state by applying voltage −V X1 , the first pulse applied to the row electrodes X 1 , X 2 , and X 3 in period t 1 generates an OFF state for all three row electrodes. Because a low bit value of 0 indicates an OFF state and a low bit value of 1 an ON state in the display data for the row electrodes X 1 , X 2 , and X 3 in FIG. 2, the corresponding states are OFF, ON, OFF. The number of mismatches is therefore one, and the voltage pulse during period t 1 is −V Y1 . In this example, the high bit states are OFF, OFF, ON, and, accordingly, the number of mismatches is one, and the voltage pulse during period t 2 is −V Y1 . It is thus sufficient to obtain the voltage pulse applied to the column electrodes by a comparison executed each selection period t.
[0266] In accordance with the fourth embodiment, when the liquid crystal elements are driven by dividing the selection period into plural parts in one frame as described above, the contrast can be improved as in the previous embodiment.
[0267] Fifth Embodiment
[0268] FIGS. 12 A, A′, B and C illustrate the fifth embodiment of the present invention. The fifth embodiment is similar to the third embodiment, e.g. the selection period is divided into plural portions and the width of the column voltage is varied to achieve a gray scale display. However, in the fifth embodiment at least one virtual electrode is employed to reduce the number of voltage levels. In the third and fourth embodiments, four voltage levels V Y2 , V Y1 , −V Y1 , and −V Y2 are used as the column electrode voltage levels, but this number of voltage levels can be further reduced by providing a virtual electrode as in the second embodiment.
[0269] [0269]FIG. 12A, A′, B and C show an example that provides a virtual electrode in the third embodiment to reduce the number of voltage levels applied to the column electrode, and is driven by dividing the selection period in to plural parts within one frame as in the fourth embodiment.
[0270] Reducing the number of voltage levels by providing a virtual electrode as described above has already been described in the second embodiment, but is described further below, including the general methodology.
[0271] First, of the h row electrodes in each subgroup, e column electrodes are operated as virtual row electrodes (virtual lines). By controlling the data matching/mismatching of these virtual row electrodes, the overall number of matches/mismatches can be controlled, and the number of drive voltage levels for the column electrodes can be reduced.
[0272] If the number of mismatches is Mi and Vc is an appropriate constant, the voltage V column applied to the column electrode is defined as
V column = V c ∑ j = 1 h a k * h + j ⊕ d k * h + j = V c ( 2 M i - h ) ( V c : c o n s t a nt )
[0273] or simply
[0274] V column =V(i)
[0275] where 0·i·h.
[0276] [0276]
[0277] In any event, V column is h+1 levels.
[0278] The case where the number of subgroups h=4 and the number of virtual row electrodes e=1 is considered by way of example below.
[0279] As in the previous embodiment, the number of levels when h=3 is four (−V Y2 , −V Y1 , V Y1 , V Y2 ). If the number of mismatches is controlled using the virtual row electrodes to be an even number, the resulting voltage levels are shown in the following table.
Original Original Number of voltage number of Virtual row mismatches Voltage level level mismatches electrode after correction after correction −V Y2 0 Match 0 Va −V Y1 1 Mismatch 2 Vb V Y1 2 Match 2 Vb V Y2 3 Mismatch 4 Vd
[0280] As shown in the above table, the original four voltage levels can be reduced to three. If the number of mismatches is controlled to be odd, the number of mismatches after correction will change in the above table to 1, 1, 3, 3 (from the top), and there will be only two voltage levels (Va, Va, Vb, Vb from the top) after correction.
[0281] If the number of subgroups h=4 and the number of unreduced voltage levels is therefore five (−V Y2 , −V Y1 , 0, V Y1 , V Y2 ), controlling the number of mismatches to be an even number using the virtual row electrodes results in the voltage levels shown in the following table.
Voltage Number of levels mismatches Number of before before mismatches Voltage level reduction reduction Virtual line after correction after correction −V Y2 0 Match 0 Va −V Y1 1 Mismatch 2 Vb 0 2 Match 2 Vb V Y1 3 Mismatch 4 Vd V Y2 4 Match 4 Vd
[0282] The original number of voltage levels can thus be reduced from five to three. Note that the voltage levels can also be set by controlling the number of mismatches to be odd.
[0283] It is not always necessary to provide these virtual row electrodes because they are not normally displayed. When they are provided, however, the virtual row electrodes can be provided in an area not affecting the display. When provided in a liquid crystal display, for example, the virtual row electrodes X n+1 . . . are provided outside the display area R as shown in FIG. 13. Alternatively, any extra row electrodes outside the normal display area R can also be used as virtual row electrodes.
[0284] The number of voltage levels can be further reduced by increasing the number e of virtual row electrodes. In the above example the number of mismatches is controlled to be divisible by two when e=1, but if e=2, the same result can be obtained by controlling the number of mismatches to be divisible by three. It is also possible to divide by three to leave a remainder of one or two.
[0285] The maximum reduction possible with the above method is 1/(e+1), or ½ when e=1 (except for 0 V).
[0286] The present embodiment as shown in FIGS. 12 A, A′, B and C simultaneously selects three row electrodes and one virtual electrode to reduce the number of voltage levels applied to the column electrodes, and drives by dividing the selection period into plural parts in one frame.
[0287] As shown in FIG. 12A, A′, B and C and FIG. 14, the fifth embodiment divides the selection period into four parts in one frame, and the number of mismatches with the display data is counted bit by bit for four row electrodes, including the virtual row electrode, in each of the four partial periods to adjust the number of mismatches to an odd number. The number of mismatches is thus either 1 or 3, and the voltage level of the column voltage waveform is therefore one of two levels, V Y1 or −V Y1 .
[0288] Considering the display shown in FIG. 13, the virtual row electrode X n+1 follows after the first three selected row electrodes X 1 , X 2 , and X 3 as shown in FIG. 8. Note that it is not essential for the virtual row electrode to be previously provided, but that when it is the virtual row electrode is preferably provided outside the display area R.
[0289] If a positive voltage applied to the row electrode is ON and a negative voltage is OFF, each of the selection periods Δt is divided into three parts, and the display data on the simultaneously selected row electrodes X 1 , X 2 , and X 3 is (00), (01), (10) as shown in FIG. 13, the data for the virtual row electrode is (11) as shown in FIG. 8.
[0290] The number of mismatches is then counted bit by bit to determine either voltage level V Y1 or −V Y1 , and the voltages for the high bits are applied for the latter two of the three period divisions and the voltage for the low bit is applied for the first one period division. Note that, as in the third embodiment, it is also possible to apply the voltage for the high bit in the first two period divisions and to apply the voltage for the low bit in the last one period division.
[0291] It is therefore sufficient to determine the pulse width of voltage V Y1 or −V Y1 by a per bit comparison with the display data, and the present embodiment can reduce the number of voltage levels applied to the column electrodes, specifically to two in the above embodiment, by always setting the number of mismatches between the display data and the row select pattern of the selected pulse applied to the virtual row electrode to 1, 3, or some other odd number. Note that an even number of mismatches can be alternatively used.
[0292] Note also that while the above embodiment has been described for a four gray scale display, a display with a larger number of gradations is also possible. For example, an eight gray scale display can be achieved by using 3-bit display data and dividing each selection period into three parts weighted to the pulse width of each display data bit. A display with 16 gradations can be achieved by using 4-bit display data and dividing each selection period into four parts weighted to the pulse width of each display data bit. Thus, a gray scale display is possible by changing the number of divisions each selection period is divided into.
[0293] Sixth Embodiment
[0294] The sixth embodiment is illustrated in FIGS. 14A and B in which the width of the column voltages are varied by pulse width modulation and at least one virtual electrode is employed to reduce the number of voltage levels, similar to the fifth embodiment. Additionally the row voltages similar to the first embodiment are applied to the row electrodes. The application of such voltages achieves a high quality gray scale display.
[0295] More specifically, the voltage waveforms applied to the simultaneously selected row electrodes are the same as that of the first embodiment shown in FIG. 1A as above, each of the selection periods t 1 -t 4 , t 5 -t 8 is divided into three parts, and when the display data of the simultaneously selected row electrodes X 1 , X 2 , and X 3 is (00), (01), (10) as shown in FIG. 13, it is sufficient for the data of the virtual electrode to be (11) as shown in FIG. 8.
[0296] The number of mismatches is then counted bit by bit to determine the voltage level, and either V Y1 or −V Y1 is applied as the voltage for the high or most significant bit in two of the three period divisions and the voltage for the low or least significant bit in one period division.
[0297] It is thus possible to obtain as high a quality of a gray scale display as the fifth embodiment.
[0298] It is to be noted that the selection periods t 1 -t 4 may be provided consecutively in one frame F, or separately in one frame F. The same is true of selection periods t 5 -t 8.
[0299] Seventh Embodiment
[0300] The seventh embodiment illustrated in FIGS. 15 A, A′, B and C is directed to a method referred to as frame rate control modulation. More specifically, a gray scale display based on frame rate control modulation turns some pixels ON during a first frame and a succeeding frame, some pixels OFF during both frames, some pixels ON during the first frame and OFF during the succeeding frame and some pixels OFF during the first frames and ON during the succeeding frame. Those pixels having their states changed from frame to frame exhibit gray scale characteristics. The gray scale display employing frame rate control modulation can be further enhanced by employing various other techniques described above, such as, the division of the selection period and the use of virtual electrodes to reduce the number of voltage levels.
[0301] The seventh embodiment is shown in FIGS. 15 A, A′, B and C whereby the number of voltage levels applied to the column electrodes is reduced using three sequential row electrodes and one virtual row electrode similarly to the sixth embodiment, and drives the display by dividing the selection period into plural parts within one frame, achieving a gray scale display by means of frame rate control modulation.
[0302] As will be understood by those of ordinary skill in the art, that while the waveform shown in FIG. 3B is used as the voltage waveform applied to the simultaneously selected row electrodes in this embodiment, the waveform shown in FIG. 3A or FIG. 48A or B may also be used.
[0303] A gray scale display based on frame rate control modulation turns some frames on and some frames off during any given frame period, and in the example shown in FIG. 16, a gradation between on and off is displayed by applying an ON voltage during F1 and an OFF voltage during F2. Of course, a gradation can be displayed by applying an OFF voltage during frame F1 and an ON voltage during frame F2.
[0304] In this embodiment, the brightness difference between F1 and F2 is also reduced and flicker becomes less noticeable because the fields are selected four times during one frame. For example, in a gray scale display using plural frame periods as one block, the position of the selection pulse can be changed within the plural frames, and the difference between frames can be reduced by interchanging periods t3 and t7, for example, in FIG. 15A.
[0305] As will be apparent, while a gray scale display can be achieved by turning one of two frames ON and one frame OFF in the above embodiment, more frames, for example 7 frames, can be grouped in one block to achieve an 8 gray scale display by changing the number of ON and OFF frames within the block, or 15 frames can be grouped in one block to achieve a 16. Thus, a display with the desired number of gradations is possible depending on the number of frames of one block.
[0306] Eighth Embodiment
[0307] The eighth embodiment is shown in FIGS. 17A and B. The eighth embodiment achieves a gray scale display by means of frame rate control modulation, dividing the selection period into plural portions, reducing the number of applied voltage levels and by varying the column pulse width by pulse width modulation. FIG. 13 shows an embodiment whereby the number of voltage levels applied to the column electrodes is reduced using three sequential row electrodes and one virtual row electrode similar to the fifth embodiment and dividing the selection period into plural parts within one frame for achieving a gray scale display by means of frame rate control modulation as noted above.
[0308] The eighth embodiment achieves a finer gray scale display by displaying plural gradations during plural frame periods. Thus, gradations between the gradations of the plural frames can be displayed.
[0309] More specifically, by displaying (00) during the first frame F1 period and during the next frame F2 period as shown in FIG. 18, a gradation actually between (00) and (01) can be displayed.
[0310] As will be apparent, display flicker can be reduced and a multiple gray scale display can be achieved by thus dividing the selection period and reducing the number of applied voltage levels, and combining pulse width modulation with frame rate control modulation for the gray scale display. Of course, the order of the selection pulses can be changed as in the sixth embodiment above.
[0311] While the fifth to eighth embodiments above have been described assuming the use of a virtual row electrode, it will be apparent to those who have read this description that a gray scale display can still be achieved by means of frame rate control modulation or by a combination of frame rate control modulation and pulse width modulation even when a virtual row electrode is not provided.
[0312] Ninth Embodiment
[0313] Each of the above embodiments have been described as achieving a four gray scale display by applying a column voltage weighted according to each bit of 2-bit display data, but it is possible to drive other numbers of gradations. For example, an eight gray scale display can be obtained using a column electrode waveform in accordance with the ninth embodiment depicted in FIG. 19.
[0314] Referring to FIG. 19, the column electrode waveform is shown therein when the display data for the pixels at the intersection of the row electrodes X 1 , X 2 , and X 3 and column electrode Y 1 are (001), (010), (100). The row electrode waveforms applied to each of the row electrodes are the same as that of the first embodiment as shown in FIG. 2.
[0315] In this embodiment, the four selection periods t 1 -t 4 in the first embodiment are each divided into three equal periods a, b, c, and the voltage waveform corresponding to the highest of the three display data bits is applied in the first period division a, the voltage waveform corresponding to the middle bit is applied in the next period division b, and the voltage waveform corresponding to the lowest bit is applied in the last period division c; each of these voltage waveforms is weighted according to each of the display data bits as in the first embodiment.
[0316] Specifically, one of the voltages −V Y6 , −V Y4 , V Y4 , or V Y6 is selected for period a according to the highest display data bit, one of the voltages −V Y5 , −V Y2 , V Y2 , or V Y5 is selected for period b according to the middle display data bit, and one of the voltages −V Y3 , −V Y1 , V Y3 , or V Y1 is selected for period c according to the lowest display data bit. The relationship between each of the voltage levels is defined as
[0317] 4*V Y1 =2*V Y2 =V Y4
[0318] 4*V Y3 =2*V Y5 =V Y6
[0319] 2*V Y1 =V Y3 −V Y1
[0320] 2*V Y2 =V Y5 −V Y2
[0321] 2*V Y4 =V Y6 −V Y4.
[0322] Under these conditions, an eight gray scale display can be achieved as in the first embodiment by generating the column electrode waveform based on the number of mismatches in each bit of the display data.
[0323] As described above, a four gray scale display is obtained in the first embodiment by selecting a voltage for each of the two equal periods into which the selection period is divided, and applying this voltage to the column electrode, but in the present embodiment an eight gray scale display is obtained by dividing the selection period into three equal parts. In addition, a sixteen gray scale display can be obtained by dividing the selection period into four equal parts, and as this indicates, the number of gradations can be increased by appropriately dividing the selection period into plural parts and applying a voltage selected for each of these parts to the column electrode. The brightness level of each gradation can also be adjusted by changing the voltage ratio applied to each column electrode, or by slightly changing the duration of each part into which the selection period is divided instead of using equal parts.
[0324] Tenth Embodiment
[0325] In a gray scale display obtained by changing the voltages applied to the column electrodes as shown in FIG. 19 of the ninth embodiment above, a voltage is applied according to each bit in sequence from the high bit in the periods a, b, c, divided according to the number of display data bits, but this sequence can be appropriately changed for each column electrode.
[0326] If, for example, in the ninth embodiment above the display of the pixels at the intersections of row electrodes X 1 , X 2 , and X 3 and column electrodes Y 2 -Y m are the same as the display of the pixels at the intersections of row electrodes X 1 , X 2 , and X 3 and column electrode Y 1 , the column voltage waveforms applied to the column electrodes Y 1 -Y m will all be identical to the waveforms shown in FIG. 19. However, rounding of the waveform applied to each pixel becomes great in this case, and display quality deteriorates.
[0327] The order of the column electrode waveforms applied to each of the column electrodes Y 1 -Y m is thus changed in this embodiment as shown in FIG. 20.
[0328] In other words, in the ninth embodiment the voltage corresponding to the highest of the three display data bits is applied in sequence to column electrode Y 1 during period a in FIG. 20, the voltage corresponding to the middle bit during period b, and the voltage corresponding to the lowest bit during period c. The same is true of the other column electrodes Y 1 -Y m .
[0329] In the tenth embodiment as shown in FIG. 20, however, if the period in which the voltage corresponding to the highest bit is applied is a, the period in which the voltage corresponding to the middle bit is applied is b, and the period in which the voltage corresponding to the lowest bit is applied is c, and the voltages are applied to column electrode Y 1 in the order (a, b, c) in sequence from the highest bit as in the second embodiment, the order is changed for the next column electrode, for example to (a, c, b) for column electrode Y 2 , (b, a, c) for column electrode Y 3 , (b, c, a) for column electrode Y 4 , (c, a, b) for column electrode Y 5 , and (c, b, a) for column electrode Y 6 , and similar combinations are repeated for Y 7 -Y m .
[0330] If this method is applied, the effects of rounding rises and falls of column electrode waveform cancel each other out, and rounding of the waveforms applied to each pixel can be reduced because waveforms in six different order combinations are applied in essentially the same number to the column electrodes,
[0331] It is appreciated that any combination of waveforms applied to the column electrodes can be used such that, for example, if there are six column electrode drivers, each combination of waveforms is applied to each column electrode driver. Thus, display quality can be improved if the number of rounding rises and falls cancel each other in the combination of waveforms applied to the respective column electrodes.
[0332] Furthermore, changing the order of the voltages corresponding to each bit of display data for each of the column electrodes Y 1 -Y m as described above can also be applied to the various embodiments described hereinbefore and below.
[0333] Eleventh Embodiment
[0334] In the ninth embodiment an eight gray scale display is obtained using a waveform as shown in FIG. 1A, i.e., as shown in FIG. 3B, as the row voltage waveform applied to the row electrodes, but the waveform shown in FIG. 3A or in the FIG. 48A or B for the conventional method can also be used. The case wherein the waveform shown in FIG. 3A is used for an eight gray scale display is described in further detail below.
[0335] The waveforms applied in the eleventh embodiment as shown in FIGS. 21 A, A′, B and C achieve an eight gray scale display based on the display data shown in FIG. 22 and using the waveform shown in FIG. 3A as the row voltage waveform applied to the row electrodes. FIG. 21A shows the row voltage waveform applied to row electrodes X 1 , X 2 , and X 3 , FIG. 21B is the column voltage waveform applied to column electrode Y 1 , and FIG. 21C is the synthesized voltage waveform applied to the pixels at the intersection of row electrode X 1 and column electrode Y 1 .
[0336] In the eleventh embodiment three sequential row electrodes are also simultaneously selected are shown in FIG. 21A, and the next three row electrodes X 4 , X 5 , and X 6 are selected after row electrodes X 1 , X 2 , and X 3 are selected as shown in FIG. 21A′, and a voltage is applied to these electrodes similarly to row electrodes X 1 , X 2 , and X 3 . Thereafter, the row electrodes are selected in order three at a time, and one frame ends when all row electrodes have been selected.
[0337] By thus applying a row voltage waveform as shown in FIG. 3A to the three simultaneously selected row electrodes, the minimum pulse width Δt is twice the minimum pulse width Δt o of the conventional method shown in FIG. 48A as described above, and all selection periods t for each of the row electrodes in one frame comprise four periods t 1 -t 4 of the size of pulse width Δt.
[0338] The above four periods t 1 -t 4 are each divided into three periods a, b, c according to the number of bits of display data, and a column voltage specifically weighted according to the bits of the display data is applied to the column electrode in each of these period divisions.
[0339] Specifically, the high bit of the display data, which is expressed as a three digit binary number as shown in FIG. 22, corresponds to the first period division a of each period t 1 -t 4 , the middle bit corresponds to the next period division b, and the low bit corresponds to the last period division c, and the specifically weighted voltage ±V Y4 or ±V Y6 is applied according to the conditions described below for the high bit, ±V Y2 or ±V Y5 is applied for the middle bit, and ±V Y1 or ±V Y3 is applied for the low bit.
[0340] It is to be noted that the ratio of the above voltage values is defined as:
[0341] V Y1 : V Y2 : V Y4 =1:2:4
[0342] V Y3 : V Y5 : V Y6 =1:2:4
[0343] V Y1 : V Y3 =1:3.
[0344] As the conditions for the above, ON is when the voltage waveform of the row electrode is positive and OFF is when negative, and a display data value of 1 is ON and 0 is OFF; the on/off state of the simultaneously selected row electrodes and the on/off state of the corresponding display data bit at the intersection of the selected row electrode and the column electrode to which the voltage is to be applied are compared for each bit position, and a voltage specified according to the number of mismatches is applied to the column electrode.
[0345] Specifically, when the number of mismatches between the row electrode and the high bit is 0, 1, 2, or 3, a voltage value −V Y6 , −V Y4 , V Y4 , or V Y6 , respectively, is applied in this embodiment; when the number of mismatches between the row electrode and the middle bit is 0, 1, 2, or 3, a voltage value −V Y5 , −V Y2 , V Y2 , or V Y5 , respectively, is applied; and when the number of mismatches between the row electrode and the low bit is 0, 1, 2, or 3, a voltage value −V Y3 , −V Y1 , V Y1 , or V Y3 , respectively, is applied.
[0346] Therefore, in the eleventh embodiment in FIGS. 21 A, A′, B and C, the three row electrodes X 1 , X 2 , and X 3 are first selected, the selected row electrodes X 1 , X 2 , and X 3 are OFF, OFF, ON, respectively, and the high bits of the display data at the intersection of the column electrode Y 1 and these row electrodes X 1 , X 2 , and X 3 are OFF, ON, ON. Comparing both, the number of mismatches is 1, and the voltage −V Y4 is applied to column electrode Y 1 in the first period division a of the first period t 1 . A weighted voltage is simultaneously applied to the other column electrodes Y 2 -Y m in the same manner.
[0347] Next, during the next period division b of the first period t 1 , the on/off state of row electrodes X 1 , X 2 , and X 3 is the same OFF, OFF, ON, and the middle bits corresponding to this period division b are, in order, ON, OFF, OFF; the number of mismatches is therefore 2, and voltage V Y2 is applied. The low bits corresponding to the last period division c are OFF, ON, OFF; the number of mismatches is therefore 2, and voltage V Y1 is applied.
[0348] During the next period t 2 , the voltages −V Y4 , V Y2 , and −V Y3 , respectively, are applied to the column electrode Y 1 during period divisions a, b, c because the on/off states of row electrodes X 1 , X 2 , and X 3 are OFF, ON, OFF, the high bits of the display data at the intersection of the column electrode Y 1 and these row electrodes X 1 , X 2 , and X 3 are OFF, ON, ON, respectively, and the number of mismatches is 1. As described above, the middle bits are ON, OFF, OFF and the number of mismatches is 2, and the low bits are OFF, ON, OFF and the number of mismatches is 0.
[0349] The above sequence is also followed in the next periods t 3 and t 4 so that a column voltage corresponding to the number of mismatches is simultaneously applied to all column electrodes Y 1 -Y m and selection of row electrodes X 1 , X 2 , and X 3 ends, the next row electrodes X 4 , X 5 , and X 6 are selected and a specified column voltage is applied in the same manner to column electrodes Y 1 -Y m , and one frame F ends when all row electrodes have been selected. Thereafter, the first row electrodes X 1 , X 2 , and X 3 are again selected in sequence and the next frame is started. The polarity of the voltage applied to the row electrodes at this time is reversed or inverted, and the polarity of the voltage applied to the column electrodes is accordingly reversed, to execute a so-called alternating current drive scheme.
[0350] As will be appreciated by one of ordinary skill in the art, it is not essential for the above voltage ratio to conform strictly to the above conditions, and it is not necessary for the periods t 1 -t 4 and the divided periods a, b, c to be strictly divided into equal parts, and can, for example, be adjusted according to the characteristics of the liquid crystals. In addition, the sequence of the divided periods a, b, c can be changed. Furthermore, display of a various number of gradations is possible by means of the same principle described above; for example, to achieve a 16 gray scale display, it is sufficient to apply voltages weighted according to each bit of display data expressed using four bits. This is also true of the other embodiments described below.
[0351] Twelfth Embodiment
[0352] The twelfth embodiment is depicted in FIGS. 23 A, A′, B and C. FIGS. 24 A-C and 25 A-C illustrate other examples of the twelfth embodiment. Referring to FIGS. 23 A, the twelfth embodiment provides a driving method similar to the eleventh, e.g. a single selection period t is provided for the row electrodes in one frame F, additionally the selection period is divided into plural parts in one frame F.
[0353] As shown in FIG. 23A, one field is defined as the period required for all row electrodes to be selected in each of the periods t 1 -t 4 , and these four fields are preferably repeated in one frame period F. Moreover these periods can be further divided and the sequence repeated for all of the row electrodes for each display data bit, as shown in FIGS. 24 A-C, FIGS. 25 A-C, and FIG. 26A-C, more fully discussed below.
[0354] Referring specifically to FIG. 23A voltage waveforms are applied whereby the four periods t 1 -t 4 in the eleventh embodiment are divided into plural parts for display drive, and FIG. 23A′ illustrates the voltage waveforms applied to row electrodes X 4 -X 6.
[0355] First, row electrodes X 1 , X 2 , and X 3 are selected and a column voltage corresponding to the number of mismatches with three bits is sequentially applied to column electrodes Y 1 -Y m in the same way as in the eleventh embodiment above, row electrodes X 4 , X 5 , and X 6 are next selected and a column voltage is again applied as above, and field f 1 for period t 1 ends when all row electrodes have been selected. Next, the row electrodes are again selected in sequence from row electrodes X 1 , X 2 , and X 3 , field f 2 corresponding to the next period t 2 is executed, and when all four fields f 1 -f 4 corresponding to the four period t 1 -t 4 are completed, one frame F is completed.
[0356] Referring to FIGS. 24 A-C an example in accordance with the twelfth embodiment is illustrated in which execution is grouped for each display data bit, i.e., for each of the subdivided periods of the four periods t 1 -t 4 in the above embodiment.
[0357] First, the first period division a in the four periods t 1 -t 4 in FIG. 1 is treated as one field f 1 until all row electrodes have been selected, and one frame is completed when field f 2 corresponding to period division b and field f 3 corresponding to period division c are similarly completed. Note that the polarity of the voltage applied to the row electrodes is reversed each field, and the voltage applied to the column electrodes is also reversed accordingly.
[0358] FIGS. 25 A-C depict another example in accordance with the twelfth embodiment in which execution is further divided and applied to all row electrodes in each of the period divisions a, b, c in FIGS. 24 A-C. In this example, the effect is the same as frame rate control modulation applied for each display data bit in the embodiment in FIG. 21 above.
[0359] When the row electrode selection period is executed plural times within one frame F as described above, the period in which the selected voltage is not applied to each row electrode, i.e., to each pixel, can be shortened, the variation in display brightness can be reduced, and a loss of contrast can be prevented.
[0360] Thirteenth Embodiment
[0361] FIGS. 26 A-C illustrate the thirteenth embodiment in accordance with the present invention. In the thirteenth embodiment, one selection period is divided into the same number of parts as there are gradation bits n, i.e., three, and a column voltage of one of six levels V Y1 -V Y6 is selectively applied to the column electrodes as in the eleventh embodiment. Additionally, in the thirteenth embodiment the number of column voltage levels can be reduced by increasing the above number of divisions.
[0362] For example, the effective voltage when driving the liquid crystal elements of a liquid crystal display panel, etc., is generally determined by the voltage amplitude and the voltage application time (pulse width), and the panel can be equally driven whether a high voltage is applied for a short time or a low voltage is applied for a long time. In other words, it is the amount of energy applied to the liquid crystal panel that drives the liquid crystal elements.
[0363] It is therefore possible to drive the liquid crystal elements with an equivalent effect by selecting from the plural voltage levels having a low level voltage and applying this voltage for an extended period rather than using a high level voltage for a shorter time period. For example, by using voltage levels V Y5 and V Y2 in place of voltage levels V Y6 and V Y4 in the first embodiment and increasing the application time, the elements can be driven in the same manner as the first embodiment. It is thereby possible to reduce the number of column voltage levels.
[0364] FIGS. 26 A-C depicts the thirteenth embodiment in which voltage waveforms are applied whereby the number of column voltage levels is decreased.
[0365] Whereas the selection periods t 1 , t 2 , t 3 , t 4 are divided into n parts, i.e., a, b, and c, in FIGS. 21 A-C, each selection period is divided into (n+1) parts, i.e., a, a, b, C, in the thirteenth embodiment. In the present embodiment the first two period divisions a, a are assigned to the voltage application time of the high display data bit.
[0366] Specifically, voltage levels V Y5 and V Y2 corresponding to the middle bit, which are half the level of V Y6 and V Y4 , are respectively substituted for the V Y6 and V Y4 voltage levels corresponding to the high bit in the eleventh embodiment, and the application time is twice that of the middle bit. As a result, the voltage applied to the liquid crystal elements are applied for twice the time as the middle bit and four times the low bit values, and the weighting ratio for each bit is 1:2:4, the same as the first embodiment shown in FIG. 1.
[0367] Thus, equivalent driving voltages as the eleventh embodiment can be achieved while applying one less column electrode voltage level.
[0368] It is apparent to one of ordinary skill in the art who has read this description that the two highest voltage levels V Y6 and V Y4 in the eleventh embodiment are eliminated by this embodiment, but the voltage levels V Y3 and V Y1 for the low bit can be used, respectively, instead of the middle bit voltage levels V Y5 and V Y2 in the eleventh embodiment, using an application time twice that of the low bits in the same way as above. Furthermore, it is also possible to eliminate four or more voltage levels, and reducing the number of voltage levels as described above is a particularly effective means of simplifying the drive circuit configuration when there are many gradation levels.
[0369] Fourteenth Embodiment
[0370] The fourteenth embodiment is depicted in FIGS. 27 A-C, 28 A-C and 29 A-C. The fourteenth embodiment is similar to the thirteenth embodiment above. Additionally, the selection periods t 1 -t 4 , in the fourteenth embodiment, is divided into plural parts within one frame F as in the twelfth embodiment.
[0371] Referring to FIGS. 27 A-C, a waveform diagrams are shown in which one selection period is divided into (n+1) parts, i.e., 4 parts, and these selection periods are divided into plural parts in one frame, specifically into four fields f, similar to the second and third embodiments. Note, however, that the selection periods can also be divided into two or three parts.
[0372] [0372]FIG. 28 a shows an example in which the driving is executed in each of the period divisions of the four periods t 1 -t 4 in the above embodiment. The first period division a of the period divisions a, a of the four periods t 1 -t 4 in FIG. 21 is treated in sequence as one grouping, and the period until all row electrodes have been selected is one field f 1 , and one frame is completed when field f 2 for the next period division a, field f 3 for period division b, and field f 4 for period division c are completed. As in the previous embodiments the polarity of the voltage applied to the row electrodes is reversed each field, and the voltage applied to the column electrodes is also reversed accordingly.
[0373] FIGS. 29 A-C show another example of the fourteenth embodiment in which execution is further divided and applied to all row electrodes in each of the period divisions a, a, b, c in FIG. 10. In other words, all the groups of row electrodes are sequentially selected after each period division.
[0374] The embodiment shown in FIGS. 28 A-C and FIGS. 29 A-C above achieve the same effect as a gray scale display achieved by weighting the voltage applied to the column electrodes for each field.
[0375] Fifteenth Embodiment
[0376] FIGS. 30 A-C illustrate the fifteenth embodiment of the present invention. As noted above, the effective voltage when driving the liquid crystal elements is generally determined by the voltage magnitude applied and the application time (pulse width). Thus, the desired gray scale display can be achieved by appropriately combining the application time and the magnitude of the voltage applied to the column electrodes.
[0377] Referring to FIGS. 30 A-C the applied voltage waveforms for an embodiment achieving a 16 gray scale display based on the display data shown in FIG. 31 by appropriately combining the application time and the magnitude of the voltage applied to the column electrode is shown therein.
[0378] This embodiment also simultaneously selects three row electrodes, and applies the row voltage to each of the row electrodes during the four selection periods t 1 -t 4 as in the first embodiment described above.
[0379] Each of these four periods t 1 -t 4 is divided into six periods a-f, and the first two period divisions a, b correspond to the highest bit in the four digit binary display data shown in FIG. 33, the next period division c corresponds to the second bit, the next two period divisions d, e to the third bit, and the last period division f corresponds to the lowest bit.
[0380] Column voltage ±V Y4 or ±V Y6 is selectively applied to the column electrodes according to the following conditions for the highest two bits, and ±V Y1 or ±V Y3 is selectively applied for the lowest two bits.
[0381] Note that the voltage value ratio is defined as:
[0382] V Y1 : V Y3 =1:3
[0383] V Y4 : V Y6 =1:3
[0384] V Y1 : V Y4 =1:4.
[0385] As above, the highest two bits and the lowest two bits use the same two voltage combinations, the highest bit and the second from the lowest bit are weighted relative to the second from highest bit and the lowest bit, respectively, by doubling the respective pulse widths; the two highest bits can thus express four gradations, the two lowest bits express four gradations, and combined these express 4×4=16 gradations.
[0386] As conditions for the above, ON is when the voltage waveform of the row electrode is positive and OFF is when negative, and a display data value of 1 is ON and 0 is OFF; the ON/OFF state of the simultaneously selected row electrodes and the ON/OFF state of the corresponding display data bits at the intersections of the selected row electrode and the column electrode to which the voltage is to be applied are compared for each bit position, and a voltage specified according to the number of mismatches is applied to the column electrode.
[0387] Specifically, when the number of mismatches between the row electrode and the highest bit is 0, 1, 2, or 3, voltage value −V Y6 , −V Y4 , V Y4 , or V Y6 , respectively, is applied to the column electrode in period divisions a, b in this embodiment; for the number of mismatches between the row electrode and the second bit, the same voltages are applied to the column electrode during period division c under the same conditions as above. When the number of mismatches between the row electrode and the third bit is 0, 1, 2, or 3, a voltage value −V Y3 , −V Y1 , V Y1 , or V Y3 , respectively, is applied to the column electrode in period divisions d, e; and for the number of mismatches between the row electrode and the lowest bit, the same voltages are applied to the column electrode during period division f under the same conditions as above.
[0388] Referring to FIGS. 30 A-C, the three row electrodes X 1 , X 2 , and X 3 are first simultaneously selected, and the selected row electrodes X 1 , X 2 , and X 3 are OFF, OFF, ON, respectively, and the highest bits of the display data at the intersection of the column electrode Y 1 and these row electrodes X 1 , X 2 , and X 3 are OFF, OFF, ON. Comparing both, the number of mismatches is 0, and the voltage −V Y6 is applied to column electrode Y 1 in the first period divisions a, b of the first period t 1 .
[0389] Next, the second from highest bits are OFF, ON, OFF and the number of mismatches is 2 when compared with the OFF, OFF, ON states of the row electrodes X 1 , X 2 , and X 3 ; voltage V Y4 is therefore applied in period division c. The second bits are ON, OFF, OFF, the number of mismatches is 2, and voltage V Y1 is applied in period divisions d, e. The lowest bits are OFF, ON, OFF, the number of mismatches is 2, and voltage V Y1 is therefore applied. A weighted voltage is applied to the other column electrodes Y 1 -Y m in a similar manner.
[0390] A column voltage corresponding to the number of mismatches is simultaneously applied to all column electrodes Y 1 -Y m in the following periods t 2 -t 4 in the same way, selection of row electrodes X 1 , X 2 , and X 3 ends, the next group of row electrodes i.e. X 4 , X 5 , and X 6 are selected, the specified column voltages are applied to the column electrodes Y 1 -Y m in the same way as described above, and when all row electrodes have been selected, one frame F ends. The sign of the voltage applied to the row electrodes is then reversed because the first row electrodes X 1 , X 2 , and X 3 are again selected in sequence and the next frame begins, and the sign of the voltage applied to the column electrodes is also reversed for so-called alternating current drive scheme.
[0391] By thus achieving the desired gray scale display by appropriately combining the time and value of the voltage applied to the column electrodes as described above, a gray scale display can be achieved with fewer voltage levels, even when there are many gradation levels.
[0392] As is now apparent it is not essential to set the voltage rate as described above in the eleventh embodiment strictly according to the above conditions, and the periods t 1 -t 4 and period divisions a-f do not need to be strictly equal. In addition, the order of the period divisions a-f can be changed as appropriate to achieve the same result.
[0393] Sixteenth Embodiment
[0394] FIGS. 32 A-C illustrate the sixteenth embodiment in which the selection period of the fifteenth embodiment is divided into plural parts within a single frame F as in the twelfth embodiment.
[0395] More specifically, as shown in FIGS. 32 A-C, the periods t 1 -t 4 are separately divided into four parts in a single frame F as in the second embodiment, one field f is defined as the selection of all row electrodes in each period, and the operation is repeated four times in one frame F. These column voltages are determined as described above.
[0396] As will be apparent to those who read this description, the fifteenth embodiment can also be driven for each display data bit or can be further divided as shown in FIGS. 28 A-C and FIGS. 29 A-C in the fourteenth embodiment.
[0397] Seventeenth Embodiment
[0398] In embodiments 11-16 above the column voltages were weighted to effectuate the gray-scale display. In the seventeenth embodiment, as shown in FIGS. 33 A-C, the row voltages are weighted to provide a gray-scale display.
[0399] FIGS. 33 A-C illustrate the applied voltage waveforms for the seventeenth embodiment changing the voltage levels applied to the row electrodes according to the display data bit to display eight gradations based on the display data shown in FIG. 22, similar to the eleventh embodiment.
[0400] As in the eleventh embodiment, the row electrodes are selected sequentially three lines at a time, and voltage V X4 or −V X4 is applied to each row electrode for the high display data bit, V X2 or −V X2 is applied for the middle bit, and V X1 or −V X1 is applied for the low bit. The ratios of the row voltages are preferably V X1 :V X2 :V X4 or 1:2:4.
[0401] As with the previous embodiments, the ON/OFF states of the row electrodes X 1 , X 2 , and X 3 and the display data ON/OFF states are compared bit by bit, and when the number of mismatches is 0, 1, 2, and 3, respectively, voltages −V Y3 , −V Y1 , V Y1 , and V Y3 are applied to the column electrodes Y 1 . . . Y n , preferably the V Y1 :V Y3 ratio is 1:3.
[0402] If the number of voltage levels on the row electrode side is increased, rather than increasing the voltage levels on the column electrode side as in the eleventh embodiment, the number of voltage levels applied to the column electrode can be significantly reduced, and the structure of the column electrode-side drive circuit shown in FIGS. 4 - 6 can be simplified.
[0403] Eighteenth Embodiment
[0404] FIGS. 34 A-C illustrate the eighteenth embodiment of the present invention in which the row voltages are weight, similar to the seventeenth embodiment and the selection period is divided into plural parts within a single frame F as in the twelfth embodiment to achieve a gray scale display. FIGS. 35 A-C and FIGS. 36 A-C illustrate other examples of the eighteenth embodiment.
[0405] FIGS. 34 A-C depicts an example in which the periods t 1 -t 4 in FIGS. 33 A-C are separately divided into four parts in a single frame F as in the twelfth embodiment, one field f is defined as the selection of all row electrodes in each period, and the operation is repeated four times in one frame F.
[0406] FIGS. 35 A-C shows another example of the eighteenth embodiment wherein the display is driven for each display data bit, i.e., in each of the period divisions of the four periods t 1 -t 4 in the previous embodiment. Specifically, the first period division a in the four periods t 1 -t 4 is treated as one field f 1 until all row electrodes have been selected, and one frame is completed when field f 2 corresponding to the other period division b and field f 3 corresponding to period division c are similarly completed. Note that the sign of the voltage applied to the row electrodes is inverted each field, and the voltage applied to the column electrodes is also inverted accordingly.
[0407] A further example of the eighteenth embodiment is shown in FIGS. 36 A-C in which the periods are divided so that all row electrodes are sequentially selected in each period division. This example achieves a gray scale display similar to the twelfth embodiment by driving the display in plural parts within one frame as described above.
[0408] Nineteenth Embodiment
[0409] FIGS. 37 A-C show the nineteenth embodiment of the present invention in which the number of selection period divisions, similar to the seventeenth embodiment, are increased to reduce the number of applied voltage levels as in the thirteenth embodiment.
[0410] More specifically, each of the periods t 1 -t 4 in FIGS. 33A is further divided into four parts in one frame F as in FIGS. 26 A-C with the first two period divisions being the application time for the high bit, and the other period divisions being the application times for the middle and low bits, respectively. Note that the relationship of the applied voltages in this embodiment is V X1 : V X2 =1:2, and V Y1 :V Y3 =1:3. The column voltages are selected in a similar manner as described above.
[0411] Twentieth Embodiment
[0412] FIGS. 38 A-C illustrate one example of the twentieth embodiment. In the twentieth embodiment the selection period, similar to the nineteenth embodiment is divided into plural parts within a single frame F. FIGS. 39 A-C and 40 A-C illustrate other examples of the twentieth embodiment.
[0413] FIGS. 38 A-C show the example where the periods t 1 -t 4 , in FIG. 39, are separately divided into four parts in a single frame F as in FIG. 25. More specifically, one field f is defined as the selection of all row electrodes in each period, and the operation is repeated four times in one frame F.
[0414] Referring to FIGS. 39 A-C, another example is shown in which execution is grouped for each period division of the four periods t 1 -t 4 in the previous embodiment; the first period division a of period divisions a, a in the four periods t 1 -t 4 in FIG. 39 is treated as one field f 1 until all row electrodes have been selected, and one frame is completed when field f 2 corresponding to the other period division a, field f 3 corresponding to period division b, and field f 3 corresponding to period division c are similarly completed. Note that the sign of the voltage applied to the row electrodes is inverted each field, and the voltage applied to the column electrodes is also inverted accordingly.
[0415] As shown in FIGS. 40 A-C, it is also possible to further divide the periods so that all row electrodes are selected in each period division.
[0416] Thus, the same effects obtained with the twelfth embodiment can thus be obtained by driving the display in plural parts within one frame as described above.
[0417] Twenty-First Embodiment
[0418] The twenty-first embodiment is shown in FIGS. 41 A-C. In this embodiment, a desired gray scale display is achieved by appropriately combining the application time and the magnitude of the voltage applied to the column electrodes, as in the fifteenth embodiment above. The display panel drives identical to that of the fifteenth embodiment by increasing the number of voltage levels on the row electrode side instead of increasing the number of voltage levels on the column electrode side as in the sixteenth embodiment.
[0419] FIGS. 41 A-C show an example in which voltage V X4 or −V X4 is used as the applied voltage level to each row electrode for the two highest display data bits, V X1 or −V X1 is applied for the two lowest bits preferably the ratio V X1 :V X4 is 1:4.
[0420] The ON/OFF states of the row electrodes X 1 , X 2 , and X 3 and the display data ON/OFF states are compared bit by bit, and when the number of mismatches is 0, 1, 2, and 3, respectively, voltages −V Y3 , −V Y1 , V Y1 , and V Y3 are applied to the column electrodes Y 1 . . . ; the V Y1 :V Y3 ratio is 1:3, similarly as discussed above.
[0421] Twenty-Second Embodiment
[0422] FIGS. 42 A-C illustrate the twenty-second embodiment of the present invention in which the selection period, similar to the twenty-first embodiment is divided into plural parts within a single frame F.
[0423] Referring to FIGS. 42 A-C the periods t 1 -t 4 are separately divided into four parts in a single frame F, as in FIGS. 24 A-C, one field f is defined as the selection of all row electrodes in each period, and the operation is repeated four times in one frame F. In this embodiment it is also possible to further divide and drive as in the previous embodiment.
[0424] As is readily apparent, the twenty-first embodiment can also be driven for each display data bit or can be further divided as in the twentieth embodiment shown in FIGS. 39 A-C and FIGS. 40 A-C.
[0425] It is to be noted that while each of the above embodiments has been described as simultaneously selecting three row electrodes, a gray scale display with the desired number of gradations is possible by simultaneously selecting two, four, or more row electrodes and applying the same concepts described above. For example, in an embodiment simultaneously selecting six row electrodes, selection periods divided into eight parts t 1 -t 8 are provided in one frame period, and voltages as shown in the table below are applied in each of the selection periods t 1 -t 8 of the six simultaneously selected row electrodes X 1 -X 6 .
t 1 t 2 t 3 t 4 t 5 t 6 t 7 t 8 X 1 V X1 V X1 V X1 V X1 −V X1 −V X1 −V X1 −V X1. X 2 V X1 V X1 −V X1 −V X1 −V X1 −V X1 V X1 V X1 X 3 V X1 V X1 −V X1 −V X1 V X1 V X1 −V X1 −V X1 X 4 V X1 −V X1 −V X1 V X1 V X1 −V X1 −V X1 V X1 X 5 V X1 −V X1 −V X1 V X1 −V X1 V X1 V X1 −V X1 X 6 V X1 −V X1 V X1 −V X1 −V X1 V X1 −V X1 V X1
[0426] Note that 0 V is applied during the unselected period. The specified row voltage is applied to each of the row electrodes X 1 -X 6 as described above, and the specified column voltage is simultaneously applied as described in the various embodiments to each of the column electrodes.
[0427] In addition, the waveform of the voltages applied to the row electrodes shall not be limited to the embodiments, and the waveforms can be changed to the waveforms as shown in FIGS. 46A and B or FIGS. 3A and B, or the pulse widths thereof can be appropriately selected or the order changed insofar as the waveforms applied to the simultaneously selected row electrodes do not become intermixed and the row electrodes can be separately driven.
[0428] The concept of simultaneously selecting plural sequential row electrodes and dividing the selection period into plural parts in one frame for liquid crystal element drive as described above can also be applied to drive liquid crystal elements using non-linear (including MIM) elements.
[0429] A drive method and display apparatus for liquid crystal elements according to the present invention as described above simultaneously selects plural sequential row electrodes, divides one selection period into plural periods, and in each of these divided selection periods applies a voltage weighted according to the desired display data to achieve a gray scale display. As a result, lengthening of the time in which the selected voltage is not applied to the pixels and a drop in contrast, flickering due to lengthening of the repeat cycle, or crosstalk due to rounding of the applied voltage waveform are prevented, and a good gray scale display can be achieved. It is also possible to reduce the number of applied voltage levels relative to the number of gradations, the drive means of the drive can be structurally simplified, and a liquid crystal element drive method and display apparatus featuring outstanding reliability and display performance can be provided by means of the invention.
[0430] While the invention has been described in conjunction with several specific embodiments, it is evident to those skilled in the art that many further alternatives, modifications and variations will be apparent in light of the foregoing description. Thus, the invention described herein is intended to embrace all such alternatives, modifications, applications and variations as may fall within the spirit and scope of the appended claims. | A multiplex driving method and driving apparatus are provided for a liquid crystal display device having a liquid crystal layer disposed between a pair of substrates, a plurality of row electrodes arranged on one of the substrates and a plurality of column electrodes arranged on the other substrate, the plurality of row electrodes being arranged in plural groups. A portion of the row electrodes are simultaneously selected a within a selection period in which the selection period is divided into a plurality of intervals. A weighted voltage is applied in accordance with desired display data in each of the plurality of intervals to achieve a gray scale display. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 501,262, filed June 6, 1983, which in turn is a continuation of application Ser. No. 250,772, filed Apr. 3, 1981, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for effecting the perforating and the gravel packing of a production zone in a subterranean well by a single trip of a work string into the well which carries both perforating and gravel packing apparatus.
2. Description of the Prior Art
As oil and gas wells are drilled to constantly increasing depths, the cost of completion or workover of a well is disproportionally increased by the number of trips of completion apparatus that must be made into the well in order to effect its completion or workover. Necessarily, every encassed producing well has to have the casing perforated in the production zone. It is equally necessary in the case of many wells to provide gravel packing in the area of the perforations to filter out sand produced with the production fluids and thus prevent its entry into the well bore and through the production conduit. It has heretofore been necessary to make several trips of a work string into the well in order to first effect the perforation of the well casing and then the gravel packing of one or more production zones surrounding the perforations. Most commonly used tubing conveyed perforating apparatus rely upon percussion firing of explosive charges. Such firing is produced by dropping a weight through the tubular work string to fire a primer carried by the perforating apparatus located at the bottom of the well. It is therefore necessary that the bore of the tubular work string be unrestricted, at least to the extent to permit the free passage of the firing weight or bar therethrough.
It has previously been suggested that the gravel packing of a plurality of production zones of a well could be accomplished in a single trip of a specially designed gravel packing apparatus into the well. Such apparatus is, for example, disclosed in U.S. Pat. No. 3,987,854 to Callihan et al. and also in the copending application Ser. No. 170,494, filed July 21, 1980, and assigned to the assignee of the present application. In both instances, however, the crossover tool which forms an essential part of such multiple zone gravel packing apparatus, has not provided an unrestricted axial passage through the crossover apparatus. Therefore, it has been a practical impossibility to enter the well with both a perforating apparatus and a gravel packing apparatus and accomplish both operations in the same trip.
SUMMARY OF THE INVENTION
This invention provides an improved apparatus for the completion of subterranean oil wells which permits the perforation of the casing at a production zone in the well and the subsequent gravel packing of a liner, screen or other filtering means positioned adjacent to the casing perforations with a single trip of the required apparatus into the well, following which the mandrel element of the gravel packing apparatus may be removed from the well, and the work string replaced by production tubing, permitting the well to be placed immediately in production.
The apparatus of this invention incorporates a unique crossover flow control mandrel for a gravel packing apparatus which, in its run-in position, defines an unimpeded axial passage through the entire gravel packing apparatus. This permits a firing weight to be freely dropped through the gravel packing apparatus to fire a perforating mechanism disposed at the bottom end of the gravel packing apparatus. During the run-in and perforating operation, a radial passage through the gravel packing mandrel, which provides communication from the interior of the bore of the mandrel through the annular fluid passage surrounding such bore into the annulus between the mandrel and the liner assembly, is closed by a sleeve which carries a ball valve seat at its upper end. The sleeve is retained in this position by a shear pin. Following the perforating operation, a ball is dropped onto the ball seat permitting fluid pressure within the work string to be increased sufficiently to set a fluid pressure operated packer. Further increase in pressure will cause a shearing of the shear pin and a downward movement of the ball seat sleeve to uncover the radial passage in the crossover mandrel assembly, thus restoring the fluid flow passages through the crossover mandrel to their normal configuration which permits the flow of gravel carrying fluid downwardly through the bore of the mandrel, thence outwardly through the uncovered radial passage into the annulus between the mandrel and the sleeve assembly, thence outwardly into the annulus between the liner assembly and the casing, and thence downwardly into the area between the screen and the casing perforations. The return fluid passes through the screen, thence into the annular passage surrounding the bore of the mandrel, and thence outwardly into the casing annulus through a radial port located above the packer, in conventional fashion.
Additionally, this invention provides a flapper valve below the ball valve which is normally held in an inoperative position relative to the continuous axial passage through the gravel packing apparatus until after the perforation of the well has been accomplished by the dropping of the firing weight, and the work string has been pressurized above the ball seat sleeve. Such flapper valve is held in its open position by a retaining sleeve and is spring biased to a closed position. The flapper valve is caused to move to its closed position after completion of the perforating operation by downward movement of the ball seat sleeve, and isolates the bore of the screen, hence the formation, from reverse fluid flow after the gravel packing is accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b constitute a schematic vertical sectional view of a combined perforating and gravel packing apparatus incorporating this invention, shown with the components thereof in their run-in positions, FIG. 1b being a vertical continuation of FIG. 1a.
FIG. 2 is a view similar to FIG. 1b but showing the operation of the perforating gun.
FIGS. 3a and 3b are views similar to FIGS. 1a and 1b but showing the position of the elements of the apparatus after the perforating operation and at the beginning of the gravel packing operation, FIG. 3b being a vertical continuation of FIG. 3a.
FIG. 4 is an enlarged scale vertical sectional view of a portion of the apparatus of FIG. 1a, illustrating in particular, the mounting of the flapper valve, with the valve shown in its open position.
FIG. 5 is a view similar to FIG. 4 but showing the flapper valve in its closed position.
FIG. 6 is a sectional view taken on the plane 6--6 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1a-1b, there is shown a combined gravel packing and perforating apparatus 10 embodying this invention with all of the elements of the apparatus shown in their "run-in" position within the bore 1a of a well casing 1. Major components of the apparatus 10 include a percussion actuated perforating gun 5, which is supported in depending relationship from a first packer element 6 by a nipple 9 having radial wall perforations 9a. The packer element 6 is in turn suitably secured to the bottom end of a hollow liner assembly 20. On the top end of the liner assemblage 20, a second packer 7 is conventionally secured. The packer 7 is of the type having a fluid pressure responsive actuator 8 which is detachably secured to the packer 7 and has its upper end secured to the end of a tubular work string 2. Depending from the actuator 8 is a hollow crossover mandrel 30. The axial bore 30a of the hollow crossover mandrel 30 extends entirely through the length of the assembly and is in direct communication with the bore 6c of the lower packer 6 and the bore of the nipple 9, hence providing direct communication with the percussion actuated perforating gun 5.
The perforating gun 5 may be any one of several well known types which contains explosive charges which are detonated to fire a plurality of radially directed charges through the walls of the casing 1, thus producing casing perforations 1b (FIG. 2) and associated perforations in the surrounding production zone of the well bore. From the description thus far, it will be readily apparent that in the run-in position of the combined perforating and gravel packing apparatus, there is provided an unrestricted axial passage from the tubular work string 2 to the perforating gun 5, thus permitting a detonating weight or bar 5a (FIG. 2) to be dropped onto the gun 5 from the top of the well to effect its discharge and the production of perforations 1b in the well casing and the surrounding production zone.
All of the aforedescribed major components of the combined perforating and gravel packing apparatus 10 are assembled to the end of the tubular work string 2 at the well head and are lowered into the casing 1 by the work string 2 until the perforating gun 5 is positioned adjacent a desired production zone.
The lower packer 6 is of the type known in the art as a mechanically actuated, retrievable packer. In other words, through mechanical manipulation of the work string 2, the lower packer 6 may be expanded into sealing engagement with the interior bore 1a of casing 1 at any selected point. Further manipulation of the work string 2 will result in the collapsing of the lower packer 6 to permit it to be moved to another position. The packer 6 may, for example, comprise the Baker Model R-3 Single Grip Retrievable Casing Packer.
Thus, the first step involved in the process after the run-in of the combined perforating and gravel setting apparatus 10 into the well casing is to effect the setting of the lower packer 6 by manipulation of the work string 2. This results in the expansion of gripping teeth 6a and annular seals 6b conventionally provided on the packer into engagement with the casing bore 1a (FIG. 2).
As previously mentioned, the top end of the lower packer 6 is conventionally secured, as by threads, to the bottom end of an elongated liner assembly 20. The liner assembly 20 is constructed in the same general manner as the liner assembly employed in the gravel packing apparatus described in the aforementioned U.S. Pat. No. 3,987,854. The construction of the liner assembly 20 will not, therefore, be described in great detail, but the principal elements thereof, starting at the bottom of the liner assembly (FIG. 1b) and moving upwardly, include the following items:
First is an O-ring seal sub 21 providing a mounting for an O-ring seal 21a which cooperates in sealing relationship with the lower tubular portion 30b of the crossover mandrel 30.
Next, the top end of the O-ring seal sub 21 is threadably secured to a conventional telltale screen 22 employed in gravel packing apparatus. Screen 22 provides a plurality of radially disposed small area passages 22a communicating between the casing annulus and the interior of the hollow screen assemblage 22. The passages 22a are sufficiently small in size to provide a barrier for the passage of the size of gravel particles with which the well is to be packed.
Then, the top end of telltale screen 22 is in turn threadably secured to the bottom end of a second O-ring seal sub 23 which defines a support for an O-ring 23a which also sealingly engages the lower tubular portion 30b of the hollow crossover mandrel 30.
The top end of the O-ring seal sub 23 is threadably engaged to the bottom of a main screen 24 around which the primary gravel pack is to be placed. The screen 24 may be of any one of several well known constructions and defines a plurality of radially disposed, restricted area fluid passages 24a which are sized to freely permit fluid flow therethrough from the casing annulus but prevent passage of the gravel particles of the size to be employed in the gravel packing operation.
The top end of the main screen 24 is threadably secured to the lower end of a blank pipe 25 which is provided with a radially projecting centering flange 25a. The top end of the blank pipe 25 is in turn threadably connected to the lower end of a conventional shearout safely joint 26 which permits release of component parts of the apparatus, including the upper packer 7, in the event that the apparatus becomes stuck in the well bore. The shearout safety joint 26 may be of conventional construction.
The top end of the shearout safety joint 26 is threadably secured to the lower end of a crossover sub 27 which has a larger interior diameter. The top of crossover sub 27 is threadably secured to the bottom end of a blank pipe 27a which has its top threadably end secured to a seal bore unit 28 which defines an internal sealing surface 28a for cooperation with seals 30g provided on the enlarged upper end 30c of the hollow crossover mandrel 30. Lastly, the top end of seal bore unit 28 is threadably secured to a connecting sleeve 29 having radial passages 29a formed therein and its top end threadably secured to the lower end of the upper packer 7.
The upper packer 7 may be any one of several well known types which may be set by the fluid pressure operated actuator 8. For example, upper packer 7 may comprise Baker model "SC-1 Packer". Since the construction and operation of this type of actuator and packer is entirely conventional, it will not be further described. The actuator 8 is detachably secured to upper packer 7 in conventional fashion and threadably secured at its top end to the lower end of the tubular work string 2.
A hollow crossover mandrel 30 is suitably secured in depending relation to actuator 8 by engagement with a depending sleeve portion 8a of actuator 8. Starting from the top of the crossover mandrel 30, there is first provided a pair of axially spaced, annular seats for seals 31a and 31b. Seal 31a slidably and sealingly engages a seal bore surface 7a formed in the upper packer 7. The seal 31b provides sealing engagement with the bore 7a of the packer 7 when the crossover mandrel is raised relative to the packer by actuator 8 in a manner to be hereinafter described.
The mandrel assembly 30 also defines an annular fluid passage 32, open at its top end, which extends downwardly and has a semi-annular lower end 32a (FIG. 4) communicating with the bore 30a extending through the upper portion 30c and the lower end 30b of the mandrel assembly 30.
Near the upper extremity of the enlarged upper portion 30c of the hollow crossover mandrel, a radial crossover port 34 is provided which permits fluid to pass from the axial bore 30a of the hollow mandrel to the exterior of the mandrel, passing through, but not communicating with the annular passage 32. Port 34 thus provides communication between the mandrel bore 30a and the annulus that exists between the exterior of the hollow crossover mandrel 30 and the interior bore 20a of the liner assembly 20.
In the run-in position of the hollow crossover mandrel, the crossover port 34 is closed by a sleeve 35 which defines at its upper end, a conical ball valve seat 35a (FIG. 4). Seals 35b and 35c respectively located above and below the crossover port 34 assure that such port will be sealed by sleeve 35 against any fluid flow from the bore 30a of the hollow crossover mandrel 30. The ball valve seat sleeve 35 is retained in the aforedescribed position with respect to the crossover port 34 by a shear pin 35d in the mandrel wall which engages a suitable annular groove 35e in the outer periphery of the sleeve 35.
Below the position of the ball valve seat sleeve 35, a flapper valve 36 is mounted for movement about a horizontal pin 36a from a vertical position, in which it does not significantly obstruct the bore 30a of the hollow crossover mandrel, to a horizontal position, shown in FIG. 5, wherein it cooperates with an upwardly facing, annular sealing surface 39a (FIG. 4) surrounding bore 30a. The flapper valve seat 39a is defined on the top portion of a second valve sealing sleeve 39 which is secured in a fixed position in the axial bore 30a of the hollow crossover mandrel 30 by a pair of C-rings 39b and 39c respectively engaging the top and bottom surfaces of the sleeve 39 and appropriate grooves formed in the bore 30a. Conventional sealing elements 39d are provided between the external surface of the sleeve 39 and bore 30a to prevent fluid leakage between the external surface of the valve seat 39 and the bore surface 30a of the hollow crossover mandrel 30. A torsion spring (not shown) is provided for flapper valve 36 to urge it towards its horizontal or closed position.
As it is best shown in the enlarged FIGS. 4-6, the flapper valve 36 includes a radially disposed, enlarged head, locking pin 36c. In the run-in position of the crossover mandrel 30, the shank portion of the enlarged head locking pin 36c is disposed within a narrow slot 38b defined by an axial projection 38a formed on the bottom end of a sleeve 38 which in turn is hung onto a radial flange 35f on the bottom end of the valve sleeve 35. The retaining slot 38b provided in the axial projection 38a of connecting sleeve 38 is enlarged at its upper end as shown at 38c so as to permit the headed locking pin 36c of flapper valve 36 to freely pass therethrough and permit the valve to assume its horizontal closed position in engagement with the valve seat 39a whenever the connecting sleeve 38 is moved axially downwardly by displacement of the valve seat sleeve 35 in a manner to be hereinafter described.
The connecting sleeve 38 is provided with a cutout portion 38d extending approximately half way around the upper portion of the sleeve to provide unimpeded communication between mandrel bore 30a and semi-annular passage 32a.
OPERATION
As previously mentioned, the entire apparatus which has heretofore been described, is run into the well casing 1 on the end of the tubular work string 2 and the perforating gun 5 is positioned opposite a region in the well casing where a production formation exists. With the perforating gun so located, the lower packer 6 is then set by manipulation of the tubular work string 2 (FIG. 2).
A detonating weight or bar 5a is then dropped through the tubular work string 2 and passes through the unimpeded axial bore 30a of the hollow crossover mandrel, bore 6c of lower packer 6, and nipple 9 and impacts on the top of the perforating gun 5, discharging the explosive charges contained therein and driving the charges carried by the gun outwardly to perforate the casing 1 and produce the perforations 1b as illustrated in FIG. 2.
Preferably prior to the firing of the perforating gun 5, the bore of the tubular work string 2 is filled with a light density fluid so that when the gun is fired, the work string will be in an "under balanced" condition, i.e., hydraulic fluid pressure at the face of the formation when the gun is fired will be less than the formation pressure, which insures that the formation pressure will force fluid into the well bore and upwardly to the surface. Such light fluid is introduced prior to the setting of the lower packer 6 and is pumped down through the tubular work string 2 displacing any heavier fluid existing in the work string, such as drilling mud, out of the bottom of the inserted apparatus through the perforated nipple 9 below the lower packer and returning to the surface around the outside of the lower packer 6, since it is not yet set.
In most cases, it is desirable to permit oils or other fluid contained in the production formation to freely flow through the perforations 1b to effect a flushing of such perforations and the fissures in the formation. Such fluid flow enters the axial bore 30a of the hollow crossover mandrel assembly 30 through the perforations 9a provided in the connecting nipple 9 and flows freely up to the work string 2 and then to the top of the well.
After a sufficient flow period to insure the adequate flushing of the perforations, the well flow is closed in conventional fashion by the introduction of a heavy kill fluid downwardly through the tubular work string 2.
As soon as the well is under control by the kill fluid, the lower packer 6 is released by manipulation of the work string 2. The entire assembly is lowered down the well bore so that the main screen 24 is positioned opposite the newly produced perforations 1b (FIG. 3a). At this position, the lower packer 6 is then reset by manipulation of the tubular work string 2 (FIG. 3b). The lower packer now in essence becomes a sump packer and is generally permitted to remain in that position (FIG. 3b).
To initiate the gravel packing operations, the upper packer 7 is set through the application of fluid pressure through the tubular work string 2. To apply such fluid pressure, a ball 40 is dropped through the tubular work string and seats on the ball valve seating surface 35a defined by the valve seat sleeve 35. The fluid pressure within the work string and the upper portion of the hollow tubular mandrel assembly 30 may now be increased to a level which will effect the hydraulic operation of the actuator 8 which effects the setting of the upper packer 7 in conventional manner (FIG. 3a). After setting of the upper packer 7, the fluid pressure within the tubular work string 2 is then increased to an extent that a shearing of the shear pin 35d is accomplished and the ball valve seat sleeve 35 moves downwardly, thus uncovering the crossover port 34 in the crossover mandrel 30 (FIG. 5.). Alternatively, the valve seat sleeve 35 may be shifted downwardly mechanically by a wireline applied force. Such downward movement is, of course, transmitted directly to the connecting sleeve 38 by a downwardly facing shoulder 35 g which moves the enlarged portion 38c of the locking slot 38b into alignment with the locking pin 36c of the flapper valve 36 and permits the flapper valve 36 to shift to its horizontal, closed position as shown in FIG. 5, under the bias of the torsion spring. The actuator 8 is released therefrom and moved upwardly by work string 2 until an indicator ring 41 on the crossover mandrel 30 contacts the bottom of seal bore 28. The hollow mandrel assembly 30 is thus elevated to position its open bottom end 30e at a point above the lowermost O-ring seal sub 21 provided on the lower portion of the liner assembly 20.
As mentioned, the initial raised position of the hollow mandrel assembly 30 is determined by the engagement of the locating ring 41 which surrounds the lower, reduced diameter portion 30k of the enlarged upper portion 30c of the hollow mandrel assembly 30. Ring 41 is of C-shaped configuration and expanded to engage the bottom end of the seal bore 28. The ring 41 is releasably retained in its expanded position on the crossover mandrel 30 by a sleeve 42 which is slidable upon the lower cylindrical mandrel portion 30b and retained in its uppermost position by one or more shear pins 42a. Thus, when it is desired to raise the crossover mandrel 30 further by raising the work string 2, sufficient upward force is applied to the tubular work string 2 to effect the shearing of the shear pins 42a and this permits the positioning C-ring 41 to move downwardly over the smaller diameter mandrel portion 30b where it will contract so as to freely pass through the bore defined by the seal bore 28. The plurality of axially spaced seals 30g provided on the periphery of the upper enlarged mandrel portion 30c insures that at all times, one or the other of such seals is engaged with seal bore 28 as the vertical position of the hollow mandrel assembly 30 is shifted during the operation of the device for gravel packing.
The fluid pressure within the tubular work string may then be reduced and a gravel carrying fluid introduced into the gravel packing apparatus through the tubular work string 2. The flow path of such gravel carrying fluid through the gravel packing portion of the apparatus 10 is conventional, passing first into the axial bore 30a of the hollow mandrel assemblage and then radially outwardly through the crossover port 34 into the annulus between the crossover mandrel 30 and the surrounding liner assembly 20. The fluid then flows through the ports 29a provided in the tubular element 29 into the annulus defined between the casing 1 and the outer periphery of the liner assembly 20. The gravel carrying fluid thus flows downwardly through the casing annulus to a position opposite the telltale screen 22. The gravel portion of the fluid will not pass the screen apertures 22a while the fluid passes inwardly to the internal bore 20a of the liner assembly.
The fluid then enters the bottom semi-annular portion 32a of the annular fluid passage 32 provided in the hollow crossover mandrel 30. It cannot flow directly upwardly through the axial bore 30a because such bore is blocked by the ball valve 40 which is subjected to the full downward pressure of the gravel carrying fluid to maintain a sealing engagement with the valve seat 35a provided on the valve seat sleeve 35. The fluid then flows through the top open end of the annular passage 32 and into the casing annulus at a point above the sealing surface 7a of the upper packer 7, because the actuator 8 has been shifted upwardly to position the top open end of annular passage 32 above the packer 7.
When the telltale screen 22 is fully covered with gravel, indicating that the gravel has reached the lowermost extremity of the region to be packed, the operator will detect a pressure increase.
Once the operator receives the pressure indication that the telltale screen 22 has been fully packed with gravel, the work string 2 may then be raised upwardly an additional distance, carrying the hollow crossover mandrel 30 with it, to, for example, position the open bottom end 30e of the hollow crossover mandrel assemblage at a position above the seal sub 23 in the liner 20. This then permits the gravel packing operation to continue, with the fluid flow being through the main screen 24, then upwardly through the annular passage 32, and then outwardly into the casing annulus at a point above the upper packer 7.
The packing operation is continued until the pressure build up indicates to the operator that the entire main screen 24 and the adjacent perforated area of the formation have been filled with gravel. At this point, there is generally excess gravel in the tubular work string 2 and after shearing the screws 42a by packing up on the work string 2, a reverse fluid flow is applied to the work string 2 to remove the excess gravel. Such reverse flow is, of course, accomplished in conventional fashion by pressurizing the casing annulus and flowing the fluid through the crossover port 34 into the bore 30a of the hollow crossover mandrel 30 and then upwardly through the tubular work string 2. It is during this operation that the flapper valve 36 performs its primary function in that it prevents the reversing fluid from entering the fluid bypass system that goes around the crossover port 34, and going down through the bore 30a of the crossover mandrel 30 to the formation.
Following completion of the removal of the excess gravel, the setting tool or actuator 8, with the hollow crossover mandrel 30 connected thereto, is removed from the well and the well is ready for subsequent testing or production operations.
While the invention has been described in terms of a specific application of the unique crossover mandrel construction to accomplishing the perforating of a well and gravel packing the perforated area in a single trip of the apparatus into the well, those skilled in the art will recognize that any operation below the gravel packing area requiring the axial passage of a tool or instrument through the unrestricted axial bore of the hollow crossover mandrel assembly embodying this invention, could also be accomplished. Thus, testing operations in a perforated well could be accomplished below the gravel packing apparatus with a single trip of the entire apparatus into the well.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | The invention provides a method and apparatus for effecting the perforating of a well casing and the gravel packing of the perforated areas of the well casing with one trip into the well of a combined perforating and gravel packing apparatus. This desirable objective is accomplished by a design of the crossover mandrel normally employed in gravel packing apparatus. The mandrel disclosed herein provides, in its run-in position, a continuous axial passage through its entire length, permitting a detonating bar to be dropped therethrough to actuate a perforating gun. Subsequent to the perforation operation, a ball is dropped and seated on an annular sleeve carried within the hollow mandrel which permits the development of internal pressure within the mandrel. Such internal pressure is employed not only to effect the setting of a fluid pressure actuated packer but also to shift the ball supporting sleeve downwardly and uncover a crossover port in the mandrel which permits the gravel packing operation to be carried out conventionally. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This is continuation-in-part of the inventors' previous application Ser. No. 347,337 filed Feb. 9, 1982 under the title METHOD OF OPERATING TURBO COMPRESSORS and now abandoned.
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to the control of turbo compressors and in particular to a new and useful apparatus and method of operating turbo compressors, particularly those of large capacity, comprising continuously measuring the rate of flow of the compressor, or a signal derived therefrom, and the discharge pressure or a pressure ratio of the compressor. The measured values are compared with permissible values therefor. In order to prevent surging, for example, before the reaching of a surge limit, it is insured that the rate of flow of the compressor does not fall below a minimum value which depends on the discharge pressure. This is accomplished through a closed loop control with analog and digital components, which operates to open one or more blowoff valves upon the attainment of a blowoff line which extends parallel to the surge limit on a pressure/flow characteristic curve of the compressor.
Surge limit controls which employ mechanicalhydraulic controllers are known. In spite of this very expensive equipment, however, with such prior art controls, the surge limit cannot be reproduced closely enough to reliably prevent surging. Another disadvantage of these hydraulic controls are their high maintenance and a considerable susceptibility to disturbances.
Further known is an electronic control for the surge limit, such as disclosed in the German publication "Mitteilung 542 der Warmestelle des Vereins deutscher Eisenhuttenleute" (communication 542 of The Heat Division of the Association of ferman Metallurgists). According to the disclosure, the surge limit control in a compressor with variable guide vane is similar to that designed for compressors with an adjustable throttle, with the difference, however, that a function generator is provided for forming the reference input of the surge limit controller, because of the non-linear curve of the surge limit.
It is a disadvantage in these prior art controls that at certain operating conditions, for example upon a manual intervention in the control or under strong pressure variations, surges in the compressor cannot be prevented with satisfactory reliability.
From German OS No. 26 23 899, an electronic control of the surge limit is known in which the output signal, depending on the actual values of pressure and flow, of the surge limit controller operating to adjust the blowoff valve, is amplified non-linearly, namely the amplification is augments if the error signal value is negative, i.e. if the operating pressure of the compressor passes into an extreme region, beyond the blowoff characteristic line. Further, in that disclosure, an extreme value selector connected ahead of the controller is responsive to the maximum error signal value, namely to the error signal value proper, or to the difference between the controller output and the manually set control signal.
This very satisfactorily operating control has the disadvantage, however, that it cannot follow the variation rate of the actual value, or evaluate whether the error signal value increases or decreases. In practice, this means that the blowoff line remains adjusted to a constant value, independently of the operating conditions.
A control method is also known, in which the position of the blowoff line within the characteristic is made dependent on the rate at which the working point moves through the performance graph.
It is a disadvantage in such and similar circuits, however, that the circuit elements operating in a purely analogous way become very expensive if various additional parameters, for example, the temperature, pressure, humidity at the suction side, or the molecular weight, are to be taken into account, or if the blowoff characteristic line is of a shape which is difficult to produce.
Brochures which have been distributed by the assigness of the present application disclose an analog system which measures flow rate through an output pressure from a compressor to produce a signal which is applied to a PI controller to control the position of a blowoff valve (Turbolog-Electronic Control System for GHH Turbomachinery from "Machinery News 3" published by M.A.N. Division GHH Sterkrade Oberhausen.
Such an analog control has the advantage of responding quickly to changes in flow and pressure but has the disadvantage of following a blowoff line which is at substantial distance from an optimum surge limit. This distance must be maintained since the factors noted above, such as temperature, humidity and molecular weight, are not taken into account.
Also see U.S. Pat. Nos. 4,298,310 and 4,384,818, both to Blotenberg, which disclose analog systems for controlling a blowoff valve of a turbo compressor. These two patents are incorporated by reference here.
A relationship is known which relates the socalled adiabatic head of a compressor to inlet and outlet pressure as well as variable such as inlet temperature, molecular weight and humidity. The adiabatic head is a more exact measurement of the compressor performance than outlet pressure which is generally used for convenience and as an approximation of adiabatic head.
While adiabatic head cannot be measured directly, it can be calculated using the relationship: ##EQU1## where: Δh ad =adiabatic head
K=adiabatic index
R=gas constant
T 1 =inlet temperature
P 1 =inlet pressure
P 2 =outlet pressure.
This relationship is known from E. Truckenbrodt: Stromungsmechanik Springer Verlag Berlin Heidelberg New York 1969, page 54.
It is known that the adiabatic index is a function of molecular weight, humidity and the like. See U.S. Pat. No. 4,156,578 to Agar et al which is incorporated here by reference.
It is also generally known to utilize digital computers or microporcessors for some control functions in plants, including plants that might use a turbo compressor. Such microprocessors or computers which are available from U.S. manufacturers are the Honeywell TDC 2000; the Micon P200; the Foxboro Microspec/Spectrum, the Fisher Controls Provox and many others. Computers available from manufacturers outside the United States include the Siemens Teleperm M; the Hartmann & Braun Contronic 3; the Kent P4000 and the Yokogawa Centum.
As known in the art, these digital computers can perform various calculations. This would include the calculation identified above for calculating adiabatic head. A drawback of such computers, however, is that they have a finite cycle time. In other words, a computation must be made on the basis of measurements taken at a certain point in time. Since it takes a certain amount of time to perform the calculations and generate a signal which could be used for control, the variable may change during this interim. It is generally known that this cycle time for above mentioned systems can be about 0.2 to 0.5 seconds. This delay is not acceptable for turbo compressors anti-surge control which can be damaged if operated beyong the surge limit even for vey short periods of time.
Another problem associated with the use of digital computers or microprocessors as a control mechanism is their relatively high failure rate which is a function of their complexity.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for and a method of operating turbo compressors which eliminates the mentioned drawbacks and ensures, with a minimum of expense, that any parameter can be taken into account and even data representing blowoff lines which are difficult to reproduce can be determined by the controller exactly.
Accordingly, an object of the invention is to provide a method of operating turbo compressors, particularly those of large capacity, wherein the compressor rate of flow and the discharge pressure (or compression ratio) of the compressor are continuously measured and compared with permissible values therefor, and wherein, in order to prevent surging, for example prior to the reaching of a surge limit, it is ensured that the rate of flow of the compressor does not fall below a minimum value which depends on the discharge pressure using a closed loop controller which operates to open blowoff valves upon receiving data or a value representing the attainment of a blowoff line that is parallel to the surge limit. According to the invention an analog controller of simple design which is responsive to a value representing a basic linear blowoff line of the pressureflow characteristic curve of the compressor which is below an optimum blowoff line therefor, adjusts the blowoff valve, and, by means of an error signal produced in a separate digital computing circuit which is superimposed on the basic control, an optimized compressor operation is obtained.
If the suction pressure P 1 is constant, only discharge pressure P 2 is measured. If P 1 is variable, the set-point for the surge line is taken from P 2 /P 1 rather than by P 2 .
A further object of the invention is to provide a device for controlling the operation of a turbo compressor which comprises first means for continuously measuring a flow rate of the compressor, second means for measuring one of a discharge pressure or a compression ratio of the compressor, and analog controller systems for controlling the compressor, which is responsive to a value representing a basic linear blowoff line on a pressure-flow curve of the compressor, the basic blowoff line being below an optimum blowoff line on the curve, and a computing circuit connected to the analog controller for computing an error signal representing a difference between data representing the basic and optimum blowoff lines in an operating pressure or pressure ratio, the computing circuit operable to apply the error signal to the analog controller to control the compressor to an optimum extent at the operating pressure or pressure ratio.
A further object of the invention is to provide such a device which is simple in design, rugged in construction and economical to manufacture.
By superimposing the error signal on the basic control signal from the analog control system, if a fault occurs in the computing circuit, the error signal falls to zero and the turbo compressor is controlled according to the basic blowoff line. In this way, satisfactory control is maintained even if the computing circuit fails. Also, it is important to note since the analog control system operates instantaneously, the invention follows even fast changing conditions which cannot normally be followed by the computing circuit alone.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, one embodiment of the invention is explained in more detail with reference to the drawings in which:
FIG. 1 is a pressure-flow diagram showing the surge limit line P, the optimum blowoff line characteristic line A, and the basic blowoff characteristic line B; and
FIG. 2 is a schematic representation of a system for carrying out the inventive method.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, in particular, the invention embodied therein, in FIG. 2 comprises a basic or analog control system including transducers 10 and 11, a function generator 8, an extreme-value selector 3, a controller 2, a transducer 1, a manually controlled integrator 7 with a keyboard 9, and digital computing means in the form of a computer 6 with galvanic islolating transducers 4, 5, 20 and 21 and the additional ones shown.
All parameters required for adjusting the blowoff characteristic line in an optimum way to the surge limit (such as suction temperature correction T 1 , parameters for flow calculation to be taken into account, humidity φ, molecular weight M, suction pressure P 1 , as well as other interesting factors) are fed into computing circuit 6 in the form of data representing these parameters.
As shown in FIG. 1, the optimum blowoff line at A is close to and parallel with the surge line P, representing the actual point at which surge will occur. The ordinate of the graph of FIG. 1 showing output pressure P 2 for compressor 30 on its output line 32 (FIG. 2) actually represents adiabatic head ΔH ab . Optimum blowoff line A is always slightly to the right of the actual surge line P for every operating point P 2 ', to maintain a safety factor of for example 70% for variables or conditions which cannot be met by the equation for calculating adiabatic head equation (1) set forth above. FIG. 1 also shows the linear basic blowoff line B which must maintain an even greater safety margin from surge line P. This additional margin must be maintained since the basic blowoff line B does not take variables such as inlet temperature, humidity and molecular weight into account.
As shown in FIG. 2, the various parameters which are used to calculate adiabatic head according to equation (1) can be measured for example from inlet line 31 for compressor 30. Transmitters 23, 25, 27 and 29, each of known design, can generate current signals which are proportional to the input temperature T 1 , the input pressure P 1 , the humidity φ and molecular weight M for the gas entering compressor 30. The current signals which are used to transmit information over relatively long distances, are supplied to transducers 22, 24, 26 and 28 respectively which convert the currents to appropriate voltages which are applied as voltage levels (data) to computer or computing circuit 6. As will be explained later, computer circuit 6 also receives additional signals (data) for completing the calculation and generating an appropriate error signal.
In the computing circuit 6, values or data representing the position of the blowoff line (B in FIG. 1) in the basic control is compared with values or data representing the optimum blowoff line (A in FIG. 1) as computed in the computing circuit, and the resulting error signal value X k is superimposed on the signal from the basic control system (8, 10, 11) at adder 12 and over transducer 4, so that the output of basic controller 2 pilots the machine to the optimum working point by blowoff valve 17 which is controlled by transducer 1, sending unit 18 and actuator 19 (which are all of known design). This comparison step will be explained in greater detail.
Upon failure or other trouble in the computing circuit 6, this circuit switches off, error signal value X k becomes zero, and the machine is further operated, on the safe side, with the basic control system alone. The separation also increases the safety and availability in instances where the output signal of the computing circuit is checked for reasonability or probability.
Computers of the type mentioned above which are all suitable as computing circuit or computer 6, are also known to be have self diagnostic circuits which can detect a fault. This can be used to artificially produce a zero signal for the error signal X k which is supplied through isolating transducer 4 to adder 12.
The operation will now be explained in connection with FIG. 1. A delivery pressure P 2 ' corresponds to a volumetric flow V B on the blowoff line B of the basic control. Through basic controller 2, the blowoff valve 17 is adjusted to obtain an actual flow rate V ist which is equal or larger than the desired flow V B . V ist is the measured volumetric flow, measured in the compressor inlet or discharge. The error signal value represented by:
X.sub.dB =V.sub.B -V.sub.ist
is zero, when the operating point is on the blowoff line and the controller is in operation.
Computing circuit 6 computes the optimum required flow rate V opt and forms therefrom the error signal valve:
X.sub.k =V.sub.opt -V.sub.ist -X.sub.dB (3)
This value is added to error signal valve X db by adder 12, so that basic controller 2 continues to adjust the blowoff valve until the input of the controler becomes zero, i.e. until V ist =V opt .
In another variant of the method, the basic blowoff characteristic line B is stored (as data) in the computing circuit 6. Then, the transfer of X dB to the basic control is omitted, since this value can be formed within the computing circuit.
It is noted that where data corresponding to the basic line B is not stored in the computing circuit 6, they can easily be calculated using the isolating transducers 20 and 21. Transducers 20 and 21 are connected to transmitters 15 and 16. Transmitter 15 is connected to the outlet line 31 and produces a current proportional to the output pressure P 2 . Transmitter 16 is connected to spaced apart pressure sensors in the compressor 30 and yield a pressure difference value which can be used as a flow rate value for a flow of gas through the compressor 30. These currents are changed to voltages in transducers 20 and 21 and provided as data to computer 6. It is noted that the same transmitters 15 and 16 are provided to the transducers 11 and 10 respectively of the analog control system. It is noted that function generator 8 connected to the output of transducer 11 generates the basic blowoff line B data from the voltage signal it receives which signal is proportional to the outlet pressure of the compressor 30. Additional details on this analog control can be found in U.S. Pat. No. 4,384,818 to Blotenberg, which was identified above. It is noted that rather than following the output pressure P 2 , the compression ratio for compressor 30 can easily be obtained since the input pressure P 1 can either be sensed in a known way or held constant, in which case the output pressure P 2 corresponds to the compression ratio.
The signal from function generator 8 and from flow rate transducer 10 are subtracted in comparator 13 to generate the analog control error X dB which is supplied to adder 12. If the two signals supplied to comparator 13 are equal, this means that the control error X dB is zero and no change is necessary for the blowoff valve 17. If the control error is negative, indicating a greater flow rate than necessary, controller 2 is operated to close down blowoff valve 17 at a rate which is determined by the controller 2 according to the size of the control signal. If a control signal is positive indicating too low a flow rate controller 2 controls valve 17 towards open position.
The more refined optimum error signal X k modifies the control error X dB in adder 12. The combined signal is supplied to an extreme value selector 3 which also is of known design and is disclosed in the Blotenberg Pat. No. 4,384,818.
Extreme value selector 3 also receives a signal from a comparator 14 which responds to a manually impressed signal. Extreme value selector 3 will select the highest value to impress on controller 2. Comparator 14 receives a signal from manually controlled integrator 7 which can output a value from zero to 100 percent depending on a manipulation of manual switch or switches 9. The manufally impressed signal is compared with the actual position of controller output 2, in comparator 14, and if the two values are not equal a control error is applied to the extreme value selector 3.
In order to perform the calculation of the equation (3), computer 6 receives a signal from the output of comparator 13 which corresponds to the basic control error X dB .
In this blowoff control for turbo compressors, the values of a number of mathematical functions are to be produced, trends are to be analyzed, and non-linear characteristics are to be stored.
This may be done with digital microprocessors or computers as noted above.
Since such systems are not yet reliable to an extent required for the operation of industrial turbo compressors, the invention uses them in conjunction with the reliable analog system.
Therefore, a combined blowoff control may be considered. All of the complicated computing is performed by a digital microprocessor 6, such as the basic controller 2, and elements 10, 11 furnish the needed reliability of control.
The basic controller 2 is simple in design and is known. The desired value is formed from the delivery pressure as measured by transducer 11. The blowoff line is represented by the straight line B in FIG. 1. A correction of the actual value of variables of the volumetric flow may frequently be omitted, which also goes for the influence of the temperature at the suction side. The blowoff line is set to insure a satisfactory protection of the machine at all working points and under any operating conditions. This frequently leads to the result that the machine is operated with an unnecessarily large margin between the surge limit and the blowoff line.
The prior art manual control of the blowoff valves is also analog in design.
Now, if a microporcessor fails, error signal value X k becomes zero and the working point adjusts to V ist =V B . This is because selector 3 then receives only the X dB signal from adder 12.
This circuit has the advantage of employing a single controller, namely the basic controller 2 which is permanently engaged. Any switching and build-up problems are thereby eliminated.
Should the microprocessor 6 be intended for more complex algorithms the evaluation of which would interfere with the operation of an analog PI controller, a somewhat modified structure is possible, wherein, with the microprocessor switched on, the integrating part in the basic controller 2 is switched off by a signal on line S. Then, the controller 2 operates only as a proportional amplifier. The microprocessor compares the output of the analog basic controller over transducer 5 with the output of the digital computer (internal to circuit 6) and adjusts the error signal value X k to obtain identical controller outputs.
The circuit of the microprocessor 6 may include elements responsive to the inverted behavior in time of the controller, in which case there is no need for modifying the structure of the controller.
Upon taking a manual control action, the microprocessor 6 must be switched off. This instruction may either be recalled from the manually controlled integrator 7 on line H or derived from a comparison between the input and output of the extreme value selector 3.
An equilibrating circuit in the computing circuit 6 provides for an elimination of jumps upon a manual control action, and upon switching on of the computing circuit.
The layout of the circuit for carrying out the invention is shown in FIG. 2. Therefrom, a person skilled in the art may derive obvious modifications. While considering the labelled blocks, the operation of the circuit is a matter of course for a person with expertise in the field. For quick reference, the various elements and values of the invention are listed as follows:
voltage-current transducer 1;
controller 2;
extreme-value selector 3;
isolator 4;
isolator 5;
computing circuit 6;
manually controlled integrator 7;
function generator 8;
keyboard 9;
current-voltage transducer for measuring the rate of flow (at the suction side) 10;
current-voltage transducer for measuring the pressure (downstream of compressor) 11;
manual control imput to computing circuit;
error signal value X k ;
structure switching of the controller S;
surge limit P;
optimum blowoff line A; and
basic blowoff line B.
The error signal value X k may be superposed on either the desired value (the control error X dB ) or on the actual value (while taking into account the sign), it may be advantageous in many instances of application to provide a penumatically hydraulically operated basic control, instead of an electronic analog control. Since the basic control is linear, thus follows a straight line, the mechanical, i.e. pneumatic or hydraulic basic control can be designed simply and properly. What is important is to keep to the inventive solution, namely the separation into a basic and a corrective control, to obtain a control which is improved and still safely prevents surging upon a failure or disturbance in the system.
The inventive circuit is also capable of making a reliable correction of the computed surge limit.
If a surge occurs, the operational data at that point are collected and stored. The corresponding point on the blowoff line is determined from the delivery pressure. The corresponding rate of flow at the surge limit is determined from the set safety margin between the surge limit and the blowoff line. If the computed and the measured rates of flow differ from each other, the blowoff line is readjusted by this difference. In advance, the measured values of the surge point may be checked for reasonableness. For example, a correction may be omitted upon the occurrence of certain disturbances which are very rare in normal operation. Further, the circuit may be designed to make a correction only if a plurality of surges of equal tendency occur.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A method and arrangement for controlling the operation of turbo compressors, particularly those of high capacity, utilizes flow rate and pressure values for an analog controller as well as a computing circuit to optimize the operation of the compressor. The compressor is assumed to have a characteristic basic linear blowoff line and an optimum non-linear blowoff line on its pressure/flow curve. The calculating or computing circuit computes an error signal representing a difference between the basic and optimum blowoff line at an operating pressure and applies the signal to the analog controller which controls the compressor to its optimum extent. An analog system connected to the controller maintains control at least according to the basic blowoff line if the computing circuit fails. | 5 |
FIELD OF THE INVENTION
The present invention relates to the use of 5-amino-pyrazole derivatives, some of which are known, for controlling undesirable microorganisms.
BACKGROUND OF THE INVENTION
It is already known that certain 5-amino-pyrazole derivatives are suitable for controlling animal pests (cf. WO-A 96-21 653). However, the use of these substances against undesirable microorganisms has hitherto not been described.
SUMMARY OF THE INVENTION
5-Amino-pyrazole derivatives of the formula
wherein R 1 , R 2 , R 3 , R 4 , R 5 and Y are defined may be used for controlling undesirable microorganisms.
DETAILED DESCRIPTION
It has now been found that 5-amino-pyrazole derivatives of the formula
in which
R 1 represents alkyl, cycloalkyl, alkoxyalkyl or halogenoalkyl,
R 2 represents hydrogen, halogen, cyano, nitro, halogenoalkylthio, aikoxycarbonyl or alkenyloxycarbonyl,
R 3 represents optionally substituted alkyl or optionally substituted cycloalkyl,
R 4 represents hydrogen, alkyl or optionally substituted cycloalkyl,
Y represents optionally substituted alkanediyl or alkenediyl and
R 5 represents optionally substituted aryl or optionally substituted aryloxy,
are highly suitable for controlling undesirable microorganisms, both in crop protection and in the protection of materials.
Surprisingly, the 5-amino-pyrazole derivatives of the formula (I) which can be used according to the invention exhibit considerably better microbicidal activity than the constitutionally most similar prior-art substances of the same direction of action.
The formula (I) provides a general definition of the 5-amino-pyrazole derivatives which can be used according to the invention.
R 1 preferably represents alkyl having 1 to 4 carbon atoms, cycloalkyl having 3 to 7 carbon atoms, alkoxyalkyl having 1 to 4 carbon atoms in the alkyl moiety and 1 to 4 carbon atoms in the alkoxy moiety or represents halogenoalkyl having 1 to 4 carbon atoms and 1 to 5 identical or different halogen atoms,
R 2 preferably represents hydrogen, fluorine, chlorine, bromine, cyano, nitro, trifluoromethylthio, difluoromethylthio, alkoxycarbonyl having 1 to 4 carbon atoms in the alkoxy moiety or represents alkenyloxycarbonyl having 2 to 4 carbon atoms in the alkenyloxy moiety,
R 3 preferably represents optionally cyano-substituted alkyl having 1 to 4 carbon atoms or represents cycloalkyl having 3 to 6 carbon atoms which is optionally mono- to trisubstituted by identical or different substituents from the group consisting of halogen and alkyl having 1 to 4 carbon atoms,
R 4 preferably represents hydrogen, alkyl having 1 to 4 carbon atoms or represents cycloalkyl having 3 to 6 carbon atoms which is optionally mono- to trisubstituted by identical or different substituents from the group consisting of halogen and alkyl having 1 to 4 carbon atoms,
Y preferably represents alkanediyl having 1 to 4 carbon atoms which is optionally mono- or disubstituted by halogen and/or cycloalkyl having 3 to 6 carbon atoms and
R 5 preferably represents phenyl or phenoxy, where each of these radicals may be mono- to tetrasubstituted by identical or different substituents from the group consisting of halogen, nitro, cyano, C 1 -C 12 -alkyl, C 1 -C 12 -alkoxy, C 1 -C 12 -alkylthio, C 1 -C 12 -halogenoalkyl, C 1 -C 12 -halogenoalkoxy, C 1 -C 12 -halogenoalkylthio, C 2 -C 12 -alkenyl, C 1 -C 4 -alkoxy-C 2 -C 12 -alkenyl, C 1 -C 4 -alkylthio-C 2 -C 12 -alkenyl, C 2 -C 12 -halogenoalkenyl, carboxyl, hydroximinoalkyl having 1 to 4 carbon atoms in the alkyl moiety, alkoximinoalkyl having 1 to 4 carbon atoms in the alkoxy moiety and 1 to 4 carbon atoms in the alkyl moiety, alkenyloximinoalkyl having 2 to 4 carbon atoms in the alkenyloxy moiety and 1 to 4 carbon atoms in the alkyl moiety, alkylcarbonyl having 1 to 6 carbon atoms in the alkyl moiety, alkylcarbonyloxy having 1 to 4 carbon atoms in the alkyl moiety, or by phenyl, phenoxy, phenylthio, benzyl, benzyloxy and/or pyridyloxy, where the six lastmentioned radicals for their part may be mono- to trisubstituted by identical or different radicals from the group consisting of halogen, nitro, cyano, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -halogenoalkyl, C 1 -C 4 -halogenoalkoxy and C 1 -C 4 -halogenoalkylthio,
or
R 5 preferably represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 6 represents phenyl or pyridyl, where each of these radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of halogen, alkyl having 1 to 4 carbon atoms, halogenoalkyl having 1 to 4 carbon atoms and 1 to 5 identical or different halogen atoms and halogenoalkoxy having 1 to 4 carbon atoms and 1 to 5 identical or different halogen atoms,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 7 represents alkyl having 1 to 6 carbon atoms or alkoxyalkyl having 1 to 6 carbon atoms in the alkoxy moiety and 1 to 6 carbon atoms in the alkyl moiety,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 8 represents alkyl having 1 to 6 carbon atoms, benzyl or pyridylmethyl, where the two lastmentioned radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of halogen, alkyl having 1 to 4 carbon atoms, halogenoalkyl having 1 to 4 carbon atoms and 1 to 5 identical or different halogen atoms and halogenoalkoxy having 1 to 4 carbon atoms and 1 to 5 identical or different halogen atoms,
or
R 5 represents a radical of the formula
R 1 particularly preferably represents methyl, ethyl, n- or i-propyl or n-, i-, s- or t-butyl, cyclopropyl, represents methoxymethyl, ethoxymethyl, methoxyethyl, ethoxyethyl, trifluoromethyl, difluoromethyl, fluoromethyl, 1-chloro-1-ethyl or 1-fluoro- 1-ethyl.
R 2 particularly preferably represents hydrogen, fluorine, chlorine, bromine, cyano, nitro, trifluoromethylthio, difluoromethylthio, methoxycarbonyl, ethoxycarbonyl, n- or i-propoxycarbonyl, n-, i-, s- or t-butoxycarbonyl or allyloxycarbonyl.
R 3 particularly preferably represents methyl, ethyl, n- or i-propyl, n-, i-, s- or t-butyl, or represents 2-cyanoethyl, cyclopropyl, cyclopentyl or cyclohexyl, where the three lastmentioned radicals may be mono- to trisubstituted by identical or different radicals from the group consisting of fluorine, chlorine, methyl and ethyl.
R 4 particularly preferably represents hydrogen, methyl, ethyl, n-propyl, isopropyl, n-, i-, s- or t-butyl or represents cyclopropyl, cyclopentyl or cyclohexyl, where the three lastmentioned radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chorine, methyl and ethyl.
Y particularly preferably represents a grouping of the formula
—CH 2 —, —CH(CH 3 )—, —CH 2 CH 2 —, —CH(C 2 H 5 )—, —CH(C 3 H 7 -i)—, —CHF—, CHCl——CH(cyclopropyl)— or —CH═CH—.
R 5 particularly preferably represents phenyl or phenoxy, where each of these radicals may be mono- to tetrasubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, nitro, cyano, methyl, ethyl, n- and i-propyl, n-, i-, s- and t-butyl, methoxy, ethoxy, n- and i-propoxy, n-, i-, s- and t-butoxy, methylthio, trifluoromethyl, difluoromethyl, trifluoromethoxy, difluoromethoxy, trifluoromethylthio, difluoromethyithio, carboxyl, hydroximinoalkyl having 1 or 2 carbon atoms in the alkyl moiety, alkoximinoalkyl having 1 to 4 carbon atoms in the alkoxy moiety and 1 or 2 carbon atoms in the alkyl moiety, alkenyloximninoalkyl having 2 to 4 carbon atoms in the alkenyloxy moiety and 1 or 2 carbon atoms in the alkyl moiety, alkylcarbonyl having 1 to 4 carbon atoms in the alkyl moiety, alkylcarbonyloxy having 1 to 4 carbon atoms in the alkyl moiety, or by phenyl, phenoxy, phenylthio, benzyl, benzyloxy and/or pyridyloxy, where the six lastmentioned radicals for their part may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, nitro, cyano, methyl, ethyl, tert-butyl, methylthio, methoxy, ethoxy, n- or i-propoxy or n-, i-, s- or t-butoxy, trifluoromethyl, trifluoromethoxy, difluoromethoxy and trifluoromethylthio,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 6 represents phenyl or pyridyl, where each of these radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, methyl, ethyl, n-propyl, halogenoalkyl having 1 or 2 carbon atoms and 1 to 3 fluorine-, chlorine- and/or bromine atoms and halogenoalkoxy having 1 or 2 carbon atoms and 1 to 3 fluorine, chlorine and/or bromine atoms,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 7 represents alkyl having 1 to 4 carbon atoms or alkoxyalkyl having 1 to 4 carbon atoms in the alkoxy moiety and 1 to 4 carbon atoms in the alkyl moiety,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 8 represents alkyl having 1 to 4 carbon atoms, benzyl or pyridylmethyl, where the two lastmentioned radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, methyl, ethyl, n-propyl, halogenoalkyl having 1 or 2 carbon atoms and 1 to 3 fluorine, chlorine and/or bromine atoms and halogenoalkoxy having 1 or 2 carbon atoms and 1 to 3 fluorine, chlorine and/or bromine atoms,
or
R 5 represents a radical of the formula
R 1 very particularly preferably represents methyl, ethyl, i-propyl, tert-butyl, methoxymethyl, 1-chlorine-1-ethyl, 1-fluorine-1-ethyl or cyclopropyl.
R 2 very particularly preferably represents hydrogen, chlorine, bromine, cyano, nitro, methoxycarbonyl, ethoxycarbonyl or allyloxycarbonyl.
R 3 very particularly preferably represents methyl, ethyl, i-propyl, tert-butyl, cyclopropyl or 2-cyanoethyl.
R 4 very particularly preferably represents hydrogen, methyl, ethyl, i-propyl or cyclopropyl.
Y very particularly preferably represents a grouping of the formula
R 5 very particularly preferably represents phenyl or phenoxy, where each of these radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, nitro, cyano, methyl, ethyl, n- and i-propyl, n-, i-, s- and t-butyl, methoxy, ethoxy, n- and i-propoxy, n-, i-, s- and t-butoxy, methylthio,. trifluoromethyl, trifluoromethoxy, difluoromethoxy, trifluoromethylthio, carboxyl, hydroximinomethyl, hydroximinoethyl, alkoximinoalkyl having 1 to 4 carbon atoms in the alkoxy moiety and 1 or 2 carbon atoms in the alkyl moiety, allyloximinoalkyl having 1 or 2 carbon atoms in the alkyl moiety, methylcarbonyl, ethylcarbonyl, methylcarbonyloxy, ethylcarbonyloxy, or by phenyl, phenoxy, phenylthio, benzyl, benzyloxy and/or pyridyloxy, where the six lastmentioned radicals for their part may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, nitro, cyano, methyl, tert-butyl, methylthio, methoxy, ethoxy, n- and i-propoxy, n-, i-, s- and t-butoxy, trifluoromethyl, trifluoromethoxy, difluoromethoxy and trifluoromethylthio,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 6 represents phenyl or pyridyl, where each of these radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, methyl, ethyl, trifluoromethyl and trifluoromethoxy,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 7 represents methyl, ethyl, n-propyl or alkoxyalkyl having 1 to 4 carbon atoms in the alkoxy moiety and 1 or 2 carbon atoms in the alkyl moiety,
or
R 5 represents phenyl or phenoxy, where each of these radicals is monosubstituted by a radical of the formula
in which
R 8 represents methyl, ethyl, n-propyl, benzyl or pyridylmethyl, where the two lastmentioned radicals may be mono- to trisubstituted by identical or different substituents from the group consisting of fluorine, chlorine, bromine, methyl, ethyl, n-propyl, trifluoromethyl and trifluoromethoxy,
or
R 5 represents a radical of the formula
The given definitions of substituents can be combined with one another as desired. Moreover, individual definitions of substituents may also apply.
Some of the 5-amino-pyrazole derivatives of the formula (I) which can be used according to the invention are known (cf. WO-A 96-21 653).
The 5-amino-pyrazole derivatives of the formula
in which
a) R 9 represents chlorine,
R 10 represents the radical
R 11 represents hydrogen,
or
b) R 9 and R 11 each represent hydrogen and
R 10 represents the radical
or
c) R 9 represents hydrogen, chlorine, cyano or ethoxycarbonyl,
R 10 represents hydrogen and
R 11 represents chlorine, bromine, methoxy or trifluoromethyl, are novel.
The 5-amino-pyrazole derivatives of the formula (Ia) can be prepared by
a) reacting 5-aminopyrazoles of the formula
in which
R 9 is as defined above
with acyl halides of the formula
in which
R 10 and R 11 are as defined above and
Hal represents chlorine or bromine,
if appropriate in the presence of an acid binder and if appropriate in the presence of a diluent,
or
b) reacting 5-amino-pyrazole derivatives of the formula
in which
R 10 and R 11 are as defined above,
with a chlorinating agent, if appropriate in the presence of a diluent and if appropriate in the presence of a catalyst.
Using the above process, it is also possible to prepare the other 5-amino-pyrazole derivatives of the formula (I).
The 5-amino-pyrazole derivatives of the formula
in which the substituents R 1 , R 2 , R 3 , R 5 and Y have the meanings given in Table 1 below are likewise novel.
TABLE 1
R 1
R 2
R 3
—Y—R 5
—CH 3
H
—CH 3
—CH 3
H
—CH 3
—CH 3
Br
—CH 3
—CH 3
Cl
—CH 3
C 2 H 5
—CN
—CH 3
C 2 H 5
Cl
—CH 3
C 2 H 5
—CN
—CH 3
C 2 H 5
—COOC 2 H 5
—CH 3
C 2 H 5
H
—CH 3
C 2 H 5
—COOC 2 H 5
—CH 3
C 2 H 5
—COOC 2 H 5
—CH 3
C 2 H 5
—CN
—CH 3
H
—CH 3
Cl
—CH 3
C 2 H 5
—COOC 2 H 5
—CH 3
—CH 3
Cl
—CH 3
—CH 3
H
—CH 2 —CH 2 —CN
—CH 3
—CN
—CH 3
C 2 H 5
—CN
—CH 3
—CH 3
—COO—CH 3
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
—CN
—CH 3
C 2 H 5
—CN
—CH 3
—CH 3
H
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
—COO—CH 3
—CH 3
C 2 H 5
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
Cl
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—CH 3
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
—C 2 H 5
—CN
—CH 3
The 5-amino-pyrazole derivatives listed in Table 1 are likewise prepared by the processes mentioned above.
Using 5-amino-3-ethyl-4-ethoxycarbonyl-1-methyl-pyrazole and (3-chlorophenyl)-acetyl chloride as starting materials, the course of the process (a) according to the invention can be illustrated by the equation below.
Using 5-(4-(4-chlorophenyl)-phenyl-acetylamino)-3-ethyl-l1-methyl-pyrazole as starting material and sulphuryl chloride as reaction component, the course of the process (b) according to the invention can be illustrated by the equation below.
The 5-aminopyrazoles of the formula (II) and acyl halides of the formula (III) required as starting materials for carrying out the process (a) according to the invention are known or can be prepared by known methods (cf. WO-A 96-21 653).
Suitable acid binders for carrying out the process (a) according to the invention are all customary inorganic or organic bases. Preference is given to using alkali metal or alkaline earth metal hydroxides, carbonates or bicarbonates and also nitrogen bases. Examples which may be mentioned are sodium hydroxide, calcium hydroxide, potassium carbonate, sodium bicarbonate, triethylamine, dibenzylamine, diisopropylamine, pyridine, quinoline, diazabicyclooctane (DABCO), diazabicyclononene (DBN) and diazabicycloundecene (DBU).
Suitable diluents for carrying out the process (a) according to the invention are all organic solvents which are customary for such reactions.
Preference is given to using optionally halogenated aliphatic or aromatic hydrocarbons, ethers or nitriles, such as, for example cyclohexane, toluene, chlorobenzene, chloroform, dichloromethane, dichloroethane, dioxane, tetrahydrofuran, diethyl ether or acetonitrile.
When carrying out the process (a) according to the invention, the reaction temperatures can be varied within a relatively wide range. In general, the process is carried out at temperatures between −40° C. and +150° C. preferably between 0° C. and 100° C.
The process (a) according to the invention is generally carried out under atmospheric pressure. However, it is also possible to operate under elevated or reduced pressure.
When carrying out the process (a) according to the invention, in general from 1 to 2 mol, preferably from 1 to 1.5 mol, of acyl halide of the formula (III) are employed per mole of 5-aminopyrazole of the formula (11). Work-up is carried out by customary methods.
The 5-amino-pyrazole derivatives of the formula (Ib) required as starting materials for carrying out the process (b) according to the invention are compounds which can be used according to the invention. They can be prepared by the process (a) according to the invention.
Suitable chlorinating agents for carrying out the process (b) according to the invention are all reagents which are customary for introducing chlorine. Preference is given to using chlorine gas, chlorine oxo acids and salts thereof, such as sodium hypochlorite or potassium hyprochlorite, furthermore chlorides, such as sulphuryl chloride, disulphur dichloride and phosphorus pentachloride.
Suitable diluents for carrying out the process (b) according to the invention are all organic solvents which are customary for such reactions.
Preference is given to using optionally halogenated aliphatic or aromatic hydrocarbons, ethers or nitrites, such as, for example, cyclohexane, toluene, chlorobenzene, chloroform, dichloromethane, dichloroethane, dioxane, tetrahydrofuran, diethyl ether or acetonitrile.
Suitable catalysts for carrying out the process (b) according to the invention are all reaction accelerators which are customary for such reactions. Preference is given to using hydrogen chloride, sodium acetate and free-radical formers, such as azoisobutyronitrile or dibenzoyl peroxide.
When carrying out the process (b) according to the invention, the reaction temperatures can likewise be varied within a relatively wide range. In general, the process is carried out at temperatures between −40° C. and +120° C., preferably between 0° C. and 80° C.
The process (b) according to the invention is generally carried out under atmospheric pressure. However, it is also possible to operate under elevated pressure.
When carrying out the process (b) according to the invention, in general from 1 to 2 mol, preferably from 1 to 1.5 mol, of chlorinating agent are employed per mole of 5-amino-pyrazole derivative of the formula (Ib). Work-up is again carried out by customary methods.
The compounds which can be used according to the invention have potent microbicidal activity and can be employed for controlling undesirable microorganisms, such as fungi and bacteria, in crop protection and in the protection of materials.
Fungicides are employed in crop protection for controlling Plasmodiophoromycetes, Oomycetes, Chytridiomycetes, Zygomycetes, Ascomycetes, Basidiomycetes and Deuteromycetes.
Bactericides are employed in crop protection for controlling Pseudomonadaceae, Rhizobiaceae, Enterobacteriaceae, Corynebacteriaceae and Streptomycetaceae.
Some pathogens causing fungal and bacterial diseases which come under the generic names listed above are mentioned as examples, but not by way of limitation:
Xanthomonas species, such as, for example, Xanthomonas campestris pv. oryzae;
Pseudomonas species, such as, for example, Pseudomonas syringae pv. lachrymans;
Erwinia species, such as, for example, Erwinia amylovora;
Pythium species, such as, for example, Pythium ultimum;
Phytophthora species, such as, for example, Phytophthora infestans;
Pseudoperonospora species, such as, for example, Pseudoperonospora humuli or Pseudoperonospora cubensis;
Plasmopara species, such as, for example, Plasmopara viticola;
Bremia species, such as, for example, Bremia lactucae;
Peronospora species, such as, for example, Peronospora pisi or P. brassicae;
Erysiphe species, such as, for example, Erysiphe graminis;
Sphaerotheca species, such as, for example, Sphaerotheca fuliginea;
Podosphaera species, such as, for example, Podosphaera leucotricha;
Venturia species, such as, for example, Venturia inaequalis;
Pyrenophora species, such as, for example, Pyrenophora teres or P. graminea (conidia form: Drechslera, syn: Helminthosporium);
Cochliobolus species, such as, for example, Cochliobolus sativus (conidia form: Drechslera, syn: Helminthosporium);
Uromyces species, such as, for example, Uromyces appendiculatus;
Puccinia species, such as, for example, Puccinia recondita;
Sclerotinia species, such as, for example, Sclerotinia sclerotiorum;
Tilletia species, such as, for example, Tilletia caries;
Ustilago species, such as, for example, Ustilago nuda or Ustilago avenae;
Pellicularia species, such as, for example, Pellicularia sasakii;
Pyricularia species, such as, for example, Pyricularia oryzae;
Fusarium species, such as, for example, Fusarium culmorum;
Botrytis species, such as, for example, Botrytis cinerea;
Septoria species, such as, for example, Septoria nodorum;
Leptosphaeria species, such as, for example, Leptosphaeria nodorum;
Cercospora species, such as, for example, Cercospora canescens;
Alternaria species, such as, for example, Altemaria brassicae;
Pseudocercosporella species, such as, for example, Pseudocercosporella herpotrichoides.
The fact that the active compounds are well tolerated by plants at the concentrations required for controlling plant diseases permits the treatment of aerial parts of plants, of propagation stock and seeds, and of the soil.
The active compounds which can be used according to the invention are particularly suitable for controlling Pyricularia oryzae on rice and for controlling cereal diseases, such as Puccinia, Erysiphe and Fusarium species. Moreover, the substances according to the invention can be used particularly successfully against Venturia, Podosphaera and Sphaerotheca. Moreover, they also have very good in vitro activity.
The active compounds which can be used according to the invention are also suitable for increasing the yield of crops. Moreover, they have reduced toxicity and are tolerated well by plants.
In the protection of materials, the compounds according to the invention can be employed for protecting industrial materials against infection with, and destruction by, undesired microorganisms.
Industrial materials in the present context are understood as meaning non-living materials which have been prepared for use in industry. For example, industrial materials which are intended to be protected by active compounds according to the invention from microbial change or destruction can be adhesives, sizes, paper and board, textiles, leather, wood, paints and plastic articles, cooling lubricants and other materials which can be infected with, or destroyed by, microorganisms. Parts of production plants, for example cooling-water circuits, which may be impaired by the proliferation of microorganisms may also be mentioned within the scope of the materials to be protected. Industrial materials which may be mentioned within the scope of the present invention are preferably adhesives, sizes, paper and board, leather, wood, paints, cooling lubricants and heat-transfer liquids, particularly preferably wood.
Microorganisms capable of degrading or changing the industrial materials which may be mentioned are, for example, bacteria, fungi, yeasts, algae and slime organisms. The active compounds according to the invention preferably act against fungi, in particular moulds, wood-discolouring and wood-destroying fungi (Basidiomycetes) and against slime organisms and algae.
Microorganisms of the following genera may be mentioned as examples:
Alternaria, such as Alternaria tenuis,
Aspergillus, such as Aspergillus niger,
Chaetomium, such as Chaetomium globosum,
Coniophora, such as Coniophora puetana,
Lentinus, such as Lentinus tigrinus,
Penicillium, such as Penicillium glaucum,
Polyporus, such as Polyporus versicolor,
Aureobasidium, such as Aureobasidium pullulans,
Sclerophoma, such as Sclerophoma pityophila,
Trichoderma, such as Trichoderma viride,
Escherichia, such as Escherichia coli,
Pseudomonas, such as Pseudomonas aeruginosa , and
Staphylococcus, such as Staphylococcus aureus.
Depending on their particular physical and/or chemical properties, the active compounds can be converted to the customary formulations, such as solutions, emulsions, suspensions, powders, foams, pastes, granules, aerosols and rrricroencapsulations in polymeric substances and in coating compositions for seeds, and ULV cool and warm fogging formulations.
These formulations are produced in a known manner, for example by mixing the active compounds with extenders, that is, liquid solvents, liquefied gases under pressure, and/or solid carriers, optionally with the use of surfactants, that is emulsifiers and/or dispersants, and/or foam formers. If the extender used is water, it is also possible to use organic solvents, for example, auxiliary solvents. The following are mainly suitable as liquid solvents: aromatics such xylene, toluene or alkylnaphthalenes, chlorinated aromatics or chlorinated aliphatic hydrocarbons such as chlorobenzenes, chloroethylenes or methylene chloride, aliphatic hydrocarbons such as cyclohexane or paraffins, for example petroleum fractions, alcohols such as butanol or glycol and their ethers and esters, ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone or cyclohexanone, strongly polar solvents such as dimethylformamide or dimethyl sulphoxide, or else water. Liquefied gaseous extenders or carriers are to be understood as meaning liquids which are gaseous at standard temperature and under atmospheric pressure, for example aerosol propellants such as halogenated hydrocarbons, or else butane, propane, nitrogen and carbon dioxide. Suitable solid carriers are: for example ground natural minerals such as kaolins, clays, talc, chalk, quartz, attapulgite, montmorillonite or diatomaceous earth, and ground synthetic minerals such as highly disperse silica, alumina and silicates. Suitable solid carriers for granules are: for example crushed and fractionated natural rocks such as calcite, marble, pumice, sepiolite and dolomite, or else synthetic granules of inorganic and organic meals, and granules of organic material such as sawdust, coconut shells, maize cobs and tobacco stalks. Suitable emulsifiers and/or foam formers are: for example nonionic and anionic emulsifiers, such as polyoxyethylene fatty acid esters, polyoxyethylene fatty alcohol ethers, for example alkylaryl polyglycol ethers, alkylsulphonates, alkyl sulphates, arylsulphonates, or else protein hydrolysates. Suitable dispersants are: for example lignin-sulphite waste liquors and methylcellulose.
Tackifiers such as carboxymethylcellulose and natural and synthetic polymers in the form of powders, granules or latices, such as gum arabic, polyvinyl alcohol and polyvinyl acetate, or else natural phospholipids such as cephalins and lecithins and synthetic phospholipids can be used in the formulations. Other additives can be mineral and vegetable oils.
It is possible to use colorants such as inorganic pigments, for example iron oxide, titanium oxide and Prussian Blue, and organic dyestuffs such as alizarin dyestuffs, azo dyestuffs and metal phthalocyanine dyestuffs, and trace nutrients such as salts of iron, manganese, boron, copper, cobalt, molybdenum and zinc.
The formulations generally comprise between 0.1 and 95 per cent by weight of active compound, preferably between 0.5 and 90%.
The active compounds which can be used according to the invention can be used as such or in their formulations also mixed with known fungicides, bactericides, acaricides, nematicides or insecticides in order thus, for example, to widen the spectrum of action or to prevent development of resistance. In many cases, synergistic effects are achieved, i.e. the activity of the mixture exceeds the activity of the individual components.
Examples of co-components in mixtures are the following compounds:
Fungicides:
aldimorph, ampropylfos, ampropylfos potassium, andoprim, anilazine, azaconazole, azoxystrobin,
benalaxyl, benodanil, benomyl, benzamacril, benzamacril-isobutyl, bialaphos, binapacryl, biphenyl, bitertanol, blasticidin-S, bromuconazole, bupirimate, buthiobate,
calcium polysulphide, capsimycin, captafol, captan, carbendazim, carboxin, carvon, quinomethionate, chlobenthiazone, chlorfenazole, chloroneb, chloropicrin, chlorothalonil, chlozolinate, clozylacon, cufraneb, cymoxanil, cyproconazole, cyprodinil, cyprofuram,
debacarb, dichlorophen, diclobutrazole, diclofluanid, diclomezine, dicloran, diethofencarb, difenoconazole, dimethirimol, dimethomorph, diniconazole, diniconazole-M, dinocap, diphenylamine, dipyrithione, ditalimfos, dithianon, dodemorph, dodine, drazoxolon,
edifenphos, epoxiconazole, etaconazole, ethirimol, etridiazole,
famoxadon, fenapanil, fenarimol, fenbuconazole, fenfuram, fenitropan, fenpiclonil, fenpropidin, fenpropimorph, fentin acetate, fentin hydroxide, ferbam, ferimzone, fluazinam, flumetover, fluoromide, fluquinconazole, flurprimidol, flusilazole, flusulfamide, flutolanil, flutriafol, folpet, fosetyl-aluminium, fosetyl-sodium, fthalide, fuberidazole, furalayl, furametpyr, furcarbonil, furconazole, furconazole-cis, furmecyclox,
guazatine,
hexachlorobenzene, hexaconazole, hymexazole,
imazalil, imibenconazole, iminoctadine, iminoctadine albesilate, iminoctadine triacetate, iodocarb, ipconazole, iprobenfos (IBP), iprodione, irumamycin, isoprothiolane, isovaledione,
kasugamycin, kresoxim-methyl, copper preparations, such as: copper hydroxide, copper naphthenate, copper oxychloride, copper sulphate, copper oxide, oxine-copper and Bordeaux rnixture,
mancopper, mancozeb, maneb, meferimzone, mepanipyrim, mepronil, metalaxyl, metconazole, methasulfocarb, methfuroxam, metiram, metomeclam, metsulfovax, imildiomycin, myclobutanil, myclozolin,
nickel dimethyldithiocarbamate, nitrothal-isopropyl, nuarimol,
ofurace, oxadixyl, oxamocarb, oxolinic acid, oxycarboxim, oxyfenthiin,
paclobutrazole, pefurazoate, penconazole, pencycuron, phosdiphen, pimaricin, piperalin, polyoxin, polyoxorim, probenazole, prochloraz, procymidone, propamocarb, propanosine-sodium, propiconazole, propineb, pyrazophos, pyrifenox, pyrimethanil, pyroquilon, pyroxyfur,
quinconazole, quintozen(PCNB), quinoxyfery
sulphur and sulphur preparations,
tebuconazole, tecloftalam, tecnazene, tetcyclasis, tetraconazole, thiabendazole, thicyofen, thifluzamide, thiophanate-methyl, thiram, tioxymnid, tolclofos-methyl, tolylfluanid, triadimefon, triadimenol, triazbutil, triazoxide, trichlamide, tricyclazole, tridemorph, triflumizole, triforine, triticonazole,
uniconazole,
validamycin A, vinclozolin, viniconazole,
zarilarnide, zineb, ziram and also
Dagger G,
OK-8705,
OK-8801,
α-(1,1-dimethylethyl)-β-(2-phenoxyethyl)-1H- 1,2,4-triazole-1-ethanol,
α-(2,4-dichlorophenyl)-β-fluoro-β-propyl-1H- 1,2,4-triazole- 1-ethanol,
α-(2,4-dichlorophenyl)-β-methoxy-α-methyl-1H-1,2,4-triazole-1-ethanol,
α-(5-methyl-1,3-dioxan-5-yl)-β[[4-(trifluoromethyl)-phenyl]-methylene]-1H-1,2, 4-triazole-1-ethanol,
(5RS,6RS)-6-hydroxy-2,2,7,7-tetramethyl-5-(1H-1,2,4-triazol-1-yl)-3-octanone,
(E)-α-(methoxyimino)-N-methyl-2-phenoxy-phenylacetamide,
1-isopropyl {2-methyl-1-[[[1-(4methylphenyl)-ethyl]-amino]-carbonyl]-propyl}-carbamate,
1-(2,4dichlorophenyl)-2-(1H-1,2,4-triazol-1-yl)-ethanone-O-(phenylmethyl)-oxime,
1-(2-methyl-1-naphthalenyl)-1H-pyrrole-2,5-dione,
1-(3,5-dichlorophenyl)-3-(2-propenyl)-2,5-pyrrolidinedione,
1-[(diiodomethyl)-sulphonyl]-4-methyl-benzene,
1-[[2-(2,4-dichlorophenyl)-1,3-dioxolan-2-yl]-methyl]-1H-imidazole,
1-[[2-(4-chlorophenyl)-3-phenyloxiranyl]-methyl]-1H-1,2,4-triazole,
1-[1-[2-[(2,4-dichlorophenyl)-methoxy]-phenyl]-ethenyl]-1H-imidazole,
1-methyl-5-nonyl-2-(phenylmethyl)-3-pyrrolidinole,
2′, 6′-dibromo-2-methyl4′-trifluoromethoxy-4′-trifluoro-methyl-1,3-thiazole-5-carboxanilide,
2,2-dichloro-N-[1-(4-chlorophenyl)-ethyl]-1-ethyl-3-methyl-cyclopropanecarboxamide,
2,6-dichloro-5-(methylthio)-4-pyrinidinyl-thiocyanate,
2,6-dichloro-N-(4-trifluoromethylbenzyl)-benzarnide,
2,6-dichloro-N-[[4-(trifluoromethyl)-phenyl]-methyl]-benzamide,
2-(2,3,3-triiodo-2-propenyl)-2H-tetrazole,
2-[(1-methylethyl)-sulphonyl]-5-(trichloromethyl)-1,3,4-thiadiazole,
2-[[6-deoxy4-O-(4-O-methyl-β-D-glycopyranosyl)-α-D-glucopyranosyl]-amino]-4-methoxy- 1H-pyrrolo[2,3-d]pyrimidine-5-carbonitrile,
2-aminobutane,
2-bromo-2-(bromomethyl)-pentanedinitrile,
2-chloro-N-(2,3-dihydro-1,1,3-trimethyl-1H-inden4-yl)-3-pyridinecarboxamide,
2-chloro-N-(2,6-dimethylphenyl)-N-(isothiocyanatomethyl)-acetamide,
2-phenylphenol (OPP),
3,4dichloro-1-[4-(difluoromethoxy)-phenyl]-1H-pyrrole-2,5-dione,
3,5-dichloro-N-[cyano-[(1-methyl-2-propynyl)-oxy]-methyl]-benzamide,
3-(1,1-dimethylpropyl-1-oxo-1H-indene-2-carbonitrile,
3-[2-(4-chlorophenyl)-5-ethoxy-3-isoxazolidinyl]-pyridine,
4-chloro-2-cyano-N,N-dimethyl-5-(4-methylphenyl)-1H-imidazole-1-sulphonamide,
4-methyl-tetrazolo[1,5-a]quinazolin-5(4H)-one,
8-(1,1-dimethylethyl)-N-ethyl-N-propyl-1,4-dioxaspiro[4.5]decane-2-methanamine,
8-hydroxyquinoline sulphate,
9H-xanthene-2-[(phenylamino)-carbonyl]-9-carboxylic hydrazide,
bis-(1-methylethyl)-3-methyl-4-[(3-methylbenzoyl)oxy]-2,5-thiophenedicarboxylate,
cis-1-(4chlorophenyl)-2-(1H-1,2,4-triazol-1-yl)-cycloheptanol,
cis-4-[3-[4-(1,1-dimethylpropyl)-phenyl-2-methylpropyl]-2,6-dimethyl-morpholine hydrochloride,
ethyl [(4chlorophenyl)-azo]-cyanoacetate,
potassium hydrogen carbonate,
methanetetrathiol sodium salt,
methyl 1-(2,3-dihydro-2,2-dimethyl- 1H-inden-1-yl)-1H-imidazole-5-carboxylate,
methyl N-(2,6-dimethylphenyl)-N-(5-isoxazolylcarbonyl)-DL-alaninate,
methyl N-(chloroacetyl)-N-(2,6-dimethylphenyl)-DL-alaninate,
N-(2,3-dichloro4-hydroxyphenyl)-1-methyl-cyclohexanecarboxamide,
N-(2,6-dimethylphenyl)-2-methoxy-N-(tetrahydro-2-oxo-3-furanyl)-acetamide,
N-(2,6-dimethylphenyl)-2-methoxy-N-(tetrahydro-2-oxo-3-thienyl)-acetamide,
N-(2-chloro4-nitrophenyl)-4-methyl-3-nitro-benzenesulphonamide,
N-(4-cyclohexylphenyl)-1,4,5,6-tetrahydro-2-pyrimidinamine,
N-(4-hexylphenyl)-1 ,4,5,6-tetrahydro-2-pyrimidinamine,
N-(5-chloro-2-methylphenyl)-2-methoxy-N-(2-oxo-3-oxazolidinyl)-acetamide,
N-(6-methoxy)-3-pyridinyl)-cyclopropanecarboxamiide,
N-[2,2,2-trichloro- 1-[(chloroacetyl)-amino]-ethyl]-benzamide,
N-[3-chloro-4,5-bis(2-propinyloxy)-phenyl]-N′-methoxy-methanimidamide,
N-formyl-N-hydroxy-DL-alanine 8 sodium salt,
O,O-diethyl [2-(dipropylamino)-2-oxoethyl]-ethylphosphoramidothioate,
O-methyl S-phenyl phenylpropylphosphoramidothioate,
S-methyl 1,2,3-benzothiadiazole-7-carbothioate,
spiro[2H]-1-benzopyrane-2,1′(3′H)-isobenzofuran]-3′-one,
Bactericides:
bromopol, dichlorophen, nitrapyrin, nickel dimethyldithiocarbamate, kasugamycin, octhilinone, furancarboxylic acid, oxytetracyclin, probenazole, streptomycin, tecloftalam, copper sulphate and other copper preparations.
Insecticides/Acaricides/Nematicides:
abamectin, acephate, acrinathrin, alanycarb, aldicarb, alphamethrin, amitraz, avermectin, AZ 60541, azadirachtin, azinphos A, azinphos M, azocyclotin,
Bacillus thuringiensis, 4bromo-2-(4-chlorophenyl)-1-(ethoxymethyl)-5-(tri-fluoromethyl)-1H-pyrrole-3-carbonitrile, bendiocarb, benfuracarb, bensultap, betacyfluthrin, bifenthrin, BPMC, brofenprox, bromophos A, bufencarb, buprofezin, butocarboxin, butylpyridaben,
cadusafos, carbaryl, carbofuran, carbophenothion, carbosulfan, cartap, chloethocarb, chlorethoxyfos, chlorfenapyr, chlorfenvinphos, chlorfluazuron, chlormephos, N-[(6-chloro-3-pyridinyl)-methyl]-N′-cyano-N-methyl-ethanimidamide, chlorpyrifos, chlorpyrifos M, cis-resmethrin, clocythrin, clofentezine, cyanophos, cycloprothrin, cyfluthrin, cyhalothrin, cyhexatin, cypermethrin, cyromazine,
deltamethrin, demeton M, demeton S, demeton S-methyl, diafenthiuron, diazinon, dichlofenthion, dichlorvos, dicliphos, dicrotophos, diethion, diflubenzuron, dimethoate, dimethylvinphos, dioxathion, disulfoton,
edifenphos, emamectin, esfenvalerate, ethiofencarb, ethion, ethofenprox, ethoprophos, etrimphos,
fenamiphos, fenazaquin, fenbutatin oxide, fenitrothion, fenobucarb, fenothiocarb, fenoxycarb, fenpropathrin, fenpyrad, fenpyroximate, fenthion, fenvalerate, fipronil, fluazinam, fluazuron, flucycloxuron, flucythrinate, flufenoxuron, flufenprox, fluvalinate, fonophos, formothion, fosthiazate, fubfenprox, furathiocarb,
HCH, heptenophos, hexaflumuron, hexythiazox,
imidacloprid, iprobenfos, isazophos, isofenphos, isoprocarb, isoxathion, ivermectin, lambda-cyhalothrin, lufenuron,
malathion, mecarbam, mervinphos, mesulfenphos, metaldehyde, methacrifos, methamidophos, methidathion, methiocarb, methomyl, metolcarb, milbemectin, monocrotophos, moxidectin,
naled, NC 184, nitenpyram,
omethoate, oxamyl, oxydemethon M, oxydeprofos,
parathion A, parathion M, permethrin, phenthoate, phorate, phosalone, phosmet, phosphamidon, phoxim, pirimicarb, pirimiphos M, pirimiphos A, profenofos, promecarb, propaphos, propoxur, prothiofos, prothoate, pymetrozin, pyrachlophos, pyridaphenthion, pyresmethrin, pyrethrum, pyridaben, pyrimidifen, pyriproxifen,
quinalphos,
salithion, sebufos, silafluofen, sulfotep, sulprofos,
tebufenozide, tebufenpyrad, tebupirimiphos, teflubenzuron, tefluthrin, temephos, terbam, terbufos, tetrachlorvinphos, thiafenox, thiamethoxam thiodicarb, thiofanox, thiomethon, thionazin, thuringiensin, tralomethrin, triarathen, triazophos, triazuron, trichlorfon, triflumuron, trimethacarb,
vamidothion, XMC, xylylcarb, zetamethrin.
It is also possible to admix other known active compounds, such as herbicides, fertilizers and growth-promoting substances.
The active compounds can be used as such or in the form of their formulations or the use forms prepared therefrom, such as ready-to-use solutions, suspensions, wettable powders, pastes, soluble powders, dusts and granules. They are used in the customary manner, for example by pouring, spraying, atomizing, spreading, foaming, brushing on and the like. It is further possible to apply the active compounds by the ultra-low volume method or to inject the active compound formulation, or the active compound itself, into the soil. The seed of the plants can also be treated.
When employing the active compounds which can be used according to the invention as fungicides, the application rates can be varied within a relatively wide range, depending on the type of application. In the treatment of parts of plants, the active compound application rates are generally between 0.1 and 10,000 g/ha, preferably between 10 and 1000 g/ha. In the treatment of seed, the active compound application rates are generally between 0.001 and 50 g per kilogram of seed, preferably between 0.01 and 10 g per kilogram of seed. In the treatment of the soil, the active compound application rates are generally between 0.1 and 10,000 g/ha, preferably between 1 and 5000 g/ha.
The compositions used for the protection of industrial materials generally comprise an amount of 1 to 95% by weight, preferably 10 to 75% by weight, of the active compounds.
The use concentrations of the active compounds which can be used according to the invention depend on the species and the occurrence of the microorganisms to be controlled and on the composition of the material to be protected. The optimal rate of application can be determined by test series. In general, the use concentrations are in the range from 0.001 to 5% by weight, preferably 0.05 to 1.0% by weight, based on the material to be protected.
The activity and the activity spectrum of the active compounds to be used according to the invention in material protection, or of the compositions, concentrates or quite generally formulations preparable therefrom can be increased by adding, if appropriate, further antimicrobially achieve compounds, fungicides, bactericides, herbicides, insecticides or other active compounds for widening the activity spectrum or obtaining special effects, such as, for example, additional protection against insects. These mixtures may have a broader activity spectrum than the compounds according to the invention.
The preparation and the use of the active compounds according to the invention are illustrated by the examples below.
PREPARATION EXAMPLES
Example 1
At room temperature, 0.47 g (0.006 mol) of pyridine is added to a solution of 0.99 g (0.005 mol) of 5-amino-4-ethoxycarbonyl-3-ethyl-1-methylpyrazole in 80 ml of dichloromethane. At the same temperature, a solution of 1.11 g (0.006 mol) of 4-methoxyphenylacetyl chloride in 20 ml of dichloromethane is then added dropwise. The mixture is stirred overnight at room temperature and then under reflux for 24 hours. After cooling, the reaction mixture is washed with dilute HCl and with dilute aqueous NaHCO 3 solution. The organic phase is dried over MgSO 4 , filtered and evaporated to dryness.
This gives 1.28 g (74% of theory) of 4-ethoxycarbonyl-3-ethyl-5-(4-methoxyphenylacetyl)-amino-1-methylpyrazole as a yellowish solid of melting point 112 to 113° C.
Example 2
At room temperature, 0.95 g (0.012 mol) of pyridine is added to a solution of 1.25 g (0.01 mol) of 5-amino-3-ethyl-1-methylpyrazole in 120 ml of dichloromethane. At the same temperature, a solution of 3.37 g (0.012 mol) of 4-(4-chlorophenoxy)phenylacetyl chloride in 30 ml of dichloromethane is then added dropwise. The mixture is stirred overnight at room temperature and then washed successively with dilute HCl and dilute aqueous NaHCO 3 solution, dried over MgSO 4 , filtered and evaporated to dryness.
This gives 3.10 g (84% of theory) of 5-(4-(4-chlorophenoxy)-phenylacetylamino)-3-ethyl-1-methylpyrazole as a brown oil.
1 H-NMR (CDCl 3 ): =1.19, 2.57, 3.56, 3.63, 3.73, 6.04, 6.92-7.03, 7.27-7.33 ppm
Example 3
At 0° C., 0.37 g (0.00275 mol) of sulphuryl chloride is added dropwise to a solution of 0.92 g (0.0025 mol) of 5-(4-(4-chlorophenoxy)phenylacetylamino)-3-ethyl-1-methylpyrazole (Ex. 2) in 10 ml of dichloromethane. The mixture is stirred overnight at room temperature and then diluted with 10 ml of dichloromethane and washed successively with water, saturated aqueous NaHCO 3 solution and saturated aqueous NaCl solution, dried over MgSO 4 , filtered and evaporated to dryness.
This gives 0.80 g (79% of theory) of 4-chloro-5-(4-(4-chlorophenoxy)-phenylacetylamino)-3-ethyl-1-methylpyrazole as a brown oil.
1 H-NMR (CDCl 3 ): =1.21, 2.57, 3.63, 3.77, 6.82, 6.92-7.04, 7.30-7.35 ppm
Example 4
At 0° C., 0.44 g (0.00275 mol) of bromine is added dropwise to a solution of 0.92 g (0.0025 mol) of 5-(4-(4-chlorophenoxy)phenylacetylamino)-3-ethyl-1-methylpyrazole (Ex. 2) in 10 ml of dichloromethane. The mixture is stirred overnight at room temperature and then diluted with 10 ml of dichloromethane and washed successively with water, saturated aqueous NaHCO 3 solution and saturated aqueous NaCl solution, dried over MgSO 4 , filtered and evaporated to dryness.
This gives 0.90 g (80% of theory) of 4-bromo-5-(4-(4-chlorophenoxy)-phenylacetylamino)-3-ethyl-1-methylpyrazole as a brown oil.
1 H-NMR (CDCI 3 ): =1.20, 2.56, 3.66, 3.77, 6.80, 6.91-7.04, 7.27-7.36 ppm
Example 5
At room temperature, 1.90 g (0.024 mol) of pyridine are added to a solution of 3.19 g (0.02 mol) of 5-amino4-chloro-3-ethyl-1-methylpyra?ole (Ex. IV-1) in 120 ml of dichloromethane. At the same temperature, a solution of 5.60 g (0.024 mol) of 4-bromophenylacetyl chloride in 30 ml of dichloromethane is then added dropwise. The mixture is stirred overnight at room temperature and then washed with dilute HCl and dilute aqueous NaHCO 3 solution. The organic phase is dried over MgSO 4 , filtered and evaporated to dryness.
This gives 4.61 g (63% of theory) of 5-(4-bromophenylacetyl)-amino-4-chloro-3-ethyl-1-methylpyrazole as a colourless solid of melting point 167-168° C.
The 5-amino-pyrazole derivatives of the formula (I) listed in Table 2 below are likewise prepared by the methods mentioned above.
TABLE 2
(I)
Melting point
or δ value
Ex.
(ppm; 1 H—NMR
No.
R 1
R 2
R 3
R 4
—Y—R 5
in CDCl 3 )
6
CH 3
CN
CH 3
H
1.27; 2.22; 3.34; 3.57 *)
7
C 2 H 5
CN
CH 3
H
124-127° C.
8
C 2 H 5
CN
CH 3
H
127-128° C.
9
C 2 H 5
CN
CH 3
H
148-151° C.
10
C 2 H 5
CN
CH 3
H
153-154° C.
11
C 2 H 5
CN
CH 3
H
171-173° C.
12
C 2 H 5
CN
CH 3
H
152-155° C.
13
C 2 H 5
CN
CH 3
H
126-128° C.
14
C 2 H 5
CN
CH 3
H
1.27; 1.68; 3.62; 3.77
15
C 2 H 5
CN
CH 3
H
170-171° C.
16
C 2 H 5
CN
CH 3
H
169-172° C.
17
C 2 H 5
H
CH 3
H
1.19; 2.57; 3.73; 6.04
18
C 2 H 5
H
CH 3
H
1.13; 1.26; 2.64; 3.37; 3.42; 5.91;
19
C 2 H 5
Cl
CH 3
H
101-103° C.
20
C 2 H 5
Cl
CH 3
C 2 H 5
1.14; 1.28; 2.66
21
C 2 H 5
Br
CH 3
H
111-112° C.
22
C 2 H 5
Br
CH 3
C 2 H 5
1.15; 1.28; 3.29
23
C 2 H 5
NO 2
CH 3
H
1.24; 2.89; 3.76; 3.83; 8.48
24
C 2 H 5
COOC 2 H 5
CH 3
H
1.20; 1.28; 1.32; 2.78; 3.69; 3.75; 4.20
25
C 2 H 5
COOC 2 H 5
CH 3
H
133-135° C.
26
C 2 H 5
COOC 2 H 5
CH 3
H
1.21; 1.32; 2.76; 3.68; 3.73; 4.25; 8.44
27
C 2 H 5
COOC 2 H 5
CH 3
H
156-158° C.
28
C 2 H 5
COOC 2 H 5
CH 3
H
1.22; 1.35; 2.74; 3.56; 4.28; 5.04
29
C 2 H 5
COOC 2 H 5
CH 3
H
1.21; 1.32; 2.78; 3.70; 3.76; 4.25
30
C 2 H 5
COOC 2 H 5
CH 3
H
1.21; 1.32; 2.78; 3.71; 3.77; 4.25; 8.48
31
C 2 H 5
COOC 2 H 5
CH 3
H
145-147° C.
32
C 2 H 5
COOC 2 H 5
CH 3
H
114-117° C.
33
C 2 H 5
Cl
CH 3
H
150-151° C.
34
C 2 H 5
Cl
CH 3
H
147° C.
35
C 2 H 5
Cl
CH 3
H
147° C.
36
C 2 H 5
H
CH 3
H
1.20; 2.56; 3.58; 3.76; 6.05
37
C 2 H 5
—COOCH 3
CH 3
H
162° C.
38
C 2 H 5
—COOCH 3
CH 3
H
1.21; 2.71; 3.73; 3.78; 3.82
39
C 2 H 5
—COOCH 3
CH 3
H
1.20; 2.79; 3.71; 3.76; 3.78
40
C 2 H 5
Br
CH 3
H
134° C.
41
C 2 H 5
COOC 2 H 5
CH 3
CH 3
1.29; 2.90; 3.15; 3.41; 3.43; 4.22
42
C 2 H 5
COOC 2 H 5
CH 3
CH 3
1.29; 2.74; 3.16; 3.44; 3.45; 4.22
43
C 2 H 5
COOC 2 H 5
CH 3
CH
1.28; 2.90; 3.13; 3.34; 3.41; 4.20
44
C 2 H 5
COOC 2 H 5
CH 3
H
1.32; 2.77; 3.70; 3.75; 4.23
45
C 2 H 5
CN
CH 3
H
1.31; 2.67; 3.61; 3.76
46
C 2 H 5
—COOC 2 H 5
CH 3
H
1.21; 1.33; 2.76; 3.71; 3.80; 4.22
47
C 2 H 5
CN
CH 3
H
62-64° C.
48
C 2 H 5
—COOC 2 H 5
CH 3
H
1.20; 1.30; 2.48; 2.76; 3.70; 3.75; 4.23
49
C 2 H 5
CN
CH 3
H
53-54° C.
50
CH 3
CN
CH 3
H
101° C.
51
CH 3
CN
CH 3
H
102-104° C.
52
CH 3
CN
CH 3
H
135-138° C.
53
CH 3
—COOC 2 H 5
CH 3
H
141-142° C.
54
CH 3
—COOC 2 H 5
CH 3
H
142-144° C.
55
CH 3
—COOC 2 H 5
CH 3
H
1.32; 2.36; 3.70; 3.76; 4.25
56
C 2 H 5
—COOC 2 H 5
CH 3
H
1.22; 1.36; 2.80; 3.70; 4.29
57
C 2 H 5
CN
CH 3
H
62-64° C.
58
C 2 H 5
—COOC 2 H 5
CH 3
H
1.21; 1.29; 2.76; 3.69; 3.75
59
C 2 H 5
CN
CH 3
H
58-60° C.
60
C 2 H 5
—COOC 2 H 5
CH 3
H
81° C.
61
C 2 H 5
CN
CH 3
H
133° C.
62
C 2 H 5
COOC 3 H 7 -i
CH 3
H
126-128° C.
63
C 2 H 5
COOC 3 H 7 -i
CH 3
H
82° C.
64
C 2 H 5
COOC 3 H 7 -i
CH 3
H
75° C.
65
C 2 H 5
CN
C 4 H 9 -t
H
165-167° C.
66
C 2 H 5
—COOC 2 H 5
CH 3
H
126-128° C.
67
C 2 H 5
CN
CH 3
H
105-107° C.
68
C 2 H 5
—COOC 2 H 5
C 4 H 9 -t
H
184° C.
69
C 2 H 5
—COOC 2 H 5
C 4 H 9 -t
H
171° C.
70
C 2 H 5
—COOC 2 H 5
CH 3
H
120° C.
71
C 2 H 5
CN
CH 3
H
178° C.
72
C 2 H 5
—COOC 2 H 5
CH 3
H
131° C.
73
C 2 H 5
CN
CH 3
H
163° C.
74
C 2 H 5
—COOCH 2 —CH═CH 2
CH 3
H
121° C.
75
C 2 H 5
—COOCH 2 —CH═CH 2
CH 3
H
1.22; 2.79; 3.73; 3.81
76
C 2 H 5
—COOC 2 H 5
C 3 H 7 -i
H
125-127° C.
77
C 2 H 5
—COOC 2 H 5
C 3 H 7 -i
H
124° C.
78
C 2 H 5
CN
C 3 H 7 -i
H
168° C.
79
C 2 H 5
CN
C 3 H 7 -i
H
190-192° C.
80
C 4 H 9 -t
H
CH 3
H
70-71 ° C.
81
C 2 H 5
—COOC 2 H 5
CH 3
H
186-187° C.
82
C 2 H 5
CN
CH 3
H
168° C.
83
C 4 H 9 -t
Br
CH 3
H
95° C.
84
C 4 H 9 -t
Cl
CH 3
H
1.34; 3.65; 3.81
85
C 2 H 5
—COOC 2 H 5
CH 3
H
85° C.
86
C 2 H 5
CN
CH 3
H
110-111° C.
87
C 2 H 5
—COOC 2 H 5
CH 3
H
1.21; 1.33; 2.79; 3.72; 3.79
88
C 2 H 5
CN
CH 3
H
1.25; 2.67; 3.63; 3.79
*) 1 H—NMR in DMSO-d 6
Example 89
A mixture of 1.0 g (4.70 mmol) of 5-amino-3-ethyl-4-ethoxycarbonyl-1-methyl-pyrazole, 0.75 g (9.40 mmol) of pyridine and 10 ml of methylene chloride is mixed with 1.07 g (5.60 mmol) of (3-chlorophenyl)-acetyl chloride and stirred at 20° C. for 18 hours. The reaction mixture is then admixed with methylene chloride and water. The organic phase is separated off, washed successively with 10% strength aqueous hydrochloric acid and saturated aqueous sodium bicarbonate solution, and then dried over magnesium sulphate, filtered and concentrated under reduced pressure. This gives 0.97 g (59% of theory) of 5-(3-chloro-phenyl-acetyl)-amino-3-ethyl4-ethoxycarbonyl-l-methyl-pyrazole in the form of an oily liquid. log P (acidic): 2.65
The 5-amino-pyrazole derivatives of the formula (I) listed in Table 3 below are likewise prepared by the methods mentioned above.
TABLE 3
(I)
Ex
Melting point
No.
R 1
R 2
R 3
R 4
—Y—R 5
or log P value
90
C 2 H 5
Cl
CH 3
H
164° C.
91
C 2 H 5
Cl
CH 3
H
187° C.
92
C 2 H 5
H
CH 3
H
147° C.
93
C 2 H 5
COOC 2 H 5
CH 3
H
135° C.
94
C 2 H 5
CN
CH 3
H
167° C.
95
C 2 H 5
COOC 2 H 5
CH 3
H
log P = 2.28
96
C 2 H 5
COOC 2 H 5
CH 3
H
log P = 2.88
Preparation of the Compound of Example 35
At room temperature, 26.74 g (75 mmol) of 5-(4-bromophenylacetyl)-amino-4-chloro-3-ethyl-1-methyl-pyrazole and 117 ml of 2 molar aqueous sodium carbonate solution are added dropwise to a mixture of 5.25 g (4.5 mmol) of tetrakis-(triphenylphosphonine)-palladium and 150 ml of toluene with stirring. With vigorous stirring, a solution of 20.48 g (82.5 mmol) of 4-trifluoromethoxyphenyl-boronic acid in 75 ml of ethanol is then added dropwise at room temperature. The reaction mixture is initially heated under reflux for 16 hours and then cooled to room temperature and admixed with water and diethyl ether. The organic phase is separated off, washed with aqueous sodium chloride solution, dried over magnesium sulphate, filtered and concentrated under reduced pressure. The product that remains is chromatographed over silica gel using a mixture of methylene chloride/ethyl acetate =1:1. This gives 16.94 g (52% of theory) of the compound of the formula given above, in the form of a solid of melting point 174° C.
The 5-amino-pyrazole derivatives of the formula
listed in Table 4 below are likewise prepared by the methods given above.
TABLE 4
Ex.
Physical
No.
R 1
R 2
R 3
—Y—R 5
constant
97
—CH 3
H
—CH 3
98
—CH 3
H
—CH 3
99
—CH 3
Br
—CH 3
100
—CH 3
Cl
—CH 3
101
C 2 H 5
—CN
—CH 3
mp = 158-159° C.
102
C 2 H 5
Cl
—CH 3
logP = 3.01
103
C 2 H 5
—CN
—CH 3
mp = 178-179° C.
104
C 2 H 5
—COOC 2 H 5
—CH 3
logP = 3.26
105
C 2 H 5
H
—CH 3
logP = 2.13
106
C 2 H 5
—COOC 2 H 5
—CH 3
logP = 3.16
107
C 2 H 5
—COOC 2 H 5
—CH 3
logP = 3.41
108
C 2 H 5
—CN
—CH 3
logP = 3.05
109
H
CH 3
logP = 2.45
110
Cl
CH 3
logP = 2.90
111
C 2 H 5
—COOC 2 H 5
—CH 3
logP = 3.28
112
—CH 3
Cl
—CH 3
mp = 125-128° C.
113
—CH 3
H
—CH 2 —CH 2 —CN
logP = 1.77
114
—CH 3
—CN
—CH 3
logP = 1.48
115
C 2 H 5
—CN
—CH 3
logP = 1.71
116
—CH 3
—COO—CH 3
—CH 3
logP = 1.50
117
—CH 3
Cl
—CH 3
118
—CH 3
Cl
—CH 3
119
—CH 3
—CN
—CH 3
logP = 1.88
120
C 2 H 5
—CN
—CH 3
logP = 1.84
121
—CH 3
H
—CH 3
logP = 2.06
122
—CH 3
Cl
—CH 3
logP = 1.50
123
—CH 3
Cl
—CH 3
logP = 1.85
124
—CH 3
Cl
—CH 3
logP = 2.32
125
—CH 3
Cl
—CH 3
logP = 2.88
126
—CH 3
Cl
—CH 3
logP = 3.31
127
—CH 3
Cl
—CH 3
logP = 3.83
128
—CH 3
C1
—CH 3
logP = 2.80
129
—CH 3
Cl
—CH 3
logP = 4.30
130
—CH 3
Cl
—CH 3
logP = 3.53
131
—CH 3
Cl
—CH 3
logP = 3.91
132
—CH 3
Cl
—CH 3
logP = 2.80
133
—CH 3
Cl
—CH 3
logP = 1.92
134
—CH 3
Cl
—CH 3
logP = 1.91
135
—CH 3
—COO—CH 3
—CH 3
logP = 2.11
136
C 2 H 5
—CN
—CH 3
logP = 2.83
137
—CH 3
—CN
—CH 3
logP = 2.36
138
—CH 3
Cl
—CH 3
logP = 3.44
139
—CH 3
Cl
—CH 3
logP = 2.81
140
—CH 3
Cl
—CH 3
logP = 3.53
141
—CH 3
Cl
—CH 3
logP = 4.09
142
—CH 3
Cl
—CH 3
logP = 3.25
143
—CH 3
Cl
—CH 3
logP = 3.79
144
—CH 3
Cl
—CH 3
logP = 3.84
145
—CH 3
Cl
—CH 3
logP = 3.64
146
—CH 3
Cl
—CH 3
logP = 3.82
147
—CH 3
Cl
—CH 3
logP = 4.08
148
—CH 3
Cl
—CH 3
logP = 2.60
149
—CH 3
—CN
—CH 3
logP = 3.17
150
—CH 3
—CN
—CH 3
logP = 2.57
151
—CH 3
—CN
—CH 3
logP = 3.20
152
—CH 3
—CN
—CH 3
logP = 3.88
153
—CH 3
—CN
—CH 3
logP = 2.95
154
—CH 3
—CN
—CH 3
logP = 3.46
155
—CH 3
—CN
—CH 3
logP = 3.42
156
—CH 3
—CN
—CH 3
logP = 3.43
157
—CH 3
—CN
—CH 3
logP = 3.24
158
—CH 3
—CN
—CH 3
logP = 3.49
159
—CH 3
—CN
—CH 3
logP = 3.70
160
—CH 3
—CN
—CH 3
logP = 2.32
161
—C 2 H 5
—CN
—CH 3
logP = 3.44
162
—C 2 H 5
—CN
—CH 3
logP = 2.81
163
—C 2 H 5
—CN
—CH 3
logP = 3.49
164
—C 2 H 5
—CN
—CH 3
logP = 3.96
165
—C 2 H 5
—CN
—CH 3
logP = 3.20
166
—C 2 H 5
—CN
—CH 3
logP = 3.74
167
—C 2 H 5
—CN
—CH 3
logP = 3.70
168
—C 2 H 5
—CN
—CH 3
logP = 3.71
169
—C 2 H 5
—CN
—CH 3
logP = 3.51
170
—C 2 H 5
—CN
—CH 3
logP = 3.77
171
—C 2 H 5
—CN
—CH 3
logP = 3.98
172
—C 2 H 5
—CN
—CH 3
logP = 2.59
USE EXAMPLES
Example A
Erysiphe Test (Wheat)/Protective
Solvent: 25 parts by weight of N,N-dimethylacetamide
Emulsifier: 0.6 part by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with water to the desired concentration.
To test for protective activity, young plants are sprayed with the preparation of active compound at the stated application rate.
After the spray coating has dried on, the plants are dusted with spores of Erysiphe graminis f.sp. tritici.
The plants are placed in a greenhouse at a temperature of about 20° C. and a relative atmospheric humidity of about 80% to promote the development of mildew pustules.
Evaluation is carried out 7 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Active compounds, application rates and test results are shown in the table below.
TABLE A
Erysiphe test (wheat)/protective
Active
compound
application
Efficacy
Active compound
rate in g/ha
in %
According to the invention:
250
100
Example B
Pyrenophora Teres Test (Barley)/Curative
Solvent: 25 parts by weight of N,N-dimethylacetamide
Emulsifier: 0.6 parts by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with water to the desired concentration.
To test for curative activity, young plants are sprayed with a conidia suspension of Pyrenophora teres. The plants remain in an incubation cabin at 20° C. and 100% relative atmospheric humidity for 48 hours. The plants are then sprayed with the preparation of active compound at the stated application rate.
The plants are placed in a greenhouse at a temperature of about 20° C. and a relative atmospheric humidity of about 80%.
Evaluation is carried out 7 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Active compounds, application rates and test results are shown in the table below.
TABLE B
Pyrenophora teres test (barley)/curative
Active
compound
application rate
Efficacy
Active compound
in g/ha
in %
According to the invention:
250
100
Example C
Podosphaera Test (Apple)/Protective
Solvent: 47 parts by weight of acetone
Emulsifier: 3 parts by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with water to the desired concentration.
To test for protective activity, young plants are sprayed with the preparation of active compound at the stated application rate. After the spray coating has dried on, the plants are inoculated with an aqueous spore suspension of the apple mildew pathogen Podosphaera leucotricha. The plants are then placed in a greenhouse at about 23° C. and a relative atmospheric humidity of about 70%.
Evaluation is carried out 10 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Active compounds, application rates and test results are shown in the table below.
TABLE C
Podosphaera test (apple)/protective
Active
compound
application rate
Efficacy
Active compound
in g/ha
in %
According to the invention:
100
92
100
100
100
100
Example D
Sphaerotheca Test (Cucumber)/Protective
Solvent: 47 parts by weight of acetone
Emulsifier: 3 parts by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with water to the desired concentration.
To test for protective activity, young plants are sprayed with the preparation of active compound at the stated application rate. After the spray coating has dried on, the plants are inoculated with an aqueous spore suspension of Sphaerotheca fuliginea. The plants are then placed in a greenhouse at about 23° C. and a relative atmospheric humidity of about 70%.
Evalution is carried out 10 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Active compounds, application rates and test results are shown in the table below.
TABLE D
Sphaerotheca test (cucumber)/protective
Active
compound
application rate
Efficacy
Active compound
in g/ha
in %
According to the invention:
100
100
100
100
Example E
Venturia Test (Apple)/Protective
Solvent: 47 parts by weight of acetone
Emulsifier: 3 parts by weight of alkylaryl polyglycol ether
To produce a suitable preparation of active compound, 1 part by weight of active compound is mixed with the stated amounts of solvent and emulsifier, and the concentrate is diluted with water to the desired concentration.
To test for protective activity, young plants are sprayed with the preparation of active compound at the stated application rate. After the spray coating has dried on, the plants are inoculated with an aqueous conidia suspension of the apple pathogen Venturia inaequalis and then remain in an incubation cabin at about 20° C. and 100% relative atmospheric humidity for 1 day.
The plants are then placed in the greenhouse at about 21° C. and a relative atmospheric humidity of about 90%.
Evaluation is carried out 12 days after the inoculation. 0% means an efficacy which corresponds to that of the control, whereas an efficacy of 100% means that no infection is observed.
Active compounds, application rates and test results are shown in the table below.
TABLE E
Venturia test (apple)/protective
Active
compound
application rate
Efficacy
Active compound
in g/ha
in %
According to the invention:
100
96
100
90
100
93
100
96 | A method of controlling a plant disease caused by a fungus comprising applying a 5-amino-pyrazole of the formula
wherein,
R1, R2, R3, R4, R5 and Y are as defined in the specification. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
In the upstream Oil and Gas Industry, paraffin, wax and asphaltene deposits on the inside surface of production tubing in oil and gas wells reduce the cross sectional area of the pipe. The reduction in the cross sectional area increases the flowing friction pressures which can reduce or completely halt production from the producing well.
Currently there are many existing methods, procedures and chemicals employed by Operators to combat paraffin in oil fields around the world where paraffin problems occur. Some of these practices include: Circulating the well with Hot Oil or Hot Water; Wireline wax cutting with various diameter gauge ring cutters or wax knives; The injection of various chemicals, paraffin inhibitors, crystal modifiers, and solvents via capillary tube, surface applications and “squeezes”; There are anti-wax sticks available which are dropped down the annulus of the well, and magnetic devices claimed to alter or prevent the formation of paraffin crystals; and there are downhole electric heaters, with a surface supplied electrical power source to raise the temperature of produced fluids above the melting point of paraffin.
However, many of these methods have limited effect or application in controlling paraffin, some even cause additional operational problems, and the battle against paraffin continues to hamper oil production operations everywhere.
Without effective treatment or removal of paraffin, oil wells can quickly stop producing due to the lack of a continuous flow conduit to the surface, and in most cases requires that the tubing be pulled and replaced in order to resume production. The loss in oil productivity due to the reduction in flow rate caused by paraffin deposition, and the costs associated with Well Service work to replace tubing are two of the constant operational costs that Operators face while producing oil from paraffin prone oil and gas fields.
The hot anti-wax knife tool provides a new and previously unavailable method of cutting and melting a hole though the wax deposited in the production tubing in order to resume the flow of produced fluids. The tool is an invention borne of necessity.
Normally occurring paraffin wax has a melting temperature of about 90 degrees Celsius. With fully charged batteries, the tool can generate cutting edge temperatures well over 90 degrees Celsius for approximately 30 to 45 minutes, long enough for the tool to be assembled, and run down into the production tubing on Wireline, where it will melt and cut a hole through the paraffin deposits and restore production from the well.
Only since the advent of the Nickel Metal Hydride (Ni-MH) rechargeable battery, is it possible for size AA or AAA batteries to be arranged together in a direct current connection that is both series and parallel. Rechargeable batteries arranged in this manner can provide sufficient power to a heating element over a reasonable period of time, to elevate the temperature of the Cutting Head above the melting point of paraffin inside the tubing. The Ni-MH batteries arranged in this configuration provide a self contained source of electrical energy, augmenting the wax cutting effect of the tool with a heated edge to melt the wax that it contacts.
I have relied extensively on my own experience, education, knowledge of physics and skills to create and realize this idea and design, and the materials used to build the functional prototype were obtained locally. The reference data contained in the “Handbook of Physics” Walter Benenson, John W. Harris, Horst Stocker and Holger Lutz Editors, published in 2002 Springer-Verlag New York, Inc. also greatly aided in the design and creation of this invention.
BRIEF SUMMARY OF THE INVENTION
The hot anti-wax knife combines basic electrical and thermodynamic principles, commonly used and available materials, and two new design components; the series-parallel Battery Pack and the parabolic cone Cutting Head, in a self contained wireline conveyed tool that converts the stored electrical energy contained in the rechargeable batteries into useful heat energy, which is focused, transferred and applied at the cutting and heating edge of the tool. The purpose of the hot anti-wax knife is to cut and melt paraffin from the inside of oil well production tubing. Solar energy is the preferred method for recharging the batteries once spent.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is an elevational view of the hot anti-wax knife identifying three main elements: the Battery Pack ( 1 ); the Separator ( 2 ) and; the Cutting Head ( 3 ). A truncated section of Sucker Rod ( 4 ) is shown with broken lines at the top of the drawing for illustrative purposes and forms no part of the Claim.
FIG. 2 is a cross section of the Cutting Head ( 3 ) identifying the Parabolic Cone ( 5 ), the Cutting Edge ( 6 ) and the Casing ( 7 ). The Receiver End Power Connector ( 8 ) is shown for illustrative purposes with broken lines and forms no part of the Claim.
FIG. 3 is a bottom plan view of the Cutting Head ( 3 ).
FIG. 4 is an elevational view of the Battery Pack Carrier shown without batteries, identifying the Positive Pole wire ( 9 ), the Battery Spacer ( 10 ), the Negative Pole wire ( 11 ) spring and, the Rigid Disk ( 12 ). The Pin End Power Connector ( 13 ) is shown for illustrative purposes with broken lines and forms no part of the Claim.
FIG. 5 is top plan view of the flat, rectangular, Battery Spacer ( 10 ) prior to folding and assembly.
FIG. 6 is a top plan view of the Cutting Head ( 3 ).
FIG. 7 is a top plan view of the Separator ( 2 ).
FIG. 8 is a bottom plan view of the Separator ( 2 ).
FIG. 9 is a perspective view of the hot anti-wax knife.
FIG. 10A is an elevational view of one embodiment of the hot anti-wax knife.
FIG. 10B is an elevational view of another embodiment of the hot anti-wax knife.
FIG. 100 is an elevational view of another embodiment of the hot anti-wax knife.
FIG. 10D is an elevational view of another embodiment of the hot anti-wax knife.
DETAILED DESCRIPTION OF THE INVENTION
The hot anti-wax knife shown assembled in FIG. 1 , is a cylindrical, wireline conveyed, rechargeable battery powered tool used to melt and cut paraffin on the inside of oil well tubing. The tool incorporates two new design components; The series-parallel Battery Pack ( 1 ), and the parabolic cone Cutting Head ( 3 ). The design of each of these elements affects the characteristics and performance of the other and they are therefore inseparable in design, function and operation of the tool.
Modified forms of the hot anti-wax knife include, but are not limited to all of the modified forms of the:
The series-parallel Battery Pack ( 1 ) and;
The Separator ( 2 ) and;
The parabolic cone Cutting Head ( 3 ).
All of the modified forms of the hot anti-wax knife, of which several are shown in FIG. 10 , are similar in shape and function, and are individually designed for various well conditions, temperature requirements, and various quantities and sizes of batteries.
The Hot Anti-Wax Knife Battery Pack ( 1 )
The Battery Pack ( 1 ) consists of a specially designed Carrier for rechargeable Ni-MH Size “AA” (R6) 1.2 Volt, or size “AAA” (HR03/DC2400) 1.2 Volt batteries which are arranged in both series and parallel connections. The Carrier is contained within a steel tube threaded at both ends to connect with the Separator ( 2 ) at the Negative pole end and fitted with a steel cap at the Positive end. The steel cap is welded to a ⅞″ Standard API Sucker Rod Pin End ( 4 ) for the connection to a Wireline Rope Socket. The Sucker Rod is included in the Specifications and drawings for illustrative purpose only and forms no part of the Claim.
The Battery Pack ( 1 ) is spring loaded and the batteries are inserted Negative end first, by removing the End Cap, and withdrawing approximately 5 cm of the positive end of the carrier from the Steel Tube. Batteries are inserted into each of the three sections formed by the Spacer ( 10 ) and the inside diameter of the Steel Tube. Each of the three sets of series connected batteries are also connected in parallel to the other two sets via the Positive Pole wire ( 9 ) ring and the Negative Pole wire ( 11 ) spring. The batteries for a nine battery tool are arranged in sets of three in series, with all three triple sets of series connected batteries also connected in parallel.
The positive ends of three of the batteries make physical and electrical contact with the Positive Pole wire ( 9 ) Ring which serves as the positive parallel connection. The remaining straight portion of the wire passes through the center of the Spacer ( 10 ) axially towards the Negative ends of the batteries through the center void formed by the three edged star of the Spacer.
At the Negative end, the Positive Pole wire ( 9 ) passes through the center hole of the electrical insulation of the Rigid Disk ( 12 ), and is fixed in place with epoxy to the disk and soldered on the other side of the disk to the positive pole of the Pin End Power Connector ( 13 ). On the battery side of the Rigid Disk ( 12 ), a spiral coil of Copper (Cu) wire is fixed creating the Negative Pole parallel connection and acting as a spring to secure the batteries in place and ensure electrical contact. The negative ends of three of the batteries make physical and electrical contact with this spring which forms the negative parallel connection.
Modified forms of the Battery Pack ( 1 ) include but are not limited to:
The capacity for four, six, nine, twelve or more size “AA” or size “AAA” rechargeable batteries and;
Various lengths, diameters and materials of the individual elements of the Battery Pack ( 1 ) and Carrier,
provided that when assembled with the appropriate number of batteries installed, all sets of series connected batteries are also connected in parallel with the other series sets of batteries.
The individual elements of the hot anti-wax knife Battery Pack ( 1 ) for six size “AA” (R6) 1.2 Volt batteries, are described as follows:
Steel Tube. A 38 mm OD, 31.5 mm ID and 13 cm long steel tube with about 7 mm of both ends externally threaded. Battery Carrier. This element of the Battery Pack ( 1 ) is shown in FIG. 4 and consists of the following individual components:
Positive Pole wire ( 9 ). Made from a single length of 1.8 mm diameter un-insulated (bare) Copper (Cu) wire approximately 17 cm long, bent and fashioned at one end into a continuous ring of about 2 cm in diameter which is aligned perpendicular and central to the axis of the Battery Pack ( 1 ) and the remaining length of straight wire. The terminal end of the wire ring end is soldered to the ring itself forming a continuous circle and the positive end of the parallel battery connection. Battery Spacer ( 10 ). Shown in FIG. 4 the Spacer is constructed from a single rectangle of construction paper 8.4 cm wide by 9.5 cm long as depicted in FIG. 5 . The paper is alternately folded on five fold lines to form six equal sections of 14 mm width each. The two long free edges are taped flush together on one side with a strip of electrical tape, to form a 9.5 cm long three edged “star” which supports and separates the sets of series connected batteries from one another and isolates the batteries from the Positive Pole wire ( 9 ) running axially through the center of the Spacer ( 10 ). Negative Pole wire ( 11 ) spring. This is also a 1.8 mm diameter bare Copper (Cu) wire approximately 21 cm in length, formed into a concentric spiral spring of from 3 to 4 loops, with the largest loop less than 28 cm in diameter. Shown in elevation in FIG. 4 . Rigid Disk ( 12 ). A disk of circuit board resin electrical insulating material 3 mm thick and 3 cm in diameter with a 4 mm hole drilled through the center and a 2 mm wide notch cut 2 mm into the edge as shown in FIG. 4 . Felt Disk. A 3 cm diameter, 3 mm thick felt disk with a 10 mm hole in the center with a 2 mm wide “spoke” cut out from the disk Pin End Power Connector ( 13 ) shown in FIG. 4 . This is a 3 mm pin end power connection of the type commercially available for charging mobile telephone batteries and forms no part of the Claim. Support Tube: A 10 mm OD and 8 mm ID plastic tube, 13 mm in length, with a 2 mm wide notch cut 2 mm into one end.
End Cap. A steel cap of 3.8 cm OD, 31.5 mm ID with a 5 mm end wall thickness, 12 mm in length and threaded for 7 mm on the inside. End Cap Plug. A cylinder of rubber 3 cm in diameter and 14 mm in length. Sucker Rod ( 4 ). Used for the connection to a Wireline Rope Socket, this is a 15 cm long Standard API ⅞″ Sucker Rod pin end. The Sucker Rod is welded at the rod end to the center of the outside end of the End Cap. Although the Sucker Rod ( 4 ), or any similarly constructed connection is required in order to use the tool by Wireline, the API ⅞″ Sucker Rod ( 4 ) itself forms no part of the Claim.
The hot anti-wax knife Battery Pack ( 1 ) and Carrier for six size “AA” batteries is constructed in the following manner:
A. Battery Pack Carrier:
a. The end of the Negative Pole wire ( 11 ) that is not part of the spring coil, is bent around the edge of the Rigid Disk ( 12 ), through the notch on the Rigid Disk and in a radial direction towards the center hole of the Rigid Disk. The terminating end is bent so that is rests parallel to the opposite side face of the Rigid Disk ( 12 ) and the last three of four millimeters of wire is bent parallel along the axis of the Carrier at the center hole of the Rigid Disk. b. The Negative Pole wire ( 11 ) terminus is soldered to the negative pole of the Pin End Power Connector ( 13 ). c. The straight end of the Positive Pole wire ( 9 ) is inserted through the center hole of the Rigid Disk ( 12 ), and glued in place with epoxy keeping 10.3 cm between the facing surfaces of the Positive Pole wire ring end and the near side of the Rigid Disk. d. The straight end of the Positive Pole wire ( 9 ) terminal end is soldered to the positive pole of the Pin End Power Connector ( 13 ). e. The plastic Support Tube is placed over the Pin End Power Connector ( 13 ) and wire terminal connections. The 2 mm notch in the Support Tube is aligned to fit over the Negative Pole wire ( 11 ) and the tube is glued in place with epoxy. f. The construction paper Battery Spacer ( 10 ) is spread opened at one end and the Positive Pole wire ( 9 ) ring end is inserted ring first into the paper Spacer and pushed through and out the other side. g. The felt disk is glued onto the power connection side of the Rigid Disk ( 12 ). h. The above completed Carrier assembly is fully inserted into the Steel Tube.
B. The End Cap Plug is glued centrally to the inside end of the End Cap with epoxy glue. C. The End Cap is screwed onto the end of the Steel Tube at the positive pole end of the battery Carrier, completing the Battery Pack ( 1 ).
The Battery Pack ( 1 ) screws into the Separator ( 2 ), which is screwed into the Cutting Head ( 3 ). The Battery Pack ( 1 ) is thermally insulated from the Cutting Head ( 3 ) by a disk of pressed asbestos thermal insulation contained within the Separator ( 2 ).
The total number, charge capacities and arrangement of either size “AAA” or “AA” rechargeable batteries in the Battery Pack ( 1 ) determines the Ohmic resistance requirement of the heating coil in the Cutting Head ( 3 ) in order to transfer an adequate amount of useful heat energy to the Cutting Edge ( 6 ) without over heating the batteries.
The Hot Anti-Wax Knife Separator ( 2 )
This element of the tool provides thermal insulation between the Cutting Head ( 3 ) and the Battery Pack ( 1 ), while still allowing for the required electrical connection. Views of the Separator ( 2 ) are shown in FIGS. 1 , 7 and 8 . The Separator ( 2 ) consists of a washer of thermal insulation “sandwiched” between two steel “end caps”, one the same outside diameter as the Cutting Head ( 3 ), and the other the same outside diameter as the Battery Pack ( 1 ).
Modified forms of the Separator ( 2 ) include but are not limited to;
Various diameters, materials, lengths and thicknesses of the individual elements,
provided that the complete Separator ( 2 ) physically and rigidly connects the Battery Pack ( 1 ) and the Cutting Head ( 3 ) together, and provides thermal insulation between them while providing a conduit for the electrical connection.
The individual elements of a hot anti-wax knife Separator ( 2 ) are described as follows:
Battery End Cap. A steel cap of 38 mm OD, 31.5 mm ID and 9 mm in length, threaded internally to connect to the Steel Tube of the Battery Pack ( 1 ). The cap has a 12 mm diameter hole through the center of the 2 mm thick end wall. The cap also has three 4 mm diameter holes at 120 degrees phasing at 11 mm radius from the center drilled axially through the end. The three 4 mm holes are counter sunk on the inside surface of the cap to accommodate machine bolt screw heads as shown in FIG. 7 . Head End Cap. A steel cap of 44 mm OD, 39.5 mm ID and 1.5 cm in length, threaded internally to connect to the Casing ( 7 ) of the Cutting Head ( 3 ). It has a 12 mm diameter hole drilled through the center of the 5 mm thick end wall. This cap also has three 4 mm diameter holes at 120 degrees phasing at 11 mm radius from the center drilled axially through the end. Insulator. A 6 mm thick pressed Asbestos or Cork washer of 44 mm diameter with a 12 mm diameter hole in the center, and three 4 mm holes at 120 degrees phasing at 11 mm radius from the center. Cork Washer. A 29 mm diameter disk of Cork, 6 mm thick, with a 12 mm hole in the center and three 7 mm wide notches cut 6 mm into the edge at 120 degrees phasing.
The hot anti-wax knife tool Separator ( 2 ) is constructed in the following manner:
A. The Insulator is sandwiched between the flat ends of the two end caps and the holes are aligned. B. Three size M3 flat head machine bolts of 18 mm length are inserted through the end caps from the Battery side cap and secured with nuts at the Head end. C. The Cork Washer is placed inside the Head End Cap, with the edge notches aligned with the protruding bolts and nuts to complete the Separator ( 2 ). A bottom plan view of the assembled Separator ( 2 ) is shown in FIG. 8 .
The Hot Anti-Wax Knife Cutting Head ( 3 )
The Cutting Head ( 3 ), as shown in FIGS. 1 , 2 , 3 and 6 , utilizes a unique design of common materials and naturally occurring shapes in order to effectively transfer electrical energy from the batteries in the Battery Pack ( 1 ) into useful heat energy at the Cutting Edge ( 6 ). A Copper (Cu) coil with a specific resistivity and length, is wound in a spiral coil onto and in direct contact with the outside surface of the apex end of a Tin (Sn) parabaloid or Parabolic Cone ( 5 ). The opposite end of the parabaloid is concave and only the circular edge and rim of the concave end of the parabaloid forms the actual heating and Cutting Edge ( 6 ) of the tool.
The Tin parabaloid with the Copper spiral heating coil in place, is insulated with layers of epoxy, aluminum foil, epoxy resin putty, and asbestos string to retain as much heat as possible in the cone, limit radial heat transfer, and promote heat transfer by conduction axially through the metal walls of the Parabolic Cone ( 5 ) to the Cutting Edge ( 6 ). All but about a 1.5 mm edge and a 3 mm rim of the parabaloid is contained within and sealed inside the steel cylinder of the Casing ( 7 ).
The physical dimensions and material of the parabaloid affects the amount of energy required to raise the temperature, and the surface area of the exposed edge and rim affects the rate of heat loss from the Cutting Head ( 3 ) into the environment. Tin (Sn) was selected for the parabaloid due to its relatively low Specific Heat Capacity and low Thermal Conductivity. The dimensions of the Parabolic Cone ( 5 ) of the Cutting Head ( 3 ) determine the energy requirement from the batteries, which in turn affects the design length and required resistance of the Copper heating coil in the Cutting Head. Therefore these two elements, the Cutting Head ( 3 ) and the Battery Pack ( 1 ), are inseparable in the tool design, form, function and performance.
Modified forms of the Cutting Head ( 3 ) include but are not limited to:
Various cross sectional areas, lengths, number of loops and resistance of the Copper (Cu) wire heating coil and; Various lengths, diameters, volumes and mass and material of the Parabolic Cone ( 5 ) and; Various lengths and diameters and materials of the Casing ( 7 ) and the holes therein and; Various adhesives, epoxy resins and thermal insulation. Each of these elements affects the thermodynamic characteristics of the Cutting Head ( 3 ), and the energy requirement from the Battery Pack ( 1 ).
The individual major components of a hot anti-wax knife Cutting Head ( 3 ) designed for a six size AA 1.2 volt Battery Pack ( 1 ) are described below and shown in cross section in FIG. 2 :
Parabolic Cone ( 5 ). A solid Tin (Sn) parabaloid 42 mm in length and 41 mm in diameter at the widest and concave end, and approximately 200 gm in mass. Heating Coil. One 0.2 mm diameter un-insulated Copper (Cu) wire of 120 cm in length is used to form the spiral heating coil. The terminal ends of this wire are each soldered to 30 cm lengths of 0.4 mm Copper (Cu) wire for construction and end connections. Casing ( 7 ) as shown in cross section in FIG. 2 . This is a 4.4 cm OD steel cylindrical tube 4.6 cm in length with a 7.5 mm wall thickness. It is milled internally from one end to an ID of 4.1 cm for 8 mm, and to an ID of 3.4 cm for 3.6 cm from the end. At the opposite end, the Casing ( 7 ) is externally milled and threaded to an OD of 39.5 mm for 8 mm from the end to accept Head End Cap of the Separator ( 2 ). Casing Ring. A 41 mm OD, 34 mm ID ring of stiff PVC, 8 mm in length, and beveled internally at one end to accommodate the external dimensions of the concave end of the parabaloid. Cone Washer. A 3 mm thick pressed asbestos washer 34 mm in diameter with a 21 mm hole in the center and fits in the annular space between the Parabolic Cone ( 5 ) and the inside of the Casing ( 7 ). Receiver End Power Connector ( 8 ). A commercially available power connection from a mobile phone battery charger. This is the receiving end of the Pin End Power Connector ( 13 ) and is shown for illustration purposes in FIGS. 2 and 6 , and forms no part of the Claim. Cork Disk. A 2 mm thick, 12 mm diameter disk of cork. Hole Insulator Tubes. Three plastic tubes of 7 mm OD and 5 mm ID and about 25 mm in length.
A hot anti-wax knife Cutting Head ( 3 ) for a six size AA battery tool is constructed in the following manner:
A. Melted candle wax is poured into an empty 42 mm ID cardboard tube to a height of 50 mm and allowed to cool. (NOTE: An inverted “bell” shaped concave depression will form in the top of the wax cylinder due to changes in density and volume of the wax as it cools. This is the “naturally occurring shape” mentioned previously in this section). A parabaloid of the designed dimensions is shaped from the wax cylinder with the apex opposite the concave end. Using the “lost wax” casting technique, plaster is poured over the wax parabaloid. Once dried, the plaster cast is heated allowing the wax to melt and pour out, leaving a cavity of the wax parabaloid shape in the plaster casting. Molten Tin (Sn) is poured into the plaster cast. The cast is broken apart and the resulting Tin (Sn) parabaloid is cleaned and shaped to the final design dimensions with a file. B. The 34 mm diameter pressed asbestos Cone Washer is glued onto the rim of the internal upset of the Casing ( 7 ) with epoxy. C. The Casing Ring is glued into the internal upset of the Casing ( 7 ) at the non-threaded end and then beveled internally to match the outer circumference of the concave end of the Parabolic Cone ( 5 ). D. The Parabolic Cone ( 5 ) is fitted inside the Casing ( 7 ), with the apex protruding though the asbestos Cone Washer. E. The Tin cone is temporarily secured in place inside the Casing ( 7 ) with clamps. F. Three 8 mm holes are drilled through the sides (walls) of the Parabolic Cone ( 5 ) and the Casing ( 7 ), from the center radially outward at equal intervals and spacing of 120 degrees phasing and at 45 degrees to the central axis. The holes pass through the center of the plane formed by the circular edge of the concave end of the parabaloid. G. The clamps are removed and the parabaloid is removed from the Casing ( 7 ). H. The Copper wire is wrapped around and onto the apex end of the bare outer surface of the parabaloid beginning at about 5.5 mm from the apex. While holding tension on the end of the wire after the last loop is in place, the wire coil is covered with a thin layer of epoxy to secure the coils in place and to reduce exposure of the wire to the atmosphere. I. The heating coil is then covered with a single layer of aluminum foil. J. One terminal end of the coil is soldered to the Positive pole of the Receiver End Power Connector ( 8 ) and the other end of the coil is soldered to the Negative pole. The Cork Disk is placed between the exposed apex of the Tin parabaloid and the bottom of the Receiver End Power Connector ( 8 ) for thermal insulation. K. A 3 mm thick layer of epoxy putty is applied over the heating coil wire, Cork Disk, and the terminal connections of the Receiver End Power Connector ( 8 ) securing them in place. L. Approximately the middle one third of the length of the parabaloid is wrapped with asbestos string which is then covered with a single layer of aluminum foil. M. The Tin Parabolic Cone ( 5 ) is again placed inside the Casing ( 7 ), with the existing holes aligned with the holes in the Casing. N. A cardboard sleeve is placed around and tapped onto the circumference of the Casing ( 7 ), in order to temporarily cover the three 8 mm holes. O. The parabaloid is again temporarily held in place with clamps. P. Using a caulking gun and a tube of adhesive, glue is injected into each of the three 8 mm holes of the Tin paraboloid, until adhesive completely fills the annular space between the parabaloid and the Casing ( 7 ) and is extruded under pressure through any remaining gaps or holes. Q. The adhesive is allowed to fully cure. R. Three 8 mm holes are drilled through the adhesive filled holes of the parabaloid and Casing ( 7 ). S. The three 7 mm OD Plastic Tubes are inserted and glued with epoxy into the three 8 mm holes in the parabaloid and Casing ( 7 ). The ends of the plastic tubes are trimmed to fit the inside surface contour of the Tin parabaloid and the outside surface of the Casing ( 7 ). T. Epoxy putty is used to partially fill the concave end of the parabaloid, the final exposed putty surface is made slightly concave, leaving only a 1.5 mm wide ring of cutting and heating edge of Tin exposed to the environment. U. Three 6 mm holes are drilled through the epoxy putty, aligned with the inserted plastic tubes in the parabaloid and Casing ( 7 ). V. Finally, the surface of the exposed face of the cured and concave epoxy putty of the Cutting Head ( 3 ) is carved in relief with three wide, spiraling grooves, shaped like curved “tear drops” starting shallow from the exposed Cutting Edge ( 6 ) of the Parabolic Cone ( 5 ) and progressively carved deeper towards the center and converging with each of the three 6 mm diameter holes in the center face of the Cutting Head ( 3 ) as shown in FIG. 3 . These channels have a maximum depth of about 2 mm at the central holes and allow wax that has melted at the edge of the tool to flow centrally towards the three 45 degree holes in the face and be discharged or extruded to the outside of the tool. | During the production of crude oil, naturally occurring paraffin can be deposited on the inside surfaces of production tubing. These wax deposits reduce the cross sectional area of the tubing and can reduce or completely halt the flow of oil from the well.
Currently there are many different methods employed in oil fields around the world to combat paraffin problems, but none are one hundred percent effective. When the available methods fail completely, costly removal and replacement of the tubing must be performed in order to resume oil production.
The hot anti-wax knife tool provides a previously unavailable method of melting a hole through the paraffin deposits in the production tubing in order to restore production. The tool utilizes rechargeable batteries in a novel arrangement which provides sufficient power to melt through paraffin using a uniquely designed heating element and cutting head. | 4 |
FIELD OF THE INVENTION
This invention relates to improvements in permitting brighter colorations within thermoplastic fibers and/or yarns while simultaneously providing more efficient production methods of manufacturing of such colored fibers as well. Generally, such fibers and/or yarns have been colored with pigments, which exhibit dulled results, or dyes, which exhibit high degrees of extraction and low levels of lightfastness. Such dull appearances, high extraction levels, and less than stellar lightfastness properties negatively impact the provision of such desirable colored thermoplastic (such as, without limitation, polypropylene) fibers and/or yarns which, in turn, prevents the widespread utilization of such fibers and yarns in various end-use applications. Thus, it has surprisingly been determined that brighter colorations, excellent extraction, and more-than-acceptable lightfastness characteristics can be provided through manufacture with certain polymeric colorants that include poly(oxyalklene) groups thereon. Fabric articles comprising such novel thermoplastic fibers and/or yarns are also encompassed within this invention.
DISCUSSION OF THE PRIOR ART
All U.S. patents cited below are herein entirely incorporated by reference.
Thermoplastic fibers have been utilized many years for myriad different fabric and textile applications. In particular, polyolefin, polyester, and polyamide fibers have been prominent as replacements for naturally occurring fibers (such as cotton and wool, for instance) due to lower costs, more reliability in supply, physical properties, and other like benefits. Colorations have been available for such thermoplastic, synthetic fibers in order to provide aesthetic, identification, and other properties. Such colorations have been mostly provided through pigments that thoroughly color the target fibers and exhibit sufficiently high lightfastness and crocking characteristics that use thereof has not been curtailed. Dyeing within baths is available for already-formed fabrics (such as knit, woven, and/or non-woven textiles), if a solid color is desired, and also for yarns with selected properties through package dyeing procedures. However, accent yarns or other fibers that require individual colorations requires coloring during production. In addition, some polymers such as polypropylene, polyethylene, etc., have not been heretofore able to accept dyes of any kind, and have thus been colored with pigment. Thus, although such pigment colorants are prevalent and generally effective at providing color within such thermoplastic fibers, there are certain drawbacks for which improvements have been unavailable. For example, pigments are notoriously capable of staining fiber manufacturing/extrusion machinery such that control of discolorations within subsequently produced fibers is rather difficult, and the time required to change colors is high. Also, pigments impart a dulling appearance, a lack of brightness, and a low luster, all believed to be due to the solid nature of such coloring agents. In addition, pigment size and dispersion limits the processability of small fibers, which are desirable for their improved touch and feel. Thus, improvements in such areas are desirable for coloring agents to be introduced within thermoplastic fibers.
In particular, it has been found that improvements in coloring individual polyolefin fibers are needed. For instance, there has been a continued desire to utilize low denier polypropylene fibers in various different products, such as apparel (due to highly effective soft hand properties), and the like. Polyolefin fibers exhibit excellent strength characteristics, highly desirable hand and feel, and do not easily degrade or erode when exposed to certain “destructive” chemicals. However, even with such impressive and beneficial properties and an abundance of polyolefin (such as polypropylene, polyethylene, and the like), which is relatively inexpensive to manufacture and readily available as a petroleum refinery byproduct, such fibers are not widely utilized in products that require fiber and/or yarn colorations therein. Specifically, although polyesters (such as polyethylene terephthalate, or PET) and polyamides (such as nylons) are generally more expensive to manufacture, such fibers do not exhibit the same unacceptable color disadvantages inherent within polyolefins. This is due in large part to the difficulties inherent in providing sufficiently bright colorations within such target polyolefin fibers and/or yarns in general. Thus, it is imperative to provide remedies to such issues to permit utilization of such lower cost polymer materials in greater varieties of end-uses.
Pigments, the most prevalent of polyolefin fiber colorants utilized throughout the fabric industry, as noted above, are, as is well-known, solid particles that require a relatively high amount to provide sufficiently deep colorations within such target materials. Because such pigments exhibit colorations within the discrete areas in which they are actually present, complete pigment presence is required to fully color such target fibers and/or yarns. If certain discrete areas of such target materials do not include any or insufficient amounts of pigments, streaks, uneven colorations, and other aesthetically displeasing results will most likely result. Hence, proper color provision via pigment presence within polyolefin fibers and/or yarns requires large amounts of such solid particles to accord the needed level of colorations therein. However, with such a large amount of pigment present within such target fibers and/or yarns comes an inevitable dull appearance as well. Without intending to be limited to any specific scientific theory, it has now been hypothesized by the inventors that such a dull appearance is attributable to the lack of transparency through the target fiber and/or yarn within which such pigments are added. The solid nature of such pigment particles basically appears to fill the entire fiber and/or yarn to the extent that light cannot pass through easily. Thus, the visible color provided by the fiber and/or yarn is limited to that portion of the scattered light that is reflected back to the viewer alone. As such, the color appears dull to the eye thereby compromising the resultant brightness effect of the fiber, and the ultimate fabric within which such a fiber is incorporated. Thus, there exists the need to provide a distinct improvement on dullness (brightness) in this type of situation in order to permit utilization of more brightly colored polyolefin fibers and/or yarns in order to permit, in turn, more aesthetically pleasing fabric articles from a coloration perspective. Furthermore, and just as important, such pigments are extremely difficult to purge from within manufacturing machinery, particularly within fiber extrusion units, such that once a new color is desired for target fiber materials, extensive purging is required for proper cleaning. Such cleaning is generally quite extensive and complicated since a small amount of residual pigment anywhere within the machinery can discolor any amount of extruded fiber therein. Thus, utilization of either potentially harmful solvents, in-depth and invasive cleaning procedures throughout the entire unit, and/or wasteful flushing processes that also potentially result in pigment effluent production within wastewater, and the norm rather than the exception for pigment-colored polypropylene methods.
Dyes have also been utilized to color not only polyolefin fibers and/or yarns, but also materials such as nylon, polyesters, cotton, and other fiber types. As noted above, in general, polyolefins are an economically superior fiber as compared with other synthetic types (polyesters, nylons, for example); however, its widespread use has been limited due to such issues as this coloration problem. Thus, although dyes have provided bright colorations in these other types of fibers, extraction and lightfastness issues have, again, severely limited utilization of such coloring agents within polyolefins. In essence, such soluble coloring agents do not react readily within polyolefin without exhibiting migration and extraction over time. Polyesters and nylons, as examples, include reactive groups that permit reaction therein with dyes (sulfonated types, for example) and which in turn do not exhibit appreciable extraction as a result. Within polyolefins, to the contrary, extraction levels are quite high for such dyes and thus unevenness in color, streaking, if not complete loss in color, are typical results. This problem is further amplified when fabrics made therefrom such dyed polyolefins are subjected to laundering treatments. Lightfastness (the ability of the target fibers and/or yarns to retain their desired color levels, if not colors at all) are generally unacceptable as well when dyes are utilized without having excessive amounts of protecting agents (UV absorbers, for example) added in addition. Furthermore, the same machinery staining issues and potential wastewater problems are present with dyes as well, albeit to a lesser degree because of the liquid nature of such coloring agents. In any event, a certain degree of difficulty still exists within liquid dye processing within polyolefin fiber and/or yarn manufacturing (extruding, for example) due to such staining characteristics. Thus, as for pigments above, efficiency is compromised during fiber manufacture such that any cost benefits of utilizing polyolefin as compared with other synthetic fiber and/or yarn types are reduced to a level that is unacceptable for displacement within the fabric industry.
In addition, with pigment coloring of fibers, the pigments are normally matched to a standard shade in a high concentration masterbatch that is then diluted with uncolored polymer during the fiber manufacture. As such, if there is a problem or mismatch between the color masterbatch, there is only limited adjustment available at the fiber manufacturing stage. This often necessitates re-manufacture of the masterbatch, adding expense and delaying the manufacturing process.
All in all, it is evident that polyolefin has suffered from coloring limitations in the past such that displacement of more expensive fiber types has not been forthcoming and that the standard coloring agents utilized today have neither imparted the necessary brightness, extraction levels, lightfastness properties, and low staining characteristics that appear to be the main obstacles to more widespread use of colored polypropylene fibers within the fabric industry. To date, there simply has not been any coloring agent that has accorded necessary bright colorations, excellent low (if not nonexistent) extraction levels, and superior lightfastness results within the polypropylene fiber and/or yarn industry.
DESCRIPTION OF THE INVENTION
It is thus an object of the invention to provide thermoplastic (such as polypropylene, as one non-limiting example) fibers and/or yarns that exhibit extremely bright and aesthetically pleasing colorations as compared to pigmented products. A further object of the invention is to provide such colorations that are of very low, if nonexistent, extraction. A further object of the invention is to provide a specific method for the production of brightly colored thermoplastic fibers that permits quick and efficient changeover from one colorant to another. Additionally, another object of this invention is to provide a brightly colored thermoplastic fiber and/or yarn that exhibits outstanding lightfastness properties, either alone or in the presence of minimal amounts of UV absorber additives. Another object of the invention is to provide a process for manufacturing fibers using liquid colors in which the shade can be adjusted to match some standard.
Accordingly, this invention encompasses a colored thermoplastic fiber compromising a liquid colorant present therein in a rod-like configuration. Furthermore, this invention encompasses a colored thermoplastic fiber including at least one liquid colorant therein, wherein said at least one liquid colorant therein exhibits a very low extraction and crocking level therefrom. Additionally, this invention encompasses a method of producing a colored thermoplastic fiber including the steps of a) providing a molten thermoplastic formulation, optionally including colored thermoplastic concentrates therein, wherein said concentrates comprise at least one liquid polymeric colorant; and b) extruding said thermoplastic formulation of step “a” within a fiber extrusion line to form a colored thermoplastic fiber, wherein, optionally at least one liquid polymeric colorant is simultaneously injected within said fiber extrusion line during extrusion of said thermoplastic formulation of step “a”; and. Optionally, this process has the additional steps of providing multiple liquid color constituents in step “a” or “b”, matching the resulting fibers to a standard, and adjusting the ratio of the multiple liquid color constituents so provided to adjust the color of the resulting fiber to match the standard. This invention also encompasses the formation of a colored film including such liquid polymeric colorants, and the formation of colored tape fibers therefrom.
As used herein, the term “thermoplastic” is intended to mean a polymeric material that will melt upon exposure to sufficient heat but will retain its solidified state, but not prior shape without use of a mold or like article, upon sufficient cooling. Specifically, as well, such a term is intended solely to encompass polymers meeting such a broad definition that also exhibit either crystalline or semi-crystalline morphology upon cooling after melt-formation through the use of the aforementioned mold or like article. For this invention, however, the thermoplastic is to be utilized to from fibers and/or yarns through any number of techniques, including, without limitation, extrusion (for multifilament and monofilament types), spinning, water- and/or air-quenching, spun-bonded and/or melt-blown non-woven products, staple fibers, bicomponent/splittalbe fibers, tape and/or ribbon fibers (through slit film procedures, as one example), and the like. Particular types of polymers contemplated within such a definition include, without limitation, polyolefins (such as polyethylene, polypropylene, polybutylene, and any combination thereof), polyamides (such as nylon), polyurethanes, polyesters (such as polyethylene terephthalate), polylactic acids, and any copolymers of these broad types, either within the same classification or not. Polypropylene fibers are most preferred, although polyesters are preferred as well. The particular polypropylene fiber and/or yarn of this invention may be of any denier, including microdeniers (below about 1.5 denier per fiber) or higher deniers 1.5 denier per fiber or higher), as merely examples.
The target fibers and/or yarns may also be textured in any manner commonly followed for polypropylene materials. One example of this is false-twist texturing, in which a twist is imparted to the fiber through the use of spindles, and while the fiber is in the twisted state it is heated and then cooled to impart into the individual filaments a memory of the twisted state. The yarn is then untwisted, but retains bulk due to the imparted memory. In another texturing embodiment, known as bulked continuous filament (BCF), the yarn is pushed with air jets into a stuffer box where it is crowded in a non-uniform state with other fibers and heated to retain the memory of this non-uniform state. The yarn is then cooled, but again retains bulk due to the imparted memory. Of course, other texturing methods, such as air texturing, gear texturing, and the like, may be used.
The term “polypropylene” is intended to encompass any polymeric composition comprising propylene monomers, either alone or in mixture or copolymer with other randomly selected and oriented polyolefins, dienes, or other monomers (such as ethylene, butylene, and the like). Such a term also encompasses any different configuration and arrangement of the constituent monomers (such as syndiotactic, isotactic, and the like). Thus, the term as applied to fibers is intended to encompass actual long strands, tapes, threads, and the like, of drawn polymer. The polypropylene may be of any standard melt flow (by testing); however, standard fiber grade polypropylene resins possess ranges of Melt Flow Indices between about 1 and 1000.
Contrary to standard manufacturing procedures and techniques for plaques, containers, sheets, and the like (such as taught within U.S. Pat. No. 4,016,118 to Hamada et al., for example), fibers clearly differ in structure since they must exhibit a length that far exceeds its cross-sectional area (such, for example, its diameter for round fibers). Fibers are extruded and drawn; articles are blow-molded or injection molded, to name two alternative production methods. Also, the crystalline morphology of polypropylene within fibers is different than that of standard articles, plaques, sheets, and the like. For instance, the dpf of such polypropylene fibers is at most about 5000; whereas the dpf of these other articles is much greater. Polypropylene articles generally exhibit spherulitic crystals while fibers exhibit elongated, extended crystal structures. Thus, there is a great difference in structure between fibers and polypropylene articles such that any predictions made for spherulitic particles (crystals) of colored polypropylene articles do not provide any basis for determining the effectiveness of coloring agents as additives within polypropylene fibers. For instance, plaques made with pigments can exhibit bright, deep shades, and still appear transparent in fiber form, dullness (low brightness) and opacity are prominent when deep shades of pigmented fibers are produced. Thus, the significant differences in form and structure between sheet-like articles and fibers (and/or yarns) of the same thermoplastic, make it difficult to predict how effective a specific coloring agent may perform within one through knowledge of the other.
The coloring agents particularly useful within this invention are those that are liquid in nature, preferably, though not necessarily, polymeric in nature [i.e., poly(oxyalkylenated)] to the extent that, upon introduction within such target polypropylene fibers, extraction therefrom is severely limited, if not nonexistent. The term “liquid” is intended to mean that such colorants are liquid at room temperature and standard pressure (25° C. at 1 atmosphere). Example colorants that meet these limitations (and thus are defined by the term “liquid polymeric colorants” herein) are those that are available from Milliken & Company under the tradename CLEARTINT®. Alternatively, liquid dyestuffs may also be utilized, although less preferred than polymeric types.
The preferred colorants in this general class are represented by the following formula (1):
R{A[(B) n ] m } x (I)
wherein
R is an organic chromophore; A is a linking moiety in said chromophore selected from the group consisting of N, O, S, SO 2 N, and CO 2 ; B is an alkyleneoxy constituent contains from 2 to 4 carbon atoms; n is an integer of from 2 to about 500; m is 1 when A is O, S, or CO 2 , and m is 2 when A is N or SO 2 N; and x is an integer of from 1 to about 5.
The molecular weight of such colorants are at least 2000 and, due to the high oxyalkylenation present, are highly water soluble and liquid at room temperature. The organic chromophore is, more specifically, one or more of the following types of compounds: azo, diazo, disazo, trisazo, diphenylmethane, triphenylmethane, xanthene, nitro, nitroso, acridine, methine, styryl, indamine, thiazole, oxazine, stilbene, or anthraquinone. In an alternative embodiment, the chromophore may be optically inactive, at least within the visible spectrum, but absorb uv radiation, as one example, thereby imparting ultraviolet protection to the target fibers. Preferably, R is one or more of azo, diazo, triphenylmethane, methine, anthraquinone, or thiazole based compounds. Such a group may produce coloring effects that are evident to the eye; however, optical brightening chromophores are also contemplated in this respect. Group A is present on group R and is utilized to attach the polyoxyalkylene constituent to the organic chromophore. Nitrogen is the preferred linking moiety. The polyoxyalkylene group is generally a combination of ethylene oxide and propylene oxide monomers. Preferably propylene oxide is present in the major amount, and most preferably the entire polyoxyalkylene constituent is propylene oxide.
The preferred number of moles (n) of polyoxyalkylene constituent per polyoxyalkylene chain is from 2 to 50, more preferably from 10 to 30. Also, preferably two such polymeric chains are present on each polymeric colorant compound (x, above, is preferably 2). In actuality, the number of moles (n) per polymeric chain is an average of the total number present since it is very difficult to control the addition of specific numbers of moles of alkyleneoxy groups. The Table below lists the particularly preferred colorants (with the range of alkoxylation present on the colorant listed due to the inexactness of production of specific chain lengths) for utilization in relation to Structure (I), above:
COLORANT TABLE Preferred Poly(oxyalkylenated) Colorants Col. # R A B(with moles) m x Color 1 Methine N 6-8 EO; 12-15 PO 2 1 Yellow 2 Benzothiazole N 6-8 EO; 10-12 PO 2 1 Red diazo 3 Triphenylmethane N 2-4 EO; 12-15 PO 2 2 Cyan 4 Aminothiophene N 0-12 EO; 12-15 PO 2 1 Violet Diazo 5 Phenyl Diazo N 8-10 EO; 10-12 PO 2 2 Orange
Such colorants provide the aforementioned, highly desirable, low extraction properties, as well as the significant bright colorations as compared with pigmented fibers.
Without intending on being limited to any specific scientific theory, it appears that such colorants are capable of complete introduction within the target polypropylene fibers to the extent that transparent thin rod-like configurations of the liquid colorants are present within the fibers after extrusion. Such configurations thus permit an even distribution of color throughout the target fiber, and, apparently, with a strong cohesive nature while present therein said fibers, such thin rod-like configurations are not amenable to easy migration from therein either. In other words, although small openings may exist within and/or at the surface of such extruded polypropylene fibers, the rod-like configurations of the colorants therein do not break, but appear to keep there rod-like appearance and the liquid colorant thus does not migrate or escape through such surface openings, even if such fibers come into contact with adhesive surfaces themselves. Such a physical appearance is shown within the drawings discussed below. In essence, empirically the liquid colorants (polymerics, preferably, although possible liquid dyestuffs may function similarly) will appear as long strands of color within extruded fibers if the methods of producing disclosed herein are employed when viewed at proper magnifications (such as from 300 to 1000×; proper viewing may be seen most readily between 500 and 600×). Cross-sectionally, such long strands will appear as small dots within the target fibers. These dots will be the tops of these rod-like structures which can then be noticed from side views as the aforementioned strands. Thus, since these strands are basically pools of liquid color stretched during the fiber extrusion process, these structures will exhibit aspect ratios (length to diameter) of from 10:1 to 500,000:1, preferably from 50:1 to 100,000:1, more preferably from 50:1 to 10,000:1, and most preferably from 100:1 to 1,000:1. Thus, the term rod-like is intended to encompass these high aspect ratio strands of liquid color within target thermoplastic fibers. Since the thermoplastic will be colorless, or at least sufficiently different in color from the added liquid coloring agent, it is relatively easy to view such rod-like structures through side views coupled with cross-sectional views. Again, the continuous strands of color or easily viewed from the side; the “dots” of tops of different strands are easily viewed in cross-section.
This rod-like configuration also provides effective and even colorations throughout such target fibers because of the ability of light to pass through such fibers and transparent film-like structures simultaneously. Thus, light is transmitted through such fibers as well as absorbed by the colorants therein due to the transparent appearance of the resultant fiber. The resultant appearance is, unexpectedly, very bright in nature, much more so, for example, than the empirical appearance of the above discussed pigmented fibers that require a large amount of solid particles therein to provide even colorations throughout, but which, as a result, also exhibit very dull appearances as well. The colored transparent nature available with these inventive liquid colorants produces the bright colorations, much like a colored filter placed over a light imparts a bright, colored effect when the light shines therethrough. The fibers themselves are generally solid in nature, and, cross-sectionally, appear as round, triangular, square, and/or rectangular in shape, but may have any cross sectional shape, such as octalobal which is popular in carpet fibers.
Such fibers (or yarns comprising such fibers) may also include the presence of certain compounds that quickly and effectively provide rigidity and/or tensile strength to the target polypropylene fiber to a level heretofore unavailable, particularly in terms of permitting high-speed spinning for greater efficiency in fiber and/or yarn manufacturing. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the nucleator compounds provide nucleation sites for polypropylene crystal growth which, in turn, appear to provide thick lamellae within the fibers themselves which, apparently (without intending on being bound to any specific scientific theory) increase the processability of the target fibers to such a degree that the tensions associated with high-speed spinning can easily be withstood. The preferred nucleating compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as sodium benzoate, certain sodium and lithium phosphate salts (such as sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11 or NA-21), zinc glycerolate, and others. Sodium benzoate, in general, is not preferred because it is known to outgas corrosive benzoic acid, among other deficiencies. Also, the amount of nucleating agent present within the inventive fiber is at least 10 ppm; preferably this amount is at least 100 ppm; and most preferably is at least 1250 ppm. Any amount of such a nucleating agent should suffice to provide the desired shrinkage rates after heat-setting of the fiber itself; however, excessive amounts (e.g., above about 10,000 ppm and even as low as about 6,000 ppm) should be avoided, primarily due to costs, but also due to potential processing problems with greater amounts of additives present within the target fibers.
Another potentially preferred class of nucleators suitable for incorporation within the inventive colored fibers include saturated metal or organic salts of bicyclic dicarboxylates, preferably saturated metal or organic salts of bicyclic dicarboxylates, preferably, bicyclo[2.2.1]heptane-dicarboxylates, or, generally, compounds conforming to Formula (I)
wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are individually selected from the group consisting of hydrogen, C 1 -C 9 alkyl, hydroxy, C 1 -C 9 alkoxy, C 1 -C 9 alkyleneoxy, amine, and C 1 -C 9 alkylamine, halogen, phenyl, alkylphenyl, and geminal or vicinal carbocyclic having up to nine carbon atoms, R′ and R″ are the same or different and are individually selected from the group consisting of hydrogen, C 1 -C 30 alkyl, hydroxy, amine, polyamine, polyoxyamine, C 1 -C 30 alkylamine, phenyl, halogen, C 1 -C 30 alkoxy, C 1 -C 30 polyoxyalkyl, C(O)—NR 11 C(O)O—R′″, and C(O)O—R′″, wherein R 11 is selected from the group consisting of C 1 -C 30 alkyl, hydrogen, C 1 -C 30 alkoxy, and C 1 -C 30 polyoxyalkyl, and wherein R′″ is selected from the group consisting of hydrogen, a metal ion (such as, without limitation, Na + , K + , Li + , Ag + and any other monovalent ions), an organic cation (such as ammonium as one non-limiting example), polyoxy-C 2 -C 18 -alkylene, C 1 -C 30 alkyl, C 1 -C 30 alkylene, C 1 -C 30 alkyleneoxy, a steroid moiety (for example, cholesterol), phenyl, polyphenyl, C 1 -C 30 alkylhalide, and C 1 C 30 alkylamine; wherein at least one of R′ and R″ is either C(O)—NR 11 C(O)O—R′″ or C(O)O—R′″, wherein if both R′ and R″ are C(O)OR′″ then R′″ both R′ and R″ may be combined into a single bivalent metal ion (such as Ca 2+ , as one non-limiting example) or a single trivalent metal overbase (such as Al—OH, for one non-limiting example). Preferably, R′ and R″ are the same and R′″ is either Na + or combined together for both R′ and R″ and Ca 2+ . Other possible compounds are discussed in the preferred embodiment section below.
Preferably, as noted above, such a compound conforms to the structure of Formula (II)
wherein M 1 and M 2 are the same or different and are independently selected from the group consisting of metal or organic cations or the two metal ions are unified into a single metal ion (bivalent, for instance, such as calcium, for example), and R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are individually selected from the group consisting of hydrogen, C 1 -C 9 alkyl, hydroxy, C 1 -C 9 alkoxy, C 1 -C 9 alkyleneoxy, amine, and C 1 -C 9 alkylamine, halogen, phenyl, alkylphenyl, and geminal or vicinal carbocyclic having up to 9 carbon atoms. Preferably, the metal cations are selected from the group consisting of calcium, strontium, barium, magnesium, aluminum, silver, sodium, lithium, rubidium, potassium, and the like. Within that scope, group I and group II metal ions are generally preferred. Among the group I and II cations, sodium, potassium, calcium and strontium are preferred, wherein sodium and calcium are most preferred. Furthermore, the M 1 and M 2 groups may also be combined to form a single metal cation (such as calcium, strontium, barium, magnesium, aluminum, including monobasic aluminum, and the like). Although this invention encompasses all stereochemical configurations of such compounds, the cis configuration is preferred wherein cis-endo is the most preferred embodiment. The preferred embodiment polyolefin articles and additive compositions for polyolefin formulations comprising at least one of such compounds, broadly stated as saturated bicyclic carboxylate salts, are also encompassed within this invention.
As they apply to this invention, then, the terms “nucleators”, “nucleator compound(s)”, “nucleating agent”, and “nucleating agents” are intended to generally encompass, singularly or in combination, any additive to polypropylene that produces nucleation sites for polypropylene crystals from transition from its molten state to a solid, cooled structure. Hence, since the polypropylene composition (including nucleator compounds in certain cases) must be molten to eventually extrude the fiber itself, the nucleator compound will provide such nucleation sites upon cooling of the polypropylene from its molten state. The only way in which such compounds provide the necessary nucleation sites is if such sites form prior to polypropylene recrystallization itself. Thus, any compound that exhibits such a beneficial effect and property is included within this definition. Such nucleator compounds more specifically include dibenzylidene sorbitol types, including, without limitation, dibenzylidene sorbitol (DBS), monomethyldibenzylidene sorbitol, such as 1,3:2,4-bis(p-methylbenzylidene) sorbitol (p-MDBS), dimethyl dibenzylidene sorbitol, such as 1,3:2,4-bis(3,4-dimethylbenzylidene) sorbitol (3,4-DMDBS); other compounds of this type include, again, without limitation, sodium benzoate, NA-11, NA-21, bicyclic dicarboxylate salts, and the like. The concentration of such nucleating agents (in total) within the target polypropylene fiber is at least 100 ppm, preferably at least 1250 ppm. Thus, from about 100 to about 5000 ppm, preferably from about 500 ppm to about 4000 ppm, more preferably from about 1000 ppm to about 3500 ppm, still more preferably from about 1500 ppm to about 3000 ppm, even more preferably from about 2000 ppm to about 3000 ppm, and most preferably from about 2500 to about 3000 ppm.
Also, without being limited by any specific scientific theory, it appears that the potential, but not required, nucleators which perform the best are those which exhibit relatively high solubility within the propylene itself. Thus, compounds which are readily soluble, such as 1,3:2,4-bis(p-methylbenzylidene) sorbitol provides the lowest shrinkage rate for the desired polypropylene fibers. The DBS derivative compounds are considered the best shrink-reducing nucleators within this invention due to the low crystalline sizes produced by such compounds. Other nucleators, such as NA-11, also impart acceptable characteristics to the target polypropylene fiber in terms of, for example, withstanding high speed spinning tensions; however, apparently due to poor dispersion of NA-11 in polypropylene and the large and varied crystal sizes of NA-11 within the fiber itself, the performance is less consistent than for the highly soluble, low crystal-size polypropylene produced by well-dispersed 3,4-DMDBS or, preferably, P-MDBS.
It has been determined that the nucleator compounds that exhibit good solubility in the target molten polypropylene resins (and thus are liquid in nature during that stage in the fiber-production process) provide more effective fiber properties for withstanding high speed spinning tension levels. Thus, substituted DBS compounds (including DBS, 3,4-DMDBS, and, preferably P-MDBS) appear to provide fewer manufacturing issues as well as lower shrink properties within the finished polypropylene fibers themselves. Although 3,4-DMDBS is preferred for such low denier fibers, any of the above-mentioned nucleators may be utilized within this invention. Mixtures of such nucleators may also be used during processing in order to provide such spinning efficiencies and low-shrink properties as well as possible organoleptic improvements, facilitation of processing, or cost.
In addition to those compounds noted above, sodium benzoate and NA-11 are well known as nucleating agents for standard polypropylene compositions (such as the aforementioned plaques, containers, films, sheets, and the like) and exhibit excellent recrystallization temperatures and very quick injection molding cycle times for those purposes. The dibenzylidene sorbitol types exhibit the same types of properties as well as excellent clarity within such standard polypropylene forms (plaques, sheets, etc.). For the purposes of this invention, it has been found that the dibenzylidene sorbitol types are preferred as nucleator compounds within the target polypropylene fibers.
Furthermore, such fibers may include other coloring agents, such as pigments, titanium dioxide, and the like, as well as fixing agents for lightfastness purposes. To that end, certain ultraviolet absorbers provide excellent protection from ultraviolet radiation and thus aids in reducing, if not preventing, color degradation due to such exposure. Any type of ultraviolet absorber compound or formulation that is dispersible within thermoplastics may be utilized within this invention. However, some non-limiting examples of such components include phenolic antioxidants, such as HOSTANOX® 245, O10, O14, O16, O3, and blends with HOSTANOX® M, all available from Clariant; processing stabilizers, such as HOSTANOX® PAR 24, SANDOSTAB® PEPQ (from Clariant), and blends with SANDOSTAB® QB; sulfur-containing co-stabilizers, such as HOSTANOX® SE 4 or SE 10; metal deactivators, such as HOSTANOX® OSP 1; light stabilizers, such as NYLOSTAB® S-EED (from Clariant, as well); and straightforward ultraviolet absorbers, such as CHIMASSORB® 2020, 944, 119, and/or 119FL, TINUVIN® 783, 353, 234, 1577, and/or 622 (all available from Ciba Specialty Chemicals). Preferred is TINUVIN® 783 for such a purpose.
In terms of providing effective colorations for brightness, it is further desirable to avoid pigments as nucleating agents; however, if desired, slight amounts of such pigments may be added for nucleation or coloration purposes if such are desired end results. Other additives may also be present, including antistatic agents, brightening compounds, clarifying agents, antioxidants, antimicrobials (preferably silver-based ion-exchange compounds, such as ALPHASAN® antimicrobials available from Milliken & Company), fillers, and the like. Furthermore, any fabrics made from such inventive fibers may be, without limitation, woven, knit, non-woven, in-laid scrim, any combination thereof, and the like. Additionally, such fabrics may include fibers other than the inventive polypropylene fibers, including, without limitation, natural fibers, such as cotton, wool, abaca, hemp, ramie, and the like; synthetic fibers, such as polyesters, polyamides, polyaramids, other polyolefins (including non-low-shrink polypropylene), polylactic acids, and the like; inorganic fibers such as glass, boron-containing fibers, and the like; and any blends thereof.
In addition, this invention can be practiced with any melt extrudable thermoplastic polymer, such as polyester, nylon, poly lactic acid, and the like, with similar results.
Such inventive fibers can be included in a fabric such as a carpet, upholstery fabric, woven fabric, knit fabric, nonwoven, pile fabric, netting, and the like. In addition, these fibers can be combined in such fabric structures as accent yarns, especially if the additional non-inventive fibers are dye accepting. In such a case, the inventive yarns provide accent yarns with bright appearance. In addition, individual yarns may be incorporated within non-fabric structures, such as, as one non-limiting example, fishing lures, and other end-uses in which brightly colored strong fibers are desirable.
Inventive yarns and fibers can be used in any standard textile process, including, without limitation, such methods as yarn texturing processes such as stuffer box, bulk continuous filament (BCF), air jet texturing, twisting, false twist testing, and the like. They can also be combined with other yarns or used in other processes to make “elegant” or “fancy” yarns, such as chenille, slub yarns, stria yarns, etc., with all of the incumbent advantages of combining the technologies. In addition, the transparent nature of the color can be used in light weight fabrics to make colored transparent fabrics such as may be desirable to show a pattern on a substrate covered by the inventive fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate a potentially preferred embodiment of producing the inventive low-shrink polypropylene fibers and together with the description serve to explain the principles of the invention wherein:
FIG. 1 is a schematic of the potentially preferred method of producing colored polypropylene fibers through typical spinning machinery.
FIG. 2 is a schematic of the potentially preferred method of producing colored polypropylene tape fibers.
FIG. 3 is a schematic of the potentially preferred method of producing colored polypropylene fibers through typical high-speed spinning machinery.
FIG. 4 is a side-view color microphotograph of a green-colored inventive polypropylene fiber magnified at 565× colored with a liquid polymeric colorant.
FIG. 5 is a side-view color microphotograph of a comparative green-colored polypropylene yarn magnified at 565× having pigments present throughout.
FIG. 6 is a cross-sectional view of a plurality of green-colored inventive polypropylene fibers magnified at 565× colored with a liquid polymeric colorant.
DETAILED DESCRIPTION OF THE DRAWING AND OF THE PREFERRED EMBODIMENT
FIG. 1 depicts the non-limiting preferred procedure followed in producing the inventive low denier polypropylene fibers. The entire fiber production assembly 10 comprises an extruder 11 including a metering pump (not illustrated) for introduction of specific amounts of polymer into the extruder 11 (to control the denier of the ultimate target manufactured fiber and/or yarn) which also comprises four [five] different zones 12 , 14 , 16 , 18 , 20 through which the polymer (not illustrated) passes at different, increasing temperatures. The molten polymer is mixed with the liquid polymeric colorant (here, Example 1 from the Colorant Table, above, preferably) within a mixer zone 22 . Basically, the polymer (not illustrated) is introduced within the fiber production assembly 10 , in particular within the extruder 11 . The temperatures, as noted above, of the individual extruder zones 12 , 14 , 16 , 18 , 20 and the mixing zone 22 are as follows: first extruder zone 12 at 210° C., second extruder zone 14 at 220° C., third extruder zone 16 at 230° C., fourth extruder zone 18 at 235° C., [fifth extruder zone 20 at 240° C.,] and mixing zone 22 at 240° C. The molten polymer (not illustrated) then moves into a spinneret area 24 set at a temperature of 240° C. for strand extrusion. All such temperatures may be modified as needed, and these levels are non-limiting and simply potentially preferred. The fibrous strands 28 then pass through an air-blown treatment shroud [area] 26 set at a temperature of 175° C. and then through a treatment area 29 whereupon a lubricant, such as water or an oil, is applied thereto the strands 28 . The strands 28 are then collected into a bundle 30 via a take-up roll 32 to form a multifilament yarn 33 which then passes to a series of tensioning rolls 34 , 36 prior to drawing. The yarn 33 then passes through a series of two different sets of draw rolls 38 , 40 , 42 , 44 which increase the speed of the collected finished strands 33 as compared with the speed of the initially extruded strands 28 . The finished strands 33 extend in length due to a greater pulling speed in excess of such an initial extrusion speed within the extruder 11 . The strands 33 are then passed through a series of relax rolls 46 , 48 and ultimately to a winder 50 for ultimate collection on a spool (not illustrated). The speed of the winder 50 ultimately dictates the speed and efficiency of the entire apparatus in terms of permitting high speed manufacturing and spinning (drawing) with minimal, if any, breakage of the target fibers during such a procedure. The draw rolls are heated to a very low level as follows: first draw rolls 38 , 40 60-70° C. and the second set of draw rolls 42 , 44 80-90° C., as compared with the remaining areas of high temperature exposure as well as comparative fiber drawing processes. The draw rolls 38 , 40 , 42 , 44 individually and, potentially independently rotate at a speed of from about 1000 meters per minute to as high as about 5000 meters per minute. The second draw rolls 42 , 44 generally rotate at a higher speed than the first in excess of about 800 meters per minute up to 1000 meters per minute over those of the first set.
FIG. 2 depicts the non-limiting preferred procedure followed in producing the inventive low-shrink polypropylene tape fibers. The entire fiber production assembly 110 comprises a mixing manifold 111 for the incorporation of molten polymer and additives (such as the aforementioned nucleator compound) which then move into an extruder 112 . The extruded polymer is then passed through a metering pump 114 to a die assembly 116 , whereupon the film 117 is produced. The film 117 then immediately moves to a quenching bath 118 comprising a liquid, such as water, and the like, set at a temperature from 5 to 95° C. (here, preferably, about room temperature). The drawing speed of the film at this point is dictated by draw rolls and tensionsing rolls 120 , 122 , 124 , 126 , 128 set at a speed of about 100 feet/minute, preferably, although the speed could be anywhere from about 20 feet/minute to about 200 feet/minute, as long as the initial drawing speed is at most about ⅕ th that of the heat-draw speed later in the procedure. The quenched film 119 should not exhibit any appreciable crystal orientation of the polymer therein for further processing. Sanding rolls 130 , 131 , 132 , 133 , 134 , 135 , may be optionally utilized for delustering of the film, if desired. The quenched film 119 then moves into a cutting area 36 with a plurality of fixed knives 138 spaced at any distance apart desired. Preferably, such knives 138 are spaced a distance determined by the equation of the square root of the draw speed multiplied by the final width of the target fibers (thus, with a draw ratio of 5:1 and a final width of about 3 mm, the blade gap measurements should be about 6.7 mm). Upon slitting the quenched film 119 into fibers 140 , such fibers are moved uniformly through a series of nip and tensioning rolls 142 , 143 , 144 , 145 prior to being drawn into a high temperature oven 146 set at a temperature level of between about 280 and 350° C., in this instance about 310° C., at a rate as noted above, at least 5 times that of the initial drawing speed. Such an increased drawing speed is effectuated by a series of heated drawing rolls 141 , 150 (at temperatures of about 360-400° F. each) over which the now crystal-oriented fibers 154 are passed. A last tensioning roll 152 leads to a spool (not illustrated) for winding of the finished tape fibers 154 .
FIG. 3 depicts the non-limiting preferred procedure followed in producing the inventive low denier polypropylene fibers. The entire fiber production assembly 210 comprises an extruder 211 including a metering pump (not illustrated) for introduction of specific amounts of polymer into the extruder 211 (to control the denier of the ultimate target manufactured fiber and/or yarn) which also comprises five different zones 212 , 214 , 216 , 218 , 220 through which the polymer (not illustrated) passes at different, increasing temperatures. The molten polymer is mixed with the nucleator compound (also molten) within a mixer zone 222 . Basically, the polymer (not illustrated) is introduced within the fiber production assembly 210 , in particular within the extruder 211 . The temperatures, as noted above, of the individual extruder zones 212 , 214 , 216 , 218 , 220 and the mixing zone 22 are as follows: first extruder zone 212 at 205° C., second extruder zone 214 at 215° C., third extruder zone 216 at 225° C., fourth extruder zone 218 at 235° C., fifth extruder zone 220 at 240° C., and mixing zone 222 at 245° C. The molten polymer (not illustrated) then moves into a spinneret area 224 set at a temperature of 250° C. for strand extrusion. All such temperatures may be modified as needed, and these levels are non-limiting and simply potentially preferred. The fibrous strands 228 then pass through an air-blown treatment area 226 and then through a treatment area 229 whereupon a lubricant, such as water or an oil, is applied thereto the strands 228 . The strands 228 are then collected into a bundle 230 via a take-up roll 232 to form a multifilament yarn 233 which then passes to a series of tensioning rolls 234 , 236 prior to drawing. The yarn 233 then passes through a series of two different sets of draw rolls 238 , 240 , 242 , 244 which increase the speed of the collected finished strands 233 as compared with the speed of the initially extruded strands 228 . The finished strands 233 extend in length due to a greater pulling speed in excess of such an initial extrusion speed within the extruder 211 . The strands 233 are then passed through a series of relax rolls 246 , 248 and ultimately to a winder 250 for ultimate collection on a spool (not illustrated). The speed of the winder 250 ultimately dictates the speed and efficiency of the entire apparatus in terms of permitting high speed manufacturing and spinning (drawing) with minimal, if any, breakage of the target fibers during such a procedure. The draw rolls are heated to a very low level as follows: first draw rolls 238 , 240 68° C. and the second set of draw rolls 242 , 244 88° C., as compared with the remaining areas of high temperature exposure as well as comparative fiber drawing processes. The draw rolls 238 , 240 , 242 , 244 individually and, potentially independently rotate at a speed of from about 1000 meters per minute to as high as about 5000 meters per minute. The second draw rolls 242 , 244 generally rotate at a higher speed than the first in excess of about 800 meters per minute up to 1000 meters per minute over those of the first set.
In FIG. 4 , the presence of rod-like structures of color is evident throughout the fiber. Such rod-like structures are basically the liquid polymeric colorants stretched in the same manner as the resin fiber is stretched during extrusion. The shear of extrusion forms long high aspect ratio rod-like configurations of liquid colorant within the target fiber. Such a rod-like structure thus imparts colorations to the target fiber while simultaneously allowing transmission of light therethrough. As such, the fiber remains transparent to light, thereby exhibiting an increased brightness and luster. Furthermore, these rod-like structures, although they remain liquid in nature, are not in individual pools of color, but are stretched in such a rod-like manner, such that the liquid component cannot be easily extracted from within the target fiber without damaging the fiber itself.
In FIG. 5 , the presence of pigment particles is evident throughout the fiber. Such pigment particles are solid in nature. The color imparted to the target fiber is thus substantially reliant upon absorption of light by such solid particles. There is little chance of light transmission through the fiber such that the fiber lacks transparency. As a result, brightness and luster are compromised such that the fiber exhibits a dulling effect, particularly in comparison with the fiber of FIG. 4 .
In FIG. 6 , the presence of “dots” of color can be seen within the cross-sectional views of the target fibers (as in FIG. 4 ). Such “dots” are the portions of the rod-like high aspect ratio structures of the liquid colorants that were stretched during extrusion. The plurality of “dots” thus shows the inclusion of numerous different rod-like structures throughout individuals fibers. Coupled with the side view (as in FIG. 4 ), it can be seen how a liquid coloring agent (polymeric type, preferably, though not necessarily) is stretched from a starting pool of liquid into this high aspect ratio strand (rod-like structure).
Inventive Fiber and Yarn Production
EXAMPLE 1
Polymeric Colorant Fibers
Yarns were made using a commercially available polypropylene fiber grade resin Amoco 7550 (melt flow of 18), using a standard fiber spinning apparatus as described previously. The five colorants from the COLORANT TABLE, above, were formed into 10% concentrates premixed with fiber grade polypropylene resin and fed into the hopper of the extruder during fiber extrusion. In one preferred embodiment, fiber grade resin polypropylene was fed into the extruder on an Alex James & Associates multifilament fiber extrusion line as noted above in FIG. 1 along with a 10% color concentrate including the required liquid polymeric colorants. Yarn was produced with the extrusion line conditions shown in Table 1 using a 68 hole spinneret, giving a yarn of nominally 150 denier. The godet roll temperatures were 67° C. (for 38 , 40 in FIG. 1 ), 85° C. (for 42 , 44 ), and 125° C. (for 46 , 48 ), respectively, with a nominal winder speed of about 1300 m/min. Pigmented fibers were also made for comparative purposes.
The extruder and cooling conditions were as follows:
TABLE #1 Procedural Conditions Extruder Temperature Zone #1 210° C. Extruder Temperature Zone #2 220° C. Extruder Temperature Zone #3 230° C. Extruder Temperature Zone #4 235° C. Mixer Temperature 240° C. Spinneret Temperature #1 240° C. Spinneret Temperature #2 240° C. Shroud Temperature 175° C.
Winder take-up speeds of 1290 m/min with draw ratios of approximately 3.5 were utilized and deniers between 150 and 200 were produced. A minimum of 3 samples were produced with concentrations of ½ and or 1% color in the Amoco 7550 for each of the colors. Extrusion conditions and physical properties of these samples are detailed in the following tables. Additionally, comparative pigmented samples were produced with three pigments provided by Standridge Color Concentrate 86600 blue 25% GSP, fade red HUV and yellow HG 25% which are identified in the table below as blue, red and yellow pigment, respectively.
TABLE #2
Procedural Conditions
Fiber Extrusion Conditions
Color
Draw
Heat Set
Sample ID
Polymer
Color
Level
Ratio
(° C.)
1
Amoco 7550
None
0
3.49
125
2
Amoco 7550
None
0
4.56
125
3
Amoco 7550
None
0
3.44
125
4
Amoco 7550
10% Colorant #3
0.5
4.56
125
5
Amoco 7550
10% Colorant #3
0.5
3.44
125
6
Amoco 7550
10% Colorant #3
0.5
3.53
125
7
Amoco 7550
10% Colorant #5
0.5
3.49
125
8
Amoco 7550
10% Colorant #5
0.5
3.44
125
9
Amoco 7550
10% Colorant #5
0.5
4.56
125
10
Amoco 7550
10% Colorant #2
0.5
3.44
125
11
Amoco 7550
10% Colorant #2
1.0
3.44
125
12
Amoco 7550
10% Colorant #2
1.0
3.44
125
13
Amoco 7550
10% Colorant #2
1.0
3.55
125
14
Amoco 7550
10% Colorant #4
0.5
3.49
125
15
Amoco 7550
10% Colorant #4
0.5
3.94
125
16
Amoco 7550
10% Colorant #4
0.5
4.56
125
17
Amoco 7550
10% Colorant #1
0.5
4.56
125
18
Amoco 7550
10% Colorant #1
0.5
3.44
125
19
Amoco 7550
10% Colorant #1
0.5
3.53
125
20
Amoco 7550
Blue Pigment
0.5
3.44
125
21
Amoco 7550
Red Pigment
0.5
3.44
125
22
Amoco 7550
Yellow Pigment
0.5
3.44
125
TABLE #1
Experimental
Fiber Properties
3%
130C
Denier
Elongation
Tenacity
Modulus
Shrinkage
Sample ID
(g/9000 m)
(%)
(g/den)
(g/den)
(%)
1
153.8
53.0
4.6
41.6
6.6
2
85.7
32.1
6.5
67.9
9.9
3
159.7
67.9
4.7
44.4
11.1
4
172.7
61.5
5.0
44.0
14.8
5
147.4
74.4
4.6
42.4
8.5
6
150.7
66.1
4.2
38.9
9.6
7
149.5
41.1
4.4
41.2
7.2
8
155.1
54.7
4.1
38.7
8.0
9
169.2
46.6
5.6
51.0
10.4
10
156.2
51.1
5.0
43.9
13.6
11
181.0
50.0
4.6
42.8
9.0
12
153.8
46.6
4.9
45.3
9.5
13
153.6
35.5
4.8
45.4
13.6
14
154.1
47.7
4.3
39.5
11.2
15
151.4
48.0
4.4
41.8
7.0
16
168.8
27.0
5.3
51.4
15.3
17
177.3
44.8
5.2
46.7
11.5
18
149.9
58.1
4.6
43.4
11.7
19
150.7
48.4
4.6
43.0
14.8
20
153.7
84.7
3.8
35.8
N/A
21
150.7
66.8
3.3
35.8
N/A
22
151.6
40.6
4.3
40.8
N/A
The above samples have similar physical properties to those of fibers spun with pigments (solution dyed) in the same polypropylene resin, however the luster of the colors is significantly different. It is also important to note that the polymeric colorants are generally non-nucleating and will, under the same processing conditions have similar physical properties while the pigments (specifically the blue pigment—Sample 20) generally are nucleating which often requires the fiber spinning equipment to be operated under different conditions to obtain similar physical properties—note the higher elongation of sample 20 in comparison to samples 21 and 22.
EXAMPLE 2
Polymeric Colorant Fibers with TiO 2 and Pigments
A series of polypropylene samples was produced under the standard fiber spinning conditions described in Example 1 to test the ability to combine both solid pigments and liquid polymeric colorants in the same fibers. The drawing conditions for these example yarns are detailed in the following table.
TABLE #3
Procedural Conditions
Spinning Conditions
Roll Speed
Roll Temperature
(m/min)
° C.
Feed Roll
800
Not heated
Draw Roll 1
805
55
Draw Roll 2
1450
75
Draw Roll 3 (A + B)
2000
120
Relax Roll
1980
Not heated
Using the standard fiber spinning conditions as described above, a series of 10 experiments were performed to produce samples with liquid polymeric colorants labeled by Milliken & Company Product numbers, and TiO 2 which is commonly used in the production of thermoplastic fibers to produce dull (9% TiO 2 ) and semi-dull (3% TiO 2 ) appearance. The fibers were successfully produced at all of the conditions tested and the list of colorants, TiO 2 levels and fiber properties are detailed in the Table below using polymeric liquid colorant mixtures available from Milliken & Company under the tradename CLEARTINT®.
TABLE #2
Fiber Properties
Polymeric
Polymeric
Color
5%
Color
Concentrate
TiO 2
Secant
Sample
(Color/
Level
Level
Denier
Elongation
Tenacity
Modulus
ID
Number)
(%)
(%)
(g/9000 m)
(%)
(g/den)
(g/den)
T1
Blue 9805
20
N/A
166
50.60
4.626
32.49
T2
Blue 9805
20
9
152
57.20
5.345
37.40
T3
Blue 5603
10
N/A
153
53.44
5.872
42.94
T4
Blue 5603
5
3
157.92
47.75
5.053
39.01
T5
Smoke 9809
10
N/A
161
31.56
4.323
37.81
T6
Smoke 9809
10
3
158
39.79
4.824
37.56
T7
Amber 9808
20
N/A
164
51.38
4.898
36.89
T8
Amber 9808
20
3
161
57.77
4.83
34.70
T9
Green 5062
10
N/A
158
51.81
5.225
40.38
T10
Green 5062
5
3
153
54.55
5.42
40.50
In addition to experiments with TiO 2 a series of experiments were conducted to determine the viability of spinning polypropylene fibers with the liquid polymeric colorants and standard fiber pigments. A series of 8 experiments, listed in the table below, were produced under the standard spinning conditions described above. The pigments, obtained from Standridge Color Concentrate, Social Circle, Ga., are commercially available and are typical of the pigments used within the polypropylene fiber industry. Specifically, the green pigment is identified as SCC 3654, the red pigment is SCC 4591 and the black pigment is SCC 23005. The polymeric colorants in these example experiments are identified as PP Green 5720, PP Red 5718, and PP Smoke 5719 for the green, red and black liquid polymeric colorant respectively (all available under the tradename CLEARTINT® from Milliken & Company).
TABLE #2
Fiber Additives
Polymer
Colorant
Pigment
TiO2
Sample
Level
Level
Level
ID
Color
(%)
(%)
(%)
P1
Green
1.8
0
0
P2
Green
1.5
1.5
0
P3
Green
0
1.5
0
P4
Red
0
1.5
9
P5
Red
2
1.5
9
P6
Black
0
1.5
0
P7
Black
2
0
0
P8
Black
2
1.5
0
EXAMPLE 3
Polymeric Colorant Fibers with Nucleators
A series of experiments were conducted using commercially available nucleators in combination with the liquid polymeric colorants (from the COLORANT TABLE, above) to produce continuous filament fibers. Using the same conditions as described in Example 1 above, 13 samples were produced using a commercially available polypropylene nucleator, Millad 3940 (MDBS). Fiber compositions for the 13 experimental samples are found in Fiber Additives Table #3 below and the physical properties of the final fibers are found in Fiber Properties Table #4.
TABLE #3
Fiber Additives
Nucleated Fiber Conditions
Addi-
tive
Color
Heat
Sample
Addi-
Level
Level
Set
Draw
ID
Polymer
tive
(ppm)
Color
%
(C)
Ratio
A
Amoco
M3940
2750
10%
0.5
125
4.0
7550
Colorant #3
B
Amoco
M3940
2750
10%
0.5
125
5.1
7550
Colorant #3
C
Amoco
M3940
2750
10%
0.5
125
3.4
7550
Colorant #3
D
Amoco
M3940
2750
10%
0.5
125
3.4
7550
Colorant #5
E
Amoco
M3940
2750
10%
0.5
125
4.0
7550
Colorant #2
F
Amoco
M3940
2750
10%
0.5
125
3.4
7550
Colorant #2
G
Amoco
M3940
2750
10%
0.5
125
5.1
7550
Colorant #2
H
Amoco
M3940
2750
10%
0.5
125
5.1
7550
Colorant #4
I
Amoco
M3940
2750
10%
0.5
125
4.0
7550
Colorant #4
J
Amoco
M3940
2750
10%
0.5
125
3.4
7550
Colorant #4
K
Amoco
M3940
2750
10%
0.5
125
5.1
7550
Colorant #1
L
Amoco
M3940
2750
10%
0.5
125
4.0
7550
Colorant #1
M
Amoco
M3940
2750
10%
0.5
125
3.4
7550
Colorant #1
TABLE #4 Fiber Properties Colored and Nucleated Fibers 130C Sample Denier Elongation Tenacity 3% Modulus Shrinkage ID (g/9000 m) (%) (g/den) (g/den) (%) A 129 65.996 4.805 46.823 8.524 B 152.5 41.467 5.555 56.61 9.64 C 154.5 93.919 3.939 36.697 6.595 D 151.1 73.769 3.825 39.584 6.973 E 131 30.29 4.474 46.237 8.678 F 155.4 40.265 3.446 36.636 5.995 G 160.4 28.747 5.044 52.14 8.136 H 153.8 23.227 5.208 52.764 8.893 I 134 23.895 3.94 39.574 8.79 J 151.3 50.934 3.06 32.392 7.019 K 163.4 20.941 5.218 54.94 9.255 L 132.1 37.146 4.768 50.275 8.849 M 159.7 72.707 3.309 34.248 6.976
Additionally using other commercially available nucleator compounds a series of yarns were produced using a Basell 35MFI fiber grade resin, Grade PDC-1302, using the green liquid colorant (PP Green 5720). In each case 1.2% of the green liquid colorant were combined with 2500 ppm of Millad 3940 (MDBS), Millad 3988 (DMDBS), HPN-68 and NA-21.
EXAMPLE 4
Polymeric Colorant Fibers with UV Absorbers
To test the spinnablity of polypropylene fibers with both the liquid polymeric colorants and a range of UV stablizers, 10 samples using a 10% concentrate of Yellow 485 polymeric colorant and various UV stabilizers were generated. The 10 samples were spun under standard sampling conditions as described in Example 2 above. The table below details the combinations and amounts of UV stabilizers with two different concentrations of the yellow colorant from the COLORANT TABLE, above.
TABLE #4
Fiber Additives
Colorant
UV
UV Stabilizer
Sample
Concentration
Stabilizer
Concentration
ID
(%)
(name)
(ppm)
Y1
2
Tinuvin 783
1000
Y2
1
N/A
N/A
Y3
1
Tinuvin 783
1000
Y4
1
Tinuvin 783
2000
Y5
1
Tinuvin 783
500
Y6
1
Tinuvin 783
10000
Y7
1
Tinuvin 783
15000
Y8
1
Tinuvin 622
10000
Y9
1
Chimassorb 844
10000
Y10
2
Tinuvin 783
10000
EXAMPLE 5
Textured Polymeric Colorant Fibers
Yarns containing 1% of the polymeric colorants PP Orange 9802 and PP Violet 9804 were air jet textured. The starting yarns were 150 denier, 72 filament yarns with standard physical properties produced in the same manner as those fibers described in Example #1 above. Two orange yarns were air jet textured with one violet yarn to produce a collaged air jet textured yarn.
EXAMPLE 6
Polymeric Colorant Fibers from Liquid Colorant Injection
For two colors, a second set of yarns was produced by directly injecting the liquid colorant into the feed throat of the extruder of the fiber spinning equipment. Basell PDC-1302, a 35 MFI HPP, was fed into the extruder at an extrusion temperature of 200° C. The polymeric colors were then injected directly into the hopper of the extrusion line using a peristaltic pump (Maguire, Model PA-6-18). In each case the pump was set to the lowest possible setting, due to size of the extrusion line and the throughput of the melt pump. The two colorants used were 10% concentrates of the violet and red colorants from the COLORANT TABLE, above. All yarns were produced under the spinning conditions described in Table 5 below.
TABLE #5 Procedural Conditions Roll Speed Roll Temperature (m/min) ° C. Feed Roll % 500 Not Heated Draw Roll 1 505 55 Draw Roll 2 1000 75 Draw Roll 3 (A + B) 1250 120 Relax Roll 1240 Not Heated
At these conditions, yarns of different deniers were produced by adjusting the melt pump speed.
EXAMPLE 7
Polymeric Colorant Monofilament
Polymeric colorant concentrates were let down into two PP resins: the first with an MFI of 12-18 g/10 min (Exxon 1154) and the second with an MFI of 4 g/10 min (Exxon 2252) at a level of 10% to give 1% colorant in the final polymer fiber. This mixture, consisting of PP resin and the polymeric colorant additive, was extruded using a single screw extruder through monofilament spinnerets with 60 holes. The PP melt throughput was adjusted to give a final monofilament denier of approximately 520 g/9000 m. The molten strands of filament were quenched in room temperature water (about 25° C.), and then transferred by rollers to a battery of airs knives, which dried the filaments. The filaments, having been dried, were run across the first of four sets of large rolls, all rotating at a speed of between 49 and 126 ft/min (dependent on draw ratio), before entering an oven approximately 14 ft long set to a temperature of 360° F. After leaving the first oven, the filaments were transferred to the second set of large rollers running at a speed of 524 ft/min (dependent on draw ratio) and then into second oven, set at a temperature of 360° F. The final two sets of rolls were both set at 630 ft/min and the oven between them was set at a temperature of 300° F. The individual monofilament fibers were then traversed to winders where they were individually wound. These final fibers are thus referred to as the PP monofilaments. Several monofilament fibers were made in this manner with the following PP Red 9803, PP Violet 9804, PP Blue 9805, and PP Green 9807.
EXAMPLE 8
Melt Blown Non-Woven with Polymeric Colorants
A colored melt blown non-woven fabric was produced using a Nordson Fiber systems pilot melt blown system. The equipment consisted of a ¾ single screw extruder (24:1) L:D ratio manufactured by J/M Laboratories—Model DTMB. The airflow was set to 30 scfm with a max temperature of 625F. The orange colorant from the COLORANT TABLE, above, in a 10% concentrate, was let down into Basell 35 MFI fiber grade resin to give a final color loading of 1% in the melt blown fabric.
EXAMPLE 9
Polyester Polymeric Colorant Fibers from Liquid Color Injection
A set of experiments similar to Example #6 was conducted using a low IV (0.62) PET resin. Two liquid polymeric colorants, PET Yellow 236 and PET Orange 226, available from Milliken & Company, were used to produce yarn samples. Free fall fiber was collected from the spinneret, which had the similar vibrant color as seen with the polypropylene fibers of Example 6.
EXAMPLE 10
BCF Fibers Including Liquid Polymeric Colorants
Cyan 9806 (from Milliken & Company) polymeric colorant was used to produce a colored bulk continuous filament (BCF) textured PP yarn. A three ply BCF 300 denier 72 filament yarn was produced using standard BCF equipment. Additionally using the liquid polymeric PP Orange 9802 colorant a single ply BCF 250 denier 72 filament textured yarn was also produced using standard BCF equipment. The colorant was added to the extrusion line using a 10% concentrate to give a final color level of 1% in the yarns.
Knitted structures (socks) of the above Examples (except for Example #8 which was already made into a non-woven fabric) were then produced.
There are, of course, many alternative embodiments and modifications of the present invention which are intended to be included within the spirit and scope of the following claims. | Improvements in permitting brighter colorations within polypropylene fibers and/or yarns while simultaneously providing more efficient production methods of manufacturing of such colored fibers as well are provided. Generally, such fibers and/or yarns have been colored with pigments, which exhibit dulled results, or dyes, which exhibit high degrees of extraction and low levels of lightfastness. Such dull appearances, high extraction levels, and less than stellar lightfastness properties negatively impact the provision of such desirable colored polypropylene fibers and/or yarns which, in turn, prevents the widespread utilization of such fibers and yarns in various end-use applications. Thus, it has surprisingly been determined that brighter colorations, excellent extraction, and more-than-acceptable lightfastness characteristics can be provided, preferably, through manufacture with certain polymeric colorants that include poly(oxyalkylene) groups thereon. Fabric articles comprising such novel fibers and/or yarns are also encompassed within this invention. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of PCT/EP2007/058097, filed on Aug. 3, 2007, which claims priority to DE 10 2006 036255.1, filed Aug. 3, 2006, the entire contents of which are hereby incorporated in total by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a holographic reconstruction system for the reconstruction of scenes, said holographic reconstruction system having an enlarged visibility region and illuminating two-dimensionally encoded light modulator cells of spatial light modulator means with coherent light.
FIELD OF THE INVENTION
The invention can be applied to a holographic reconstruction system, for example of the type of a holographic projection device as disclosed by the applicant in the international publication WO 2006/119760, titled “PROJECTION DEVICE AND METHOD FOR HOLOGRAPHIC RECONSTRUCTION OF SCENES”.
The projection device preferably comprises in addition to a light modulator with a modulator surface of a cell matrix, light modulator cells and an illumination device for emitting coherent light, an imaging system with a first and a second imaging means. The first imaging means images the light modulator in an enlarged manner onto the second imaging means. The second imaging means images the spatial frequency spectrum, the Fourier spectrum of the light modulator, into a visibility region. The visibility region is thus the image of the used diffraction order in the Fourier plane of the video hologram. In order for the first imaging means to be able to image the entire light modulator onto the second imaging means, all contributions of a desired diffraction order must be covered by the first imaging means. This is achieved by focussing the modulated light on the first imaging means in which the spatial frequency spectrum is created. For this, the light modulator is illuminated by a wave which converges in the direction of light propagation. The first imaging means thus lies in the spatial frequency spectrum of the video hologram. Together with the observer window, the second imaging means defines a reconstruction volume. A scene is reconstructed in this reconstruction volume. The reconstruction volume also continues backwards to any extent beyond the second imaging means. The observer is thus able to see the reconstructed scene in the reconstruction volume through the observer window.
Light which is capable of generating interference typically illuminates two-dimensional spatial light modulator means in order to present video holograms.
A method for the holographic reconstruction with an enlarged visibility region is described in document Mishina T., Okui M., Okana F.: “Viewing zone enlargement method for sampled hologram that uses high-order diffraction”, Applied Optics, Vol. 4, No. 8, p. 1489-1499. A light source illuminates a light modulator in which a hologram is encoded. A lens creates a Fourier plane of the hologram, and a spatial frequency filter in the form of an aperture mask filters out diffraction orders from the Fourier plane. The aperture mask has an aperture pattern, which can be controlled temporally and spatially, and through which multiple diffraction orders of the Fourier transform of the hologram can be transmitted sequentially and be strung together such that the reproduced image—the reconstructed three-dimensional object—can be seen by the observer in an enlarged visibility region.
A problem is that for enlarging the visibility region the multiple diffraction orders having different intensities are filtered and joined sequentially. For this, the filter requires controllable openings in the Fourier plane of the hologram. Because the intensity of the diffraction orders in the visibility region differs, the intensity of the illuminating light must be controlled sequentially as well. Further, extensive software means are required, e.g. for switching and controlling the apertures. The sequential representation of the hologram and the filtering process must be performed at sufficient speed, so to prevent the reconstructed image from flickering.
SUMMARY OF THE INVENTION
The present invention is based on a holographic reconstruction system for the reconstruction of scenes, where optical focussing means track a light wave front modulated by a video hologram to at least one eye position of an observer eye in a visibility region. Light which is capable of generating interference illuminates a two-dimensionally encoded modulator cell matrix of spatial light modulator means and thus modulates the light wave front. The modulator cells of the modulator cell matrix are arranged in modulator cell rows and modulator cell columns. Because it is irrelevant to the functionality of the present invention whether encoding means encode the modulator cell matrix structured in modulator cell rows or in modulator cell columns, the term ‘cell rows’ will be used for the arrangement of the encoded cell structure.
When the modulated wave front propagates on to the eye position, the optical focussing means perform an optical Fourier transformation of the modulated wave front in its focal plane, such that a Fourier transform of the modulated light wave front is created in the Fourier plane.
It is the object of the present invention to provide technical means which enlarge the visibility region optically in an inexpensive manner. When modulating the light wave front, which reconstructs a three-dimensional scene, the effective number of cells in one dimension shall in particular be multiplied in comparison to the respective number of cells in that dimension of the modulator matrix.
This is achieved in the holographic reconstruction system according to this invention by using a specific method of encoding the spatial light modulator means for modulating the light front which is capable of generating interference in conjunction with a spatial division of the light wave front, deflection and spatial filtering of the divided light wave front.
According to this invention, hologram computation means associate the information of the total light wave front which is required for the holographic reconstruction to multiple wave front strips, and compute for each video hologram of the video sequence strip holograms which comprise multiple hologram segments.
The hologram computation means are connected to encoding means which encode the spatial light modulator means using a combination of both time division multiplexing and spatial division multiplexing modes. The encoding means encode the spatial light modulator means with the content of a strip hologram in the time division multiplex mode and with its hologram segments in the spatial division multiplex mode. All hologram segments of each strip hologram together have such a number of hologram pixels that the strip holograms are disposed side by side in cell rows on the modulator cell matrix as spatial division multiplex structure of the corresponding hologram segments.
As a result of the illumination of the modulator cell matrix with a light wave front which is capable of generating interference, the modulator cell matrix modulates partial light waves propagating parallel which comprise the information of a hologram segment and which are assigned to a strip hologram.
To solve the object of the present invention, the following elements are disposed in the light path of the light wave front, in addition to the modulator cell matrix and the focussing means:
First optical deflection means which deflect the partial light waves propagating parallel of the modulated wave front in different directions such that their Fourier transforms appear in a step-like manner in the focal plane, A spatial frequency filter which lies in a focal plane of the focussing means and which lets pass the same diffraction order of all modulated partial light waves, Second optical deflection means which string together the passing diffraction orders of the partial light waves so to form a wave front strip, A time division multiplex control system, which works in synchronism with the time division multiplex mode of the hologram computation means, and which discretely adjusts adjustable third optical deflection means such that these deflection means dispose the wave front strips side by side, such that the modulated wave front appears and all wave front strips holographically reconstruct the desired scene in the time division multiplex mode.
In other words, all hologram segments which are encoded during a signal frame of the video signal belong to one strip hologram and modulate partial light waves, propagating parallel, of a wave front strip with the hologram segments. The modulator cell matrix modulates the remaining strip holograms by way of time division multiplexing, such that the strip holograms holographically reconstruct the scene by way of time division multiplexing.
It is a known disadvantage that the cell structure of the modulator cell matrix modulates in addition to a desired diffraction order parasitic diffraction orders, for which a Fourier transformation is performed by the optical focussing means. The Fourier transformation causes a spatial frequency spectrum to be generated in the focal plane of the focussing means for each partial light wave.
In order to optically enlarge the visibility region according to the object of this invention, first optical deflection means laterally deflect the partial light waves of a strip hologram in one dimension such that the partial light waves appear in a step-like offset manner in the focal plane of the optical focussing means. These deflection means have static angle settings. This has the advantage that a simple spatial frequency filter with a step-like structure of fix apertures can be used in order to separate with high efficiency the same respective diffraction order, which is desired for reconstructing, of each modulated partial light wave from the disturbing parasitic diffraction orders.
Second optical deflection means string together the passing diffraction orders of all modulated partial light waves such that a modulated light wave strip is generated, which is made up of the joined partial light waves. The second optical deflection means thus compensate the optical deflection of the partial light waves which are organised in a spatial division multiplex process in order to make up for the spatial multiplexing.
As a result of the lateral deflection in one dimension, this modulated light wave strip exhibits a hologram pixel resolution which is a multiple of the number of the hologram segments. A multiplication of the diffraction angle of the modulator cell matrix is thus achieved in one dimension of the modulator cell matrix, which corresponds to an enlargement of the visibility region according to the object of the present invention.
The first optical deflection means can be a prism array which is disposed in the optical path of the wave front and which displaces the modulated partial light waves in one dimension, i.e. horizontally or vertically against one other, such that the modulated partial light waves are disposed side by side in the focal plane of the focussing means in a step-like manner and offset by one diffraction order.
The encoding means preferably assign each hologram segment on the cell structure of the modulator cell matrix with multiple adjacent horizontal modulator cell rows, such that only few, for example three, hologram segments lie on the modulator cell matrix. According to the number of hologram segments, the first optical deflection means comprise multiple, for example three, prisms which stretch entirely across the modulator cell matrix in one dimension. The longitudinal sides of the prisms adjoin to one another, and the prisms exhibit different inclinations. The inclinations are chosen such that the same diffraction orders of the adjacent partial light waves are adjoined in the focal plane after the deflection such that a seamless connection of the step-like offset same diffraction orders is achieved. This can be achieved if the maximum diffraction angle of the light modulator means in the direction of deflection defines the inclinations of the prisms.
According to a preferred embodiment of this invention, the first optical deflection means can be a prism array with micro prisms, where each matrix section is assigned with a multitude of micro prisms, which direct the partial light waves in a step-like manner according to the structure of the spatial frequency filter. This facilitates a more light-weight design of the projection system and reduces the volume of the hologram projector.
The spatial frequency filter may preferably be an aperture mask with apertures each of which letting pass a single diffraction order of the modulated partial light wave. However, a different mask with transparent and light-impermeable areas, for example a photographic film copy or the like, can be used instead of an aperture mask. This mask then comprises step-like offset transparent areas which correspond to the form and position of the same diffraction orders in the plane where the spatial frequency filter is disposed.
The second optical deflection means is also a prism array. The prisms lie in the optical path in order to string together the modulated, filtered and step-like offset partial light waves in one dimension so to form one light wave strip.
The second optical deflection means are preferably also micro prisms, a multitude of which being assigned to each matrix section. These micro prisms can also be adjusted as regards their angular range and be connected to a position controller which is adjusted by an eye finder such that the light wave strips with their partial light waves are directed according to an eye position. This way, if the adjustable optical deflection means are enlarged, the modulated partial light waves can be tracked at least in one dimension according to the changes of eye positions.
In order to save room inside the device, the second optical deflection means can be disposed directly on the spatial frequency filter.
The discretely adjustable third optical deflection means are well known from beam-projection display devices. Such a device has movable mirrors or rotating polygonal mirrors for reproducing an image on a display surface, and deflects the light for example row by row. The international publication WO 2006053793, titled “BEAM-PROJECTION DISPLAY DEVICE AND METHOD FOR OPERATING A BEAM-PROJECTION DISPLAY DEVICE” may be referred to as an example. The third optical deflection means can also be controllable micro prisms.
It appears to a person skilled in the art, that it is not relevant for the practical embodiment of this invention whether the modulator cells of each cell row are disposed horizontally or vertically.
Considering this, the visibility region can for example be broadened in the spatial division multiplex mode by horizontally stringing together multiple hologram segments, i.e. by increasing the horizontal resolution. In this context, the hologram computation means can compute a larger number of strip holograms for each video hologram in order to increase with the help of the encoding means the vertical resolution in the time division multiplex mode.
If the holographic reconstruction system exhibits such a structure, micro prisms in the second deflection means which are adjustable as regards their angular range and which are connected to a position controller, can direct the generated modulated light wave strips in accordance with horizontal changes of the eye position.
According to a preferred embodiment of the present invention, the focussing means exhibit horizontally and vertically different focal planes such that both a Fourier plane and an image plane can be created in the same plane. A focal plane is therein disposed as close as possible to the spatial frequency filter, such that a Fourier transform of the partial light waves appears on the spatial frequency filter in the direction of deflection of the first deflection means. The second focal plane lies such that the focussing means vertically project the illuminated modulator cell matrix on to the second deflection means.
In the present case, the focussing means realise in the horizontal direction a Fourier transformation of the modulated wave front near the spatial frequency filter, and in the vertical direction an imaging of the light modulator means near the second deflection means.
In a specific embodiment, the focussing means have a focal length f x in one direction and are disposed at that distance f x after the light modulator means, such that the Fourier transform of the partial light waves is generated on the spatial frequency filter at that distance f x after the focussing means, such that the diffraction orders of the modulated partial waves, which are emitted by the light modulator means at different angles, appear spatially separated on the spatial frequency filter.
The focussing means have for example a vertical focal length f y , where f y =f x /2 and where the distances between the light modulator means and focussing means, and between the focussing means and the spatial frequency filter plane are 2f y . An image of the hologram segments on the modulator cell matrix then is generated in the spatial frequency filter plane.
SHORT DESCRIPTION OF FIGURES
The present invention will be described in more detail below with the help of a number of embodiments and drawings, wherein
FIG. 1 is a perspective view of a part of the holographic reconstruction system according to the present invention,
FIG. 2 is a schematic view of a modulator cell matrix of spatial light modulator means,
FIG. 3 shows an example of a deflection means in the form of a prism array in a projection system according to the present invention,
FIG. 4 is an example of the step-like offset of the modulated partial light waves with the help of the prism array according to FIG. 3 ,
FIG. 5 is a schematic view illustrating the function of the focussing means, where
FIG. 5 a is a top view of the modulated and Fourier-transformed wave front and
FIG. 5 b is a side view of the wave front which images the video hologram in the vertical direction into a plane,
FIG. 6 illustrates the structure of the spatial frequency filter,
FIG. 7 is a schematic view showing a side view of the optical path of a device according to the present invention,
FIG. 8 is a top view of the device according to this invention with a one-dimensional diffuser,
FIG. 9 is a side view of one embodiment of the device according to this invention according to FIG. 7 with an adjustable third optical deflection means in the form of a rotating mirror having a rotation axis,
FIG. 10 shows the graph of the desired diffraction orders for the modulated partial light waves, and
FIG. 11 illustrates a deflection pattern generated when rotating the rotating mirror, with the modulated partial light waves which are deflected in vertical steps being arranged next to each other in rows.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a detail of a holographic reconstruction system 1 for the holographic reconstruction of scenes with a light modulator 2 on which a sequence of video holograms is encoded. Light which is capable of generating interference (not shown) illuminates the modulator cell matrix 4 of a spatial light modulator 2 with m modulator cell rows at n modulator cells each, focussing means, here in the form of a lens 7 , and a spatial frequency filter 8 .
According to the present invention, a first optical deflection means, here in the form of a prism array 11 , is disposed between the light modulator 2 and the lens 7 . Hologram computation means 3 compute for each video hologram strip holograms S 1 . . . S 3 with hologram segments H 11 . . . H 33 . An encoding device (not shown) encodes one after another the modulator cell matrix 4 with hologram segments of the strip holograms S 1 . . . S 3 . FIG. 1 thus shows different sequentially encoded modulator cell matrices 4 , 4 ′ and 4 ″ in assigned cell regions 12 , 13 , 14 with the hologram segments H 11 . . . H 33 , the horizontally deflecting static prism array 11 , focussing means in the form of a lens 7 and a spatial frequency filter in the form of an aperture mask 8 with attached second optical deflection means, the vertically deflecting prisms 51 , 52 and 53 . The prism array 11 realises a horizontal, step-like displacement 9 of the partial light waves which are modulated by the cell regions 12 , 13 , 14 . The aperture mask 8 has step-like offset openings 15 , 16 , 17 which are disposed below the prisms 51 , 52 , 53 and which filter only one chosen diffraction order out of the Fourier transform of the partial light waves of the hologram segments. The prisms 51 , 52 and 53 vertically deflect the filtered partial light waves such that the latter hit a third deflection device 54 , which can be pivoted around a horizontal axis, such that the hologram segments of each strip hologram S 1 , S 2 or S 3 appear one after another as light wave strips. The deflection device 54 is synchronised by a time division multiplex controller 55 with the time multiplex mode of the hologram computation means, such that an entirely modulated light wave front with the structure and modulation of all strip holograms S 1 . . . S 3 is made available for a holographic reconstruction through an exit pupil 56 .
FIG. 2 shows the modulator cell matrix 4 of the light modulator 2 , which exhibits n modulator cells 6 and m cell columns 5 in a cell row, where, in the present case, three cell columns 5 form one cell row 12 , 13 , 14 .
As shown in FIG. 3 , the prism array 11 comprises three prisms 21 , 22 , 23 , which are disposed side by side vertically, and which exhibit different inclinations 24 , 25 , 26 with different inclination angles −α, 0°, +α, said inclinations 24 , 25 , 26 being chosen such that the corresponding diffraction angle ranges Θ x1 , Θ x2 , Θ x3 of adjacent prisms 21 , 22 , 23 are adjoined such that horizontally a seamless connection of the step-like offset 9 of the modulator rows 12 , 13 , 14 can be achieved, as shown in FIG. 4 .
The maximum number of the adjoined diffraction angle ranges corresponds to the number m of the cell rows 5 into which the light modulator 2 is structured during the encoding process. However, the prism array 11 would comprise very many very narrow prisms, and the subsequently disposed movable deflection means would have to position very finely. The narrow prisms would be prone to great diffraction effects. It is therefore sensible not to adjoin the maximum number of angular ranges that corresponds with the number m of cell rows 5 .
In FIG. 1 , for example, only three prisms 21 , 22 , 23 are thus used, i.e. each prism 21 , 22 and 23 is assigned with one third of the cell rows 5 , where that third may then be a modulator row 12 or, as will be explained below, may comprise a hologram.
The maximum horizontal diffraction angle of the light modulator 2 defines the diffraction angle ranges Θ x1 , Θ x2 , Θ x3 of the prisms 21 , 22 , 23 .
As shown in FIG. 3 , the light modulator 2 with a cell pitch of 10 μm exhibits a maximum diffraction angle Θ x of 3.6° at a wavelength λ of 633 nm. The value of 3.6° also represents the angular range of a diffraction order. In order to also select the corresponding diffraction order of an adjacent partial light wave, the adjacent prism 24 or 26 must deflect the light by +3.6° or −3.6°, respectively.
FIG. 3 shows the prism 21 with an incident partial light wave 27 and the modulated partial light wave 33 which is deflected by the angle δ. The prism angle is the angle α of the inclination 24 . A partial light wave 27 which enters the lower face of the prism 21 is deflected by the angle α when it exits the upper face. The relation between α and δ is given as δ=arcsin (n*sinα)−α(I), where n is the refractive index of the prism 21 . For small angles α, the linear approximation δ≈(n−1)*α can be derived from equation (I).
Given a refractive index n of 1.5, a prism angle α of 7.2° is thus required in order to deflect an incident partial wave 27 by 3.6°. Because according to the linear approximation the deflection angle δ does not depend on the angle of incidence on the lower face of the prism, the angular range of one diffraction order is deflected by 3.6°. If the central prism 22 has a prism angle of 0°, according to the above-mentioned linear approximation, the adjacent prisms 21 and 23 must have prism angles of +7.2° and −7.2°, respectively, and the next but one prism must have prism angles of +14.4° and −14.4°, respectively.
In contrast to FIG. 1 , where the prism array 11 is disposed behind the light modulator 2 , it is also possible to dispose the prism array 11 in front of the light modulator 2 .
The combined arrangement of light modulator 2 and prism array 11 can also be considered as a single-row light modulator with n*m cells, where one row comprises n*k cells. The prism array 11 is therein used for spatial division multiplexing, i.e. the hologram segments H 11 , H 12 , H 13 , which correspond to the adjoined angular ranges Θ x1 , Θ x2 , Θ x3 , are encoded simultaneously, but spatially separated on the light modulator 2 .
The maximum diffraction angle Θ x of the light modulator 2 is λ/p, where p is the cell pitch of the light modulator 2 and λ is the wavelength of the incident light. The maximum diffraction angle Θ x also limits a diffraction order. In one diffraction order, the diffraction pattern can be controlled by encoding the light modulator 2 . The diffraction pattern is repeated in higher diffraction orders. The higher diffraction orders adjoin the angular range Θ x of the zeroth diffraction order on both sides.
The spatial frequency filter according to this invention prevents parasitic diffraction orders from entering the used diffraction orders of the partial light waves of the prisms 21 , 22 and 23 . This is important because a parasitic diffraction order is only a periodic continuation of the used diffraction order, and parasitic diffraction orders which enter the visibility region would substantially disturb the holographic reconstruction. This is why the spatial frequency filter may only let pass the used diffraction order of the partial wave front, which is divided by each prism 21 , 22 , 23 .
One possibility for this is shown in FIG. 5 with FIG. 5 a and FIG. 5 b in combination with FIG. 6 . The focussing means which lie in the optical path, and which are illustrated as lens 7 here, exhibit vertically and horizontally different focal planes. It is thus achieved that both a Fourier transform of the video hologram and an imaging of the light modulator are disposed in the same plane 28 . This means that the Fourier plane is identical to the image plane.
FIG. 5 a is a side view. The lens 7 (L x ) is disposed behind the illuminated light modulator 2 . That lens has the focal length f x in the horizontal direction and is disposed behind the light modulator 2 at that distance f x . A Fourier transform of the modulated light wave front is generated in the horizontal direction in the filter plane 28 at the distance f x behind the lens 7 . The diffraction orders which, starting from the light modulator 2 , run at different angles are spatially separated in the filter plane 28 as a result of the Fourier transformation.
FIG. 5 b is a side view. The lens 7 has the vertical focal length f y , where f y =f x /2. The distance of 2f y both between the light modulator 2 and the lens 7 , and between the lens 7 and the filter plane 28 , causes the holograms segments on the light modulator to be projected vertically into the filter plane 28 .
Because the filter plane 28 is a Fourier plane horizontally and an image plane vertically, the spatial frequency filter 8 is disposed in the filter plane 28 in the present invention. This is shown in FIG. 6 . The numbers entered on the spatial frequency filter 8 describe the diffraction orders of the Fourier transforms. In the Figure, the central section 30 of the spatial frequency filter 8 comprises the −1 st , 0 th and 1 st diffraction order of a prism 22 . In the upper segment 31 , the diffraction orders of the adjacent prism 21 are displaced to the left by one diffraction order, because the angle of the prism 21 is chosen such that there is a deflection by one diffraction order. The same applies to the lower section 32 , which corresponds to the prism 23 , but with an offset by one diffraction order to the right. Because the vertical and horizontal focal lengths of the lens 7 differ, a Fourier transform of the light wave front lies in the filter plane 28 and the diffraction orders are spatially separated while the lens 7 images the encoded light modulator 2 vertically.
The spatial frequency filter 8 exhibits openings 15 , 16 , 17 , which only let pass the selected diffraction order of each hologram segment 12 , 13 , 14 . This results in a structure of step-like offset rectangular apertures 15 , 16 , 17 , and the selected diffraction orders of the hologram segments are adjoined while the spatial frequency filter 8 absorbs all undesired diffraction orders. This prevents mutual interference of the various diffraction orders. The horizontally adjoined selected diffraction orders multiply the diffraction angle of a light modulator 2 .
FIG. 6 illustrates a step-like offset of the adjoined angular ranges Θ x1 , Θ x2 , Θ x3 . Whether or not the offset 9 must be compensated in the vertical direction, and how this is done, depends on the subsequent optical arrangement or a subsequent optical system, according to the intended use of the device. The light filtered in the filter plane 28 can be directed into a subsequent optical arrangement, as shown in FIGS. 7 , 8 and 9 , e.g. for a holographic illumination device or for a holographic projection system.
FIG. 7 is a side view of the device 1 according to this invention for adjoining diffraction orders of an encoded light modulator 2 for use in a subsequent arrangement 34 . The compensation of the step-like offset 9 with a deflection device 40 in the form of a one-dimensional diffuser is shown in FIG. 8 . In the embodiment, the prism array 11 , which comprises the three prisms 21 , 22 , 23 , is disposed behind the light modulator 2 . The drawn bundles of rays 18 , 19 , 20 represent the selected diffraction orders of the prism 21 , prism 22 and prism 23 . The used diffraction orders of the partial light waves are offset as regards their angles Θ x1 , Θ x2 , Θ x3 , and are thus spatially separated in the filter plane 28 behind the lens 7 . A lens 38 horizontally images the filter plane 28 into an exit plane 39 . This is why the diffraction orders, which are spatially separated in the filter plane 28 , are spatially separated there again. The prisms 21 , 22 , 23 of the prism array 11 horizontally direct the modulated bundles of rays 18 , 19 , 20 into different adjacent angular ranges Θ x1 , Θ x2 , Θ x3 . The diffraction angle range Θ x =Θ x1 +Θ x2 +Θ x3 of the light modulator 2 is thus enlarged in the horizontal direction.
FIG. 8 is the corresponding side view. The prism array 11 , which vertically deflects the light waves, is disposed behind the light modulator 2 . The lens 7 images the prisms 21 , 22 , 23 into the filter plane 28 , where the spatial frequency filter 8 is disposed. The lens 38 vertically realises a Fourier transformation into the exit plane 39 , where the Fourier transforms of the partial light waves lie. However, the modulated light of the hologram segments runs into different angular ranges Θ y1 , Θ y2 , Θ y3 .
Because in the horizontal direction the light is radiated into different angular ranges Θ x1 , Θ x2 , Θ x3 , only an offset total angular range (Θ x , Θ y ) as shown in FIG. 10 can be covered. The individual angular ranges 43 , 44 , 45 with Θ x1 , Θ y1 ; Θ x2 , Θ y2 ; Θ x3 , Θ y3 are adjoined in a step-like offset manner. As shown in FIG. 8 , a one-dimensional diffuser 40 which acts in the vertical direction diffuses the light in the arrangement 34 , and so a continuous angular coverage is achieved over a total angular range Θ y of at least Θ y1 +Θ y2 +Θ y3 .
If the encoded information of the light modulator 2 is constant in the vertical direction, the vertical diffuser 40 will be sufficient for compensating the offset 9 , where, however, any vertical information will be lost. This is why only a horizontal diffraction pattern with horizontal structure can be used, such as a sequence of parallel lines in the vertical direction. Such a projection device can serve in a holographic reconstruction device to realise a backlight with virtual light sources. In this case, the light modulator 2 is encoded with a computer-generated hologram which reconstructs light points or light lines which serve to illuminate a second light modulator on which the video hologram is encoded.
However, if the projection system is provided primary for generating a holographic reconstruction, a one-dimensionally deflecting rotating mirror 41 will be required instead of the one-dimensional diffuser 40 , as shown in FIG. 9 . The rotating mirror 41 deflects the light of the light modulator 2 in the vertical direction. The arrangement 35 is more flexible than that with the one-dimensional diffuser 40 , because the light modulator 2 is encoded with a new strip hologram while the rotating mirror 41 is in motion. Thereby, a visibility region is generated which comprises sub-regions which are adjoined vertically in a step-like manner. It thus becomes possible to structure and enlarge the visibility region in the vertical direction as well.
Because the Fourier transformation with the help of the lens 38 also produces vertical parasitic diffraction orders, these parasitic diffraction orders must be blocked by a horizontal aperture gap filter in the exit plane 39 (not shown). The top view is the same as shown in FIG. 7 .
The rotating mirror 41 disposed in the exit plane 39 (not shown) has a horizontal rotation axis 42 . The beams from the angular ranges 43 , 44 , 45 are thus deflected vertically.
FIG. 10 shows the angular ranges 43 , 44 , 45 , which are covered if the mirror is not in motion. Horizontally, the angular ranges of the used diffraction order are adjoined. Vertically, encoding the modulated cells in adjacent modulator rows 12 , 13 , 14 causes step-like offset angular ranges 43 , 44 , 45 to appear in the filter plane 28 . This is why no rectangular angular range, which would be parallel to the axes of the coordinate system, can be covered if the rotating mirror 41 is at a fix position.
FIG. 11 shows a deflection pattern when rotating the rotating mirror 41 with step-like offset angular ranges 43 , 44 , 45 in the vertical direction, where the angular ranges are seamlessly adjoined by the rotating mirror 41 . The angular ranges 43 , 44 , 45 with same hatching are displayed simultaneously. If the light modulator 2 is re-encoded in synchronism with the movement of the rotating mirror, the hologram can also be structured in the vertical direction. The angular ranges with the same Θ y and different Θ x are generated at different times in the modulator, as can be seen in the Figure (different hatching). Thanks to the vertical deflection, a rectangular angular range 46 can be covered, which is shown as a dotted area in FIG. 11 . The appendices 47 , 48 at the upper 36 and lower edges 37 can be gated out or hidden through an empty light modulator content.
This is achieved when reconstructing the hologram 4 either by illuminating each sub-hologram 12 , 13 , 14 , . . . of the light modulator 2 under different angles, where the illumination angle changes in steps which correspond to the maximum diffraction angle Θ x1 , Θ x2 , Θ x3 , . . . , Θ xk of a modulator row 12 , 13 , 14 , . . . , or by illuminating them under a fix angle, e.g. in the normal direction (the z direction). The light of the hologram 4 , which is diffracted by each sub-hologram 12 , 13 , 14 , . . . , will then be deflected under an angle which is also step-wise enlarged according to the maximum diffraction angle Θ x1 , Θ x2 , Θ x3 , . . . , Θ xk . Both variants can be realised e.g. with the light modulator 2 and the prisms 21 , 22 , 23 , . . . which each cover a sub-hologram 12 , 13 , 14 , . . . of the hologram 4 . Their respective inclinations 24 , 25 , 26 , . . . are enlarged in steps according to the diffraction angles Θ x1 , Θ x2 , Θ x3 , . . . , Θ xk .
In contrast to prior art solutions, a major advantage of the present invention is that the spatial frequency filter is static, fitted with fix, localised openings in the mask, and that it works without a shutter device.
Depending on the application, the present invention makes it possible either to virtually enlarge the resolution of spatial light modulator means or to enlarge the visibility region for a holographic reconstruction. | The invention relates to a holographic reconstruction system for the reconstruction of scenes having at least one video hologram modulated wave front, and an enlarged visibility region. The system utilizes two-dimensional coded light modulator cells of spatial light modulation means and optical focusing means, which realize a Fourier transformation of the modulated wave front in their focal plane. First optical deflection means deflect the parallel disposed partial light waves such that their Fourier transformations appear as cascading in the focal plane. A spatial frequency filter located on the focal plane, lets each of the same diffraction orders of all modulated partial light waves pass, and second optical deflection means arrange the wave front strips next to each other at the modulated wave front, which reconstructs the scene. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a radiation detector for detecting low-intensity radiation, in particular for detecting individual photons, and an associated operating method.
The published document Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, page 137-152 describes CCD detectors (Charge Coupled Devices) which are used for radiation detection. These known CCD detectors comprise a plurality of parallel image cell rows, each having a plurality of image cells arranged one behind another, in which the radiation to be detected generates signal electrons. These signal electrons are initially held in potential wells which are generated in the region of the individual image cells by an electrode arrangement. By means of suitable electrical control of the electrode arrangement, the signal electrons are further transported along the image cell rows from image cell to image cell and pass within the individual image cell rows to a signal output to which an output amplifier is connected, which amplifies the output signal, so that even low-intensity radiation can be detected. In the case of the known CCD detectors, the output amplifier comprises, for example, a simple transistor which is integrated, together with the CCD detector onto a semiconductor substrate.
However, a disadvantage of the aforementioned known CCD detectors is the unsatisfactory sensitivity, which is insufficient for detecting individual photons with energies of less than 30 eV.
From A. D. HOLLAND: “New developments in CCD and pixel arrays”, Nuclear Instruments and Methods in Physics Research A. vol. 513 (2003), 308-312 and from the publication mentioned there, JERRAM et al.: “The LLLCCD: Low Light Imaging Without the Need for an Intensifier”, Proceedings of SPIE, vol. 4306 (2001), 178-186, a CCD structure with an avalanche amplifier as the output amplifier is known. However, in this prior art, the individual image cell rows of the CCD structure open into a common shift register which shifts the signal electrons serially into a further shift register in which multi-step avalanche amplification takes place.
However, these known detector structures with multi-step serial avalanche amplification have a variety of disadvantages. The serial readout of the signal electrons, for example, leads to a lower read-out speed and to a correspondingly low image refresh rate. Furthermore, the avalanche amplification takes place in multiple steps, which leads to a high level of non-linearity.
Furthermore, from HYNECEK, J.: “CCM—a new low-noise charge carrier multiplier suitable for detection of charge in small pixel CCD image sensors”, IEEE Transactions on Electron Devices, vol. 39, No. 8 (1992), 1972-1975, a CCD detector structure is known wherein avalanche amplification of the signal electrons takes place. However, avalanche amplification takes place within the CCD detector structure and not in a separate output amplifier.
Furthermore, US2005/0083567A1 and WO02/37139A1 describe detector arrangements, although these are less relevant.
It is an object of the invention, in the above described known CCD detector, to improve the sensitivity.
This aim is achieved with a radiation detector according to the invention and a corresponding operating method according to the invention.
SUMMARY OF THE INVENTION
The invention covers the general technical teaching of using a plurality of parallel avalanche amplifiers to amplify the output signals of the individual image cell rows of the CCD structure.
The use of an avalanche amplifier offers the advantage that the signal charge carriers read out from the individual image cell rows can also be amplified, even when individual photons are being detected, far beyond the noise of the read-out electronics.
In contrast to the known radiation detectors, the radiation detector according to the invention also enables the detection of individual photons with energies of less than 30 eV. However, the invention is not restricted to radiation detectors that have such a high level of sensitivity. Rather, the invention also includes radiation detectors with a lower sensitivity which, for example, can only detect single photons with an energy of greater than 30 eV.
The parallel arrangement of the individual avalanche amplifiers at the signal outputs of the individual image cell rows offers the advantage that a high image refresh rate is possible. For example, the radiation detector according to the invention may have an image refresh rate of at least 100, 500 or 1000 frames per second.
Preferably, the individual avalanche amplifiers each have a single avalanche region (high-field region) in which the avalanche amplification takes place. With the invention, the avalanche amplification therefore preferably takes place in a single step and not in multiple steps, as in the aforementioned publications by HOLLAND and JERRAM.
Furthermore, the avalanche region in the invention is preferably spatially separated from the image cells, whereas the avalanche amplification in the aforementioned known publication by HYNECEK takes place within the detector structure.
In a preferred exemplary embodiment of the invention, the radiation detector has a CCD detector structure for detecting the radiation, as described by Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, pages 137-152, so that the content of this publication regarding the structure and operational method of the CCD detector structure is to be added in its entirety to the present description. For example, the CCD detector structure may be a pn-CCD detector structure or a MOS-CCD detector structure, as described in the aforementioned publications. The combination of the avalanche amplifier according to the invention with a pn-CCD detector structure is particularly advantageous, however, since the signal charge carriers are stored in a pn-CCD detector structure at a depth in the range of approximately 2 μm to 15 μm and are further transported along the image cell rows, so that the signal charge carriers can then be accelerated in a vertically arranged avalanche amplifier to the surface of the semiconductor structure to a read-out electrode situated there.
However, with regard to the image cells serving for radiation detection, the invention is not restricted to a CCD detector structure, but is essentially also able to be realized with other types of image cells that generate signal charge carriers.
It should also be mentioned that signal electrons are preferably used in the individual image cells as signal charge carriers. However, it is fundamentally also possible that holes which are transported along the image cell rows to the signal output are used in the individual image cells as signal charge carriers.
Preferably, in the radiation detector according to the invention, the image cells and the avalanche amplifier are integrated together in a semiconductor substrate. By this means, capacitance-laden connection lines between the signal outputs of the individual image cell rows and the associated output amplifiers can be largely dispensed with.
In a preferred embodiment of the invention, the individual avalanche amplifiers each have an avalanche region with an electric avalanche field that is angled relative to the surface of the semiconductor substrate. In this embodiment, the signal charge carriers are therefore not accelerated parallel to the surface of the semiconductor substrate, but at a particular angle to the surface.
Preferably, the avalanche field is herein oriented substantially perpendicularly to the surface of the semiconductor substrate. This is advantageous in particular if, for radiation detection, a pn-CCD detector structure is used in which the signal charge carriers are stored and further transported at a depth of approximately 2-15 μm, since the signal charge carriers can then be accelerated in the avalanche region of the avalanche amplifier perpendicularly to a read-out electrode situated at the surface of the semiconductor substrate. The acceleration of the signal charge carriers therefore preferably takes place in the direction of the surface of the semiconductor substrate.
However, it is also fundamentally possible within the scope of the invention that the signal charge carriers are accelerated in the avalanche region away from the surface of the semiconductor substrate into the semiconductor substrate. In such a case, the signal charge carriers must then be transported back again from the depth of the semiconductor substrate to a read-out electrode arranged on the surface of the semiconductor substrate, which is fundamentally possible.
It should also be mentioned that, in addition to the avalanche amplifiers, the individual output amplifiers preferably each have a transistor amplifier, wherein the avalanche amplifiers are preferably connected upstream before the transistor amplifiers. These transistor amplifiers may be conventional MOSFETs (MOSFET=Metal Oxide Semiconductor Field Effect Transistor) or JFETs (JFET=Junction Field Effect Transistor). However, the invention is not restricted, with regard to the types of transistor amplifiers, to the aforementioned types of transistor amplifiers, but can fundamentally also be carried out with other amplifier types.
The combination of transistor amplifiers with avalanche amplifiers enables a relatively small amplification factor in the range of approximately 100 to 1000. This offers the advantage that, at such low amplification factors, there is only a small probability that the avalanche processes taking place in the avalanche amplifiers generate optical photons which are erroneously detected in adjoining image cells, which would result in crosstalk between adjoining image cells.
It is therefore preferably provided that the amplification factor of the individual avalanche amplifiers is so small that no crosstalk takes place between the adjoining avalanche amplifiers or between avalanche amplifiers and adjoining image cells. It should be considered herein that crosstalk of this type can never be completely prevented for statistical reasons, since the optical photons possibly generated in the avalanche amplifiers are always erroneously detected with a statistical probability. However, it can be assumed that practically no crosstalk takes place if the erroneous detection quota, that is, the ratio of correctly detected photons to erroneously detected photons is greater than 10 2 , 10 4 or 10 6 . Preferably, the amplification factors of the individual avalanche amplifiers therefore amounts to a maximum of 500, 1000, 5000 or 10000.
In a preferred exemplary embodiment of the invention, it is further provided that the amplification factor of the output amplifiers, that is, of the transistor amplifiers and/or of the avalanche amplifiers, is adjustable. This offers the advantage that the amplification factor can be adjusted to the intensity of the radiation to be detected. Given a relatively high intensity of the radiation to be detected, the avalanche amplifiers can practically be switched off, so that they have an amplification factor of k=1. This switching off of the avalanche amplifiers when detecting radiation of high intensity is useful, since the amplification factor of the additional transistor amplifiers is then sufficient to generate an output signal that can be evaluated, whilst crosstalk from the individual avalanche amplifiers is then precluded. In the detection of low intensity radiation, the avalanche amplifiers can be switched on with an amplification factor of k>>1 in order that, in an extreme case, individual photons can also be detected.
It should also be mentioned that the output amplifiers, i.e. the transistor amplifiers and/or the avalanche amplifiers, preferably have a substantially linear amplification in order to avoid distortions in the image detection.
The radiation detector according to the invention also preferably has an adjustable image refresh rate, which advantageously enables adaptation to the intensity of the radiation to be detected. On detection of high intensity radiation, a relatively high image refresh rate can be set, since then relatively short integration periods are sufficient in the individual image cells in order to generate sufficient signal charge carriers. With a lower intensity of radiation to be detected, however, a lower image refresh rate is preferably set, leading to a longer integration time in the individual image cells, so that even given a lower photon flux, a sufficient number of signal charge carriers can be generated.
It should also be mentioned that the invention not only includes the aforementioned radiation detector according to the invention, but also a corresponding operating method, which is also contained in the above general description.
Within the context of the operating method according to the invention, the amplification factor of the avalanche amplifier is preferably set depending on operating conditions of the radiation detector, wherein, for example, the operating conditions may relate to the photon flux and/or the intensity of the radiation to be detected.
Furthermore, in the context of the operating method according to the invention, the image refresh rate is preferably also set depending on the operating conditions of the radiation detector, wherein these operating conditions include, for example, the photon flux and/or the intensity of the radiation to be detected.
The image refresh rate is preferably set according to a saw-tooth characteristic, depending on the photon flux. The saw-tooth characteristic preferably has two rising edges, wherein the avalanche amplifiers are switched off in one edge of the saw-tooth characteristic and have an amplification factor of k=1, whereas the avalanche amplifiers are switched on in the other rising edge of the saw-tooth characteristic and have an amplification factor of k>>1.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
Other advantageous embodiments of the invention are characterized in the dependent claims or are described in greater detail below, together with the description of the preferred exemplary embodiments of the invention based on the drawings, in which:
FIG. 1 shows a schematic circuit diagram of a radiation detector according to the invention with a matrix-shaped CCD detector structure and an output amplifier unit, wherein the radiation detector is connected to a conventional CAMEX amplifier,
FIG. 2 shows a schematic cross section along an image cell row of the CCD detector structure according to FIG. 1 , with an avalanche amplifier and a downstream p-channel MOSFET,
FIG. 3 shows a modification of FIG. 2 wherein an n-channel SSJFET is connected downstream of the avalanche amplifier,
FIG. 4 shows a further modification of FIG. 2 , wherein the output amplifier is a DEPFET with integrated avalanche amplification, and
FIG. 5 shows a saw-tooth characteristic for setting the image refresh rate depending on the intensity of the radiation to be detected.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows, in schematic form, a radiation detector 1 according to the invention with a conventional matrix-shaped CCD detector structure 2 and an output amplifier unit 3 wherein the output amplifier unit 3 is integrated together with the CCD detector structure 2 on a common semiconductor substrate.
On the output side, the radiation detector 1 is connected to a conventional CAMEX amplifier 4 , as described, for example, in Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, pages 207-210, so that with regard to the structure and operational method of the CAMEX amplifier 4 , reference is made to the above publication which is to be added in its entirety to the present description regarding the CAMEX amplifier 4 . In place of the CAMEX amplifier 4 , however, a different amplifier type may also be used.
The CCD detector structure 2 is also conventionally constructed, as in Gerhard Lutz: “Semiconductor radiation detectors”, Springer Verlag 2 nd edition 2001, pages 137-152. A detailed description of the construction and functionality of the CCD detector structure 2 can therefore be dispensed with in the following, since the content of the previously mentioned publication concerning the structure and the functional method of the CCD detector structure 2 is to be added in its entirety to the present description. It should merely be mentioned at this point that the CCD detector structure 2 has a plurality of image cell rows in each of which a plurality of image cells 5 are arranged one behind the other, wherein the radiation to be detected in the individual image cells 5 of the CCD detector structure 2 generates signal electrons which are each transported within the individual image cell rows to a signal output 6 .
The output amplifier unit 3 of the radiation detector 1 has a plurality of parallel output amplifiers 7 which are connected in parallel to the individual signal outputs 6 of the individual image cell rows of the CCD detector structure 2 . The parallel arrangement of the individual output amplifiers 7 offers the advantage that, due to the parallel readout a relatively high image refresh rate of more than 1000 images per second is possible.
The individual output amplifiers 7 each have an avalanche amplifier 8 and a transistor amplifier 9 connected downstream, wherein the avalanche amplifiers 8 and the transistor amplifiers 9 each have an adjustable amplification factor and enable detection of individual photons.
The amplification factor of the individual avalanche amplifiers 8 in the switched-on state lies in the range of 100 to 1000, wherein amplification factors in this range are small enough to prevent the optical photons which arise in the avalanche amplifiers 8 due to the avalanche amplification from causing crosstalk in adjoining image cell rows.
Furthermore, the radiation detector 1 according to the invention has an adjustable image refresh rate r, wherein the setting for the image refresh rate r and for the amplification factor k of the avalanche amplifier 8 is described below on the basis of FIG. 5 . FIG. 5 shows a saw-tooth characteristic 10 which represents the relationship between the image refresh rate r and the intensity A of the radiation to be detected. The characteristic 10 has a rising edge 11 in the region of a large radiation intensity A and in the region of a lower radiation intensity A, it has a further rising edge 12 , wherein the two edges 11 , 12 are linked to one another by a vertical edge 13 .
In the region of the edge 11 of the characteristic curve 10 , the intensity A of the radiation to be detected is so large that the avalanche amplifiers 8 can be switched off and therefore have an amplification factor of k=1, so that no optical photons at all that could lead to undesirable crosstalk are generated in the avalanche amplifiers 8 . With decreasing radiation intensity A, however, the image refresh rate r must be reduced in accordance with the shape of the edge 11 of the characteristic curve 10 , in order that the integration time frames are sufficient in the individual image cells 5 of the CCD detector structure 2 in order to generate sufficient signal electrons.
If the radiation intensity A undershoots a predetermined limit value A LIMIT , reducing the image refresh rate r is no longer adequate to generate sufficient signal electrons in the image cells 5 despite the low radiation intensity A. If the intensity A LIMIT is undershot, the avalanche amplifiers 8 are switched on accordingly and operate with an amplification factor k>>1, so that the image refresh rate r can be increased again. If the intensity A of the radiation to be detected decreases further, the image refresh rate r can be reduced again according to the shape of the edge 12 of the characteristic curve 10 .
In this operating mode, every photon is detected. However, it is not necessary to collect a plurality of photons in an image cell 5 in order to remain above the electrical noise threshold. The image refresh rate r is selected such that the probability of collecting a plurality of photons in the same image cell 5 remains small.
The structure of the radiation detector 1 will now be described based on FIG. 2 .
The radiation detector 1 has a weakly n-doped semiconductor substrate 14 , wherein a p-doped rear electrode 16 is arranged on a back side 15 of the semiconductor substrate 14 .
The CCD detector structure 2 is integrated onto the front side 17 of the semiconductor substrate 14 , said CCD detector structure 2 being designed in this exemplary embodiment as a pn-CCD detector structure. The construction and the functionality of the CCD detector structure 2 is described, for example, by Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, pages 137-152, so that reference is also made in this regard to this publication. At this point, it should only be mentioned that the pn-CCD detector structure has a plurality of electrodes 18 - 22 which transport the signal electrons generated in the individual image cells 5 of the CCD detector structure 2 in the semiconductor substrate 14 in the direction of the arrow at a depth T which lies in the range of 0.25 R to 0.5 R, wherein R is the grid spacing of the electrodes 18 - 22 .
The cross-sectional view in FIG. 2 also shows the structure of the avalanche amplifier 8 , which has a read-out electrode A, a control electrode 23 and a buried p-doped semiconductor region 24 . By means of suitable driving of the control electrode 23 , an electric field which is directed approximately perpendicularly to the front side 17 of the semiconductor substrate 14 is produced in an avalanche region AB (high-field region) between the buried semiconductor region 24 and the read-out electrode A, and the signal electrons supplied by the CCD detector structure 2 are accelerated upwardly to the read-out electrode A, wherein the field can be adjusted so that avalanche amplification takes place in the avalanche amplifier 8 . With regard to the operational method and structure of the avalanche amplifier 8 , reference is also made to the German patent application 10 2004 022 948.1-33, which concerns an avalanche radiation detector, so that the content of this patent application is to be added to the present description.
The read-out electrode A of the avalanche amplifier 8 is connected to a gate G of the transistor amplifier 9 which in this exemplary embodiment is configured as a p-channel MOSFET and has an implanted source S and an implanted drain D. The structure and operational method of a p-channel MOSFET is described, for example, by Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, pages 165-175, so that the content of this publication with regard to the structure and functional method of the transistor amplifier 9 is to be added to the present description.
Finally, an n-doped buried semiconductor region 25 is arranged in the semiconductor substrate 14 and this region is intended to prevent the emission of holes to the rear electrode 16 . The semiconductor region 25 can simultaneously serve to conduct the signal electrons. It does not have to run through continuously, but can be interrupted or raised.
The buried semiconductor region 25 is raised beneath the avalanche amplifier 8 , so that the signal electrons are focused in the avalanche region of the avalanche amplifier 8 .
FIG. 3 shows an alternative exemplary embodiment which largely corresponds to the exemplary embodiment described above and illustrated in FIG. 2 , so that to avoid repetition, reference is made to the above description with regard to FIG. 2 , wherein the same reference signs are used for corresponding elements.
A peculiarity of this exemplary embodiment consists therein that the transistor amplifier 9 is designed as an n-channel SSJFET (SSJFET=Single-Sided Junction Field Effect Transistor). The structure and operational method of the n-channel SSJFET is described, for example, by Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, pages 233-238, so that the content of this publication with regard to the structure and functional method of the n-channel SSJFET is to be added in its entirety to the present description.
Finally, FIG. 4 shows a further exemplary embodiment which largely agrees with the exemplary embodiment described above and illustrated in FIG. 2 so that, to avoid repetition, reference is made to the above description, wherein the same reference signs are used for corresponding elements.
A peculiarity of this embodiment consists therein that the avalanche amplifier 8 is spatially integrated with the transistor amplifier 9 , wherein the transistor amplifier 9 is designed as a DEPFET (DEPFET=Depletion Field Effect Transistor). The structure and operational method of a DEPFET of this type is described, for example, by Gerhard LUTZ: “Semiconductor radiation detectors”, Springer Verlag, 2 nd edition 2001, pages 243-253, so that the content of this publication with regard to the structure and functional method of the n-channel SSJFET is to be added in its entirety to the present description. It should only be mentioned at this point that the transistor amplifier 9 designed as a DEPFET has a gate G, a source S, a drain D and a reset contact C 1 . Furthermore, under the gate G, the DEPFET has a buried n-doped semiconductor region 26 .
The invention is not restricted to the exemplary embodiments described above. Rather, many variants and developments thereof are possible, which also make use of the inventive concept and therefore fall within the scope of protection.
REFERENCE SIGNS
1 radiation detector
2 CCD detector structure
3 output amplifier unit
4 CAMEX amplifier
5 image cells
6 signal outputs
7 output amplifiers
8 avalanche amplifiers
9 transistor amplifiers
10 characteristic curve
11 , 12 , 13 edges of the characteristic
14 semiconductor substrate
15 back side
16 rear electrode
17 front side
18 - 22 electrodes
23 control electrode
24 buried semiconductor region
25 buried semiconductor region
26 buried semiconductor region
A read-out electrode
AB avalanche region | The invention relates to a radiation detector ( 1 ) for detecting low-intensity radiation, especially for detecting individual photons. The radiation detector includes a plurality of rows of image cells ( 5 ) with respective pluralities of image cells ( 5 ) disposed one after the other and respective signal outputs ( 6 ). The radiation to be detected generates signal charge carriers in the individual image cells ( 5 ), the charge carriers being transported along the rows of image cells to the respective signal output ( 6 ). A plurality of output amplifiers ( 7 ) are connected in parallel to one of the signal outputs each of the individual image cell columns and amplify the signal charge carriers. The invention is characterized in that the output amplifiers ( 7 ) include respective avalanche amplifiers ( 8 ). | 7 |
This is a division of application Ser. No. 08/716,215 filed Nov. 6, 1996.
BACKGROUND OF THE INVENTION
The present invention relates to a patterning unit of a warp knitting machine and more particularly to a patterning unit which controls the position of a guide point provided on a holding member individually by means of a linear pulse motor and to control methods thereof.
Hitherto, patterning of a warp knitting machine has been carried out by lapping patterning reeds in which guide points are mounted in a direction of a row of needles of the patterning reed based on means for lapping the patterning reeds such as a chain drum and an electronic patterning unit. However, because only the same quantity of lapping can be obtained for all the guide points mounted on one patterning reed, the superiority of patterning effect caused by a number of patterning reeds is proportional to the number of patterning reeds.
In view of the prior art problem described above, the present applicant proposed a new patterning unit previously in Japanese Patent Application No. 06-200750 (PCT/JP95/00032). This patterning unit is arranged such that guide points are provided individually as part of moving elements in a fixed guide path which corresponds to the patterning reed so as to be movable individually within the guide path.
However, even though the above-mentioned patterning unit patterns through the control of the movement of the moving elements on which the guide points are provided by utilizing linear pulse motors, it has left room for improvement in the following points:
(1) When a number of holding members increases, it is necessary to deal with it by thinning the linear pulse motor further;
(2) It is necessary to solve the problem of short life of a bearing caused by a large attraction force generated between a stator and a moving element of the linear pulse motor;
(3) It is necessary to take measures for preventing erroneous operation due to step-out power failure and external noise in the positioning control;
(4) With the increase of numbers of the holding members and of moving elements, it is necessary to improve a wiring method for wiring connection cables to the moving elements to realize a range in which the moving elements can be moved freely. This is a problem in mounting to the warp knitting machine;
(5) With the increase of numbers of the holding members and moving elements, it is necessary to simplify the assembly and adjustment of the unit. This is a problem in mounting to the warp knitting machine;
(6) It is necessary to correct a pitch error which might be caused by the difference in working precision of pitches of poles of a stator assembled to the holding member, in working precision of pitches of knitting needles and in expansion coefficient of the holding members due to environmental temperature changes;
(7) In operation, because a plurality of layers of patterning reeds, i.e. the holding members, are disposed, it is necessary to simplify the replacement of the guide point and its alignment with a knitting needle of each moving element which is located behind another; and
(8) With the increase of the number of moving elements to be mounted, a control method is required which allows each moving element to be positioned at high-speed in synchronism with the rapid rotation of the warp knitting machine while maintaining the free movable range of each moving element and which can realize the above-mentioned points (3) through (7) at low cost.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a patterning unit of a warp knitting machine and control methods thereof which are arranged so as to solve each of the problems described above.
The present invention is arranged such that in a patterning unit of a warp knitting machine in which a stator of a linear pulse motor is assembled in a holding member functioning as a guide path and a plurality of moving elements are provided at arbitrary intervals on the same path, part of the moving element is constructed as a guide point or a guide bar, and poles of the moving element are disposed so as to face to poles on both sides of the stator.
Thereby, suction forces generated between the stator and the moving element cancel each other and the burden placed on a bearing section is reduced as a result. Therefore, the thickness of the poles of the moving element may be reduced to about a half without dropping a thrust of the moving element. Accordingly, an increased number of the holding members is made possible by thinning the linear pulse motor.
The present invention is also arranged such that in the patterning unit described above, coils of the poles of the moving element, i.e. moving element driving coils, NS directions of two field magnets within the moving elements facing the poles on the both sides of the stator and teeth of the stator are set so that a magnetic path of the field magnets runs in the same direction.
Thereby, a leakage magnetic flux is reduced and the magnetic flux generated by both field magnets and excited coils pass through each pole, so that the thrust may be uniform and the guide point is positioned stably.
Further, the present invention solves the aforementioned problems in the patterning unit of the warp knitting machine in which a stator of a linear pulse motor is assembled in a holding member functioning as a guide path and a plurality of moving elements are provided at arbitrary intervals on the same path and part of the moving element is constructed as a guide point or a guide bar, by adopting the following control methods.
A first inventive method for controlling the patterning unit of the warp knitting machine described above is to control the acceleration or deceleration of the linear pulse motor by providing a position sensor in connection with the poles of the stator and the poles of the moving element and by confirming by the position sensor that the poles of the moving element have moved a unit of one pulse with respect to a positioning command to generate a next positioning pulse.
Thereby, information for positioning the moving element is logically incorporated as moving conditions in the positioning control commands, so that the moving element follows reliably in accordance with the command values and is positioned accurately. At this time, the correction of position and the like may be readily made, thus guaranteeing more accurate positioning control by controlling the positioning by setting a number of pulses per gage at a plurality of pulses.
A second inventive method for controlling the patterning unit of the warp knitting machine described above is to provide absolute position detecting means whose span is adjusted according to the pitch of the pole of the stator disposed in the holding member to control the relationship between a position detected value detected by the position detecting means and the excitation of the moving element driving coils.
Thereby, the position of the moving element is always detected so that the moving element is caused to follow in accordance with the position control command values, thus becomes unnecessary to return to the reference position by performing a zero return operation even if power is turned on again after power failure and the machine will not step out due to electrical noise and external noise such as a difference in tension of patterning yarns and in yarn feeding methods.
A third inventive method for controlling the patterning unit of the warp knitting machine described above is to control the positioning of the moving element by carrying out optimum positioning acceleration or deceleration by finding current control and excitation switching timings of the moving element driving coil from the position detected value. Thereby, it becomes possible to carry out the positioning reliably in a short time, to execute a stop at the accurate position and to prevent step-out.
A fourth inventive method for controlling the patterning unit of the warp knitting machine described above is to control the positioning of the moving element freely by way of wireless control by supplying electric power and transmitting signals to the moving element by using a non-contact method utilizing a magnetic coupling of a power receiving coil of the moving element and an induction coil attached to the holding member or a contact method in which a conductive portion is provided on a part of the holding member and a slip ring is contacted. Thereby, it becomes possible to realize the small and light-weight machine, to increase the thrust and to increase the speed.
A fifth inventive method for controlling the patterning unit of the warp knitting machine described above is to control the positioning of the moving element by mounting a microcomputer or a logic circuit on the moving element to reduce an amount of control signals transmitted to the induction coil for the correction of position and the like.
In this case, even if the amount of information to be transmitted by the induction line increases and the processing capacity of the moving element positioning control computer increases, the positioning of the moving element may be controlled individually by the microcomputer or the logic circuit mounted on the moving element without being restricted by the amount of information of the control signals. Then, it allows the load of the moving element positioning control computer to be reduced significantly, the positioning to be accommodated with the high speed rotation and to be controlled accurately at high speed, thus allowing the machine to be put into more practical use.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic perspective view of a warp knitting machine to which one embodiment of an inventive patterning unit and a control method thereof is applied;
FIG. 2 is a section view of a holding member, including a guide point, showing a structural example in which two sets of poles of a stator are disposed on the both sides of the holding member in the patterning unit in FIG. 1;
FIG. 3 is a partly cutaway perspective view showing the embodiment in which a linear pulse motor in which poles of a moving element are disposed so as to face to the poles of the stator on the both sides and a magnetostrictive sensor used for detecting the position of the moving element are mounted in the patterning unit in FIG. 1;
FIG. 4 is a structural view showing a relationship between the poles of the moving elements and the poles of the stator of the linear pulse motor in the patterning unit in FIG. 1;
FIG. 5 is a block diagram showing one example of a control mechanism for controlling the patterning unit by the linear pulse motor in the patterning unit in FIG. 1;
FIG. 6 is a signal waveform chart of output signals of the magnetostrictive absolute sensor for detecting the position of the poles of the moving element and the position of the pole of the stator in the patterning unit in FIG. 1;
FIG. 7 is a graph showing a relationship among position control parameters of the linear pulse motor in the patterning unit in FIG. 1;
FIG. 8 is a partly cutaway perspective view of an embodiment of a patterning unit without connection cables;
FIG. 9 is a block diagram showing one example of a control mechanism of a unit according to an embodiment in which power is supplied and control signals are transmitted by a non-contact method in the patterning unit in FIG. 8;
FIG. 10 is a block diagram showing one example of a control mechanism of the moving element, an induction coil and a receiving coil in the patterning unit in FIG. 8;
FIG. 11 is a signal waveform chart showing an example of signals of a power supplying oscillation section of the moving element in the patterning unit in FIG. 8;
FIG. 12 is a partly cutaway perspective view of an embodiment in which the poles of the moving element are disposed so as to face only to one side of the poles of the stator;
FIG. 13 is a block diagram showing one example of a positioning control mechanism using microcomputers mounted to the moving element;
FIG. 14 is a signal waveform chart showing an example of signals of the power supplying oscillation section of the moving element in the patterning unit in the embodiment shown in FIG. 13;
FIG. 15 is an explanatory diagram of an exemplary data array of the control signal transmitted by a control signal induction coil;
FIG. 16 is a block diagram showing one example of a control mechanism according to an embodiment in which two lines consisting of a power supplying induction coil and the control signal induction coil are applied; and
FIG. 17 is a partly cutaway perspective view of a part of the moving element showing an embodiment in which a moving element per holding member is constructed by attaching a guide bar.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be explained below with reference to the drawings.
FIG. 1 is a schematic perspective view of a warp knitting machine to which one embodiment of a patterning unit and a control method of the present invention is applied. The reference numeral (1) denotes a traverse which is part of a machine frame, (2) hangers suspended from and fixed to the traverse 1 at intervals of a certain distance, (3) holding members in each of which a stator of a linear pulse motor extends in a direction of width of the knitting machine and a certain number of which are fixed to the hanger 2 in parallel, and (4) moving elements which reciprocate linearly on the holding member 3 and to each of which a guide point 5 (5a-1, 5a-2, 5a-3) is attached. Normally, several to ten-odd moving elements 4 are mounted to the holding member 3 which constitutes, at least partly, the stator of the linear pulse motor across the width of the knitting machine so as to be movable in accordance to a patterning program.
Provided within a control section 6 are known control units, i.e. a position control circuit, a linear pulse motor driving circuit, a position detecting circuit and a patterning counter with a memory. Because their structure is well known, an explanation thereof is omitted. A position controlling method of the linear pulse motor is explained below in detail with reference to FIGS. 4, 5, 6 and 7 because it is an essential part of the present invention.
Each holding member 3 has a signal cable 7 as one of means for transmitting signals to each moving element 4 at one end thereof. The reference numeral (8) denotes knitting needles, (9) a trick plate, and (10, 11) a lever and an arm for driving the trick plate 9 which are mounted to a supporting shaft 12. The trick plate 9 is oscillated together with the knitting needles 8 in a direction of A. Any type of knitting needles beside those conventionally used such as a opposite needle, a latch needle, a beard needle and the like way be used for the knitting needle 8 so long as it has a similar function.
Next, a structure of a driving section containing the stator of the linear pulse motor incorporated in the holding member 3 and the moving element 4 will be explained.
FIG. 2 is a longitudinal section view of an embodiment in which the moving elements 4 are attached to both sides of the holding member 3 provided on a holder 13 and FIG. 3 is a partly cutaway perspective view of one side thereof. The stator 18 on which toothed poles are formed on both sides thereof is provided in the holding member 3 across the whole length of the knitting width so that the moving elements 4 may be moved throughout the knitting width. Normally, several to ten-odd moving elements 4 (4-1, 4-2, . . . 4-n) are mounted to the holding member 3. A moving element bearing 14 holds the moving element 4 and the guide point 5 attached to the moving element 4.
The moving element 4 of the linear pulse motor is constructed as follows. In the figure, the reference numerals (15: 15a, 15b) denote field magnets (magnets), (16: 16a-1, 16a-2, 16b-1, 16b-2) poles of the moving element, and (17: 17a-1, 17a-2, 17b-1, 17b-2) moving element driving coils. The poles 16a-1 and 16a-2 of the moving element, the moving element driving coils 17a-1, 17a-2 and the poles 16b-1 and 16b-2 and the moving element driving coils 17b-1 and 17b-2 are disposed so as to face to the poles of the stator 18 in order to cancel out large attraction forces generated between the poles 16 of the moving elements 4 and the poles of the stator 18. Thereby, because a load placed on the moving element bearing 14 as well as the gap between the both poles may be reduced, a thrust is maintained, heat generated is reduced, the miniaturization of the bearing and the prolongation of its life is realized by reducing an exciting current applied to the moving element driving coils 17. Further, the whole moving element 4 may be thinned by miniaturizing the moving element driving coils 17 and the moving element electrodes 16.
A magnetostrictive absolute sensor probe 19 is mounted across the whole range of the knitting width of the holding member 3. A position detecting sensor magnet 20 is mounted on each moving element 4 (4-1, 4-2, . . . 4-n) (See FIG. 5). The magnetostrictive absolute sensor probe 19 detects the position of each moving element 4 by detecting the position of the sensor magnet 20 of the moving element 4 on the holding member 3 to create data for controlling the position. A flexible cable is used as a signal cable 7a connecting a linear pulse motor driving circuit provided in the control unit with the moving element driving coil 17 of the moving element 4 to allow the moving element 4 to move freely. The signal cable 7a is explained below with respect to an embodiment in which the cable is eliminated.
FIG. 4 is a structural diagram showing a relationship between the poles of the moving element and the poles of the stator of the linear pulse motor of the patterning unit of the present invention. Because its basic structure is known, a detailed explanation of its basic operation is omitted and its operational principle is explained only about the part related to the present invention.
Several problems are solved by disposing two sets of the poles 16 of the moving elements and the moving element driving coils 17 so as to face to the poles on both sides of the stator 18, by arranging phases of the upper and lower teeth, i.e. the poles of the stator 18, so as to be opposite, and by configuring directions of NS of the upper and lower field magnets 15a and 15b to be also opposite.
While it has been described with respect to the explanation of FIGS. 2 and 3 that the load placed on the moving element bearing 14 can be reduced significantly by adopting the structure in which the attraction forces generated between the upper and lower poles are canceled, it is also a solution for the biggest problem of the linear pulse motor used in the inventive unit. Further, because the gap between the poles is minimized by solving the problem of the attraction force, the thrust is increased. While it has been also described before, a difference in magnetic flux density is caused between the inner poles close to the field magnets 15a and 15b and the outer poles due to a difference in resistance of magnetic paths and leakage flux from the prior art structure, causing a dispersion of the thrust among the inner and outer poles. This problem is solvable in the present invention by configuring the two sets of upper and lower linear pulse motors by assorting the inner poles with the outer poles, by arranging (alternating) the upper and lower teeth of the poles of the stator 18 so as to be opposite and by arranging the NS directions of the field magnets 15a and 15b so as to be also opposite.
Further, the dispersion of the thrust is minimized and the performance of position control is improved by connecting the upper and lower moving element driving coils 17a-1 and 17b-1 for A phase to the same phase and connecting the upper and lower moving element driving coils 17a-2 and 17b-2 for B phase to the same phase in the same manner to set the pole Nos. 1p, 2p, 3p and 4p of the moving elements shown in FIG. 4 so that when the upper side ones are positioned outside, the lower side ones are positioned inside and when the upper side ones are positioned inside, the lower side ones are position outside.
As shown by a broken line in FIG. 4, the path φ of the magnetic flux generated when the field magnets 15a and 15b and the moving element driving coils 17a-1 and 17b-1 are excited always passes through both the upper field magnet 15a and the lower field magnet 15b, thus providing highly efficient thrust. The highly efficient thrust is obtained also when the moving element driving coils 17a-2 and 17b-2 are excited by the same reason.
In the present embodiment, a pitch Pd of the pole of the stator 18 is set at four times a gage pitch (1/18 inch=1.411 mm) of the guide point. In the structure shown in FIG. 4, the movement per pulse is 1.411 mm in the case of one-phase excitation or two-phase excitation as it is known. The movement per pulse is 0.705 mm in the case of the one-two-phase excitation method. In the present embodiment, a combined method of the one-phase excitation and the one-two-phase excitation is adopted in order to carry out the position control per 1.411 mm pitch. The position control method is described below with reference to FIGS. 5, 6 and 7.
Next, an exemplary control method of the patterning unit of the above-mentioned embodiment of the present invention is explained with reference to FIG. 5.
The reference numeral (30) denotes a computer for pattern control. A pattern data disk 31 prepared beforehand based on lace pattern structures is read into an internal memory of the pattern control computer 30. This pattern data, which is to be decomposed per holding member by a moving element positioning control computer 23 of each holding member, is transmitted as a pattern data signal S8a and is stored in the memory in the moving element positioning control computer 23. When the knitting machine is driven, periodic signals S5 and S6 are sent from a proximity sensor 25 and a disk 26, for the proximity sensor 25 for an underlap starting signal, provided on a main shaft 24 of the knitting machine and from a proximity sensor 27 and a disk 28, for the proximity sensor 27 for an overlap starting signal, respectively, to the moving element positioning control computer 23.
Each of the pattern guide point moving elements 4-1, 4-2, . . . 4-n disposed on the holding member 3 contains the linear pulse motor and its position is controlled by exciting the moving element driving coils. The reference numerals (20-1, 20-2, . . . 20-n) denote magnets for sensors for detecting the position of the moving elements, (19) the magnetostrictive absolute sensor probe for detecting the position of the moving elements, (19a) a sensor amplifier, (19b) a circuit for detecting the position of each moving element by counting an output signal S1 of the sensor amplifier 19a, and (21-1, 21-2, . . . 21-n) pulse motor driving circuits for sending signals S4-1, S4-2, . . . S4-n, for exciting the moving element driving coils of the linear pulse motor, to each of the moving elements 4-1, 4-2, . . . 4-n to position them.
The moving element positioning control computer 23 controls the position of each of the guide points 5a-1, 5a-2, . . . 5a-n attached to the moving elements 4-1, 4-2, . . . 4-n in accordance to the pattern data based on positional elements 4-1, 4-2, . . . 4-n stored therein and moving element position detected signals S2 and signals generated by commands S3-1, S3-2, . . . S3-n for positioning the moving elements 4-1, 4-2, . . . 4-n, which are synchronized with the periodic signals S5 and S6 of the main shaft of the knitting machine, are transmitted by the pulse motor driving circuits 21-1, 21-2, . . . 21-n.
Further, as a known method for controlling the position of the pulse motor, there is a method of guaranteeing the prevention of step-out during startup and positioning to a target position by generating slow-up and slow-down pulses. However, this slow-up and slow-down method cannot guarantee 100% accuracy due to the fluctuation of load and external noise even if a safety factor is increased.
The present embodiment is adapted to carry out the positioning reliably in the shortest time using a control method explained in detail below referencing FIGS. 6 and 7.
FIG. 6 shows a relationship between the output signals of the magnetostrictive absolute sensor and the poles of the stator 18. In the present embodiment, the pitch of the pole of the stator 18 corresponds to four gages and there are four ways of positioning positions of GA1, GA2, GA3 and GA4.
In the present embodiment, the position detecting circuit is designed so as to detect the position in unit of 1/8 of the movement of one gage (1.411 mm) from GA1 to GA2. When the span of the knitting width of the holding member 3 is adjusted and positioned so that the output signals of the magnetostrictive absolute sensor agree with the pitch of the pole of the stator 18, the relationship shown in FIG. 6 is obtained as a result.
Position detection values are represented by binary numbers like S2-0 (20), S2-1 (21), S2-2 (22), S2-3 (23) . . . Although S2-4 and above are omitted, they are detected by values of 16 bits. Accordingly, as for a guide address, the unit of S2-3 (23) becomes a guide address detection value of the guide point (moving element). Three bits S2-0, S2-1 and S2-2 below that are information on movement required for the positioning control of the linear pulse motor.
FIG. 7 represents a relationship among positioning control parameters of the linear pulse motor. The reference symbol (Pc) denotes a position detected value of the moving element 4, (S2) a signal for exciting the moving element driving coil 17 of the linear pulse motor, (i0, i1, i2, i3, i4, i5, i6, i7) exciting current parameters of the moving element driving coil 17, and (ΔP0, ΔP1) the movement per pulse of the linear pulse motor. That is (ΔP0) is the movement in case of the one-two-phase excitation and (ΔP1) is the movement in case of the one-phase excitation. (Sn) of the horizontal axis represents a number of times of sampling for detecting the position. The sampling period is 1.6 msec. in the present embodiment. (ts) denotes time (msec). (Δf) represents a speed of the moving element 4 and indicates a varied movement of a detected value in one sampling period. (d0, d1, d2) denote control parameters indicating distances to positioning target values. (Δd) denotes a parameter of an allowance between a position detected position and a position for exciting the moving element driving coil of the linear pulse motor. Δd is important as a parameter for preventing step-out and is set as Δd≦12 in the detected value. It is set as ΔD≦12 in the present embodiment considering the safety factor because the step-out condition is brought about when Δd>16 as is well known.
An embodiment concerning to each parameter and the positioning control method will be explained below.
A positioning time of the moving element synchronized with a number of revolutions of the knitting machine of 400 rpm to 450 rpm is within 50 msec. in the underlap positioning and within 18 msec. in the overlap positioning. While there is a fluctuation of the allowance more or less depending on a number of the holding members, the reliable positioning has is guaranteed in a short time in any case. The lapping illustrated in FIG. 7 presents the movement of 12 gages. Positioning is started by the underlap starting signal and, at the startup for the start dash, the rise time is minimized by charging the current of i7 and i6 fully for the performance of the driving circuit. It is accelerated by adding ΔP1=8 when the position detected value approaches to a difference with the exciting position Δd=4 to move the exciting position. While it turns out as Δd=12 at that moment, the exciting position is moved further when the detected position of the moving element approaches to Δd=4, thus repeating this process sequentially until reaching to the target position. This method represents the shortest startup of the moving element conforming to a time constant of inertia thereof. This control is performed with the period of the position detecting sampling of 1.6 msec.
Control parameters and a control method for stopping at the next target value will be explained. While the stopping control starts at the point of time when the position of the signal S2 for exciting the moving element driving coil of the linear pulse motor reaches to the target position as described above, the moving element is at the position distant from the target position by 1.5 gage at the point of time when the signal S2 reaches to the target because Δd≦12. Then, a moving velocity Δf at that time is found. The operation of FIG. 7 is then carried out in accordance to d0, d1 and d2 and the exciting currents of i1, i2 and i3 set in advance by the value of Δf, as follows.
At first, when the position approaches to d2 with respect to the target value, the exciting position is returned by ΔP1 to excite the point one gage before the target value. Assume the exciting current at this time as i3. That is, it acts as a brake for stopping at the target position. Next, the exciting position is approached to the target position by ΔP0 at the point of time when it approaches to the position of d1. The exciting current at this time is i2. Then, when the exciting position is advanced by ΔP0 at the point of time when it approaches to the position of d0, the exciting position reaches to the positioning target. The exciting current at this time is i1.
The above control method allows the moving element to be stopped at the target position in the shortest time by optimally setting the parameters Δf, d0, d1, d2, i1, i2 and i3. i0 is the exciting current after the stop and a current value conforming to a torque for holding the stop is selected.
The method of the present embodiment allows the positioning in the shortest time by controlling the position detected position of the moving element and the exciting position of the moving element driving coil, i.e. the command value, always at intervals of the period of the position detecting sampling of 1.6 msec. and by controlling always so as to prevent the step-out which is the biggest problem of the linear pulse motor.
The control parameters may be applied to all the moving elements so long as they have the same structure by setting the optimal values once.
The performance of the patterning unit may be improved further by minimizing the dispersion of thrust by constructing the linear pulse motor as shown in FIG. 4 as described above and by reducing the thickness and weight of the moving element and by increasing the thrust.
Next, an embodiment in which power is supplied and control signals are transmitted in a non-contact manner without using cables, will be explained as a method for controlling each driving coil of the moving elements 4-1, 4-2, . . . 4-n for the guide points disposed on the holding member 3. This embodiment solves the problems of the restricted movement range of the moving element and the short life of the cables as well as the problem in mounting and realizes free patterning by eliminating the connection cables to the moving elements.
FIG. 8 shows one example of the patterning unit from which the connection cables are removed. The parts structurally common with those in FIG. 3 are designated with the same reference numerals and an explanation thereof is omitted. Only parts added to the upper edge portion are explained below.
A unit is formed by assembling a ferrite plate 40 secured to the holding member 3, an induction coil 34 secured in parallel with the ferrite plate 40 in the longitudinal direction, a power receiving coil 35 provided in correspondence with the induction coil 34 at the upper part of the moving element 4, a rectifier circuit 36, a driving circuit 37 and a signal detecting circuit 38.
A control method using the above-mentioned unit is explained referencing FIGS. 9, 10 and 11. It is noted that the explanation of the control method common with that in the previous embodiment shown in FIG. 5 is omitted and only the additional control method is explained.
Commands S3-1, S3-2, . . . S3-n for positioning the moving elements 4-1, 4-2, . . . 4-n generated by the moving element positioning control computer 23 in FIG. 9 are input to a signal converter circuit 32 to be converted into a serial pulse signal S10 which is input to a power supplying and oscillating section 33. The power supplying and oscillating section 33 outputs a power signal S11 whose oscillation frequency is modulated by the serial pulse signal S10 for positioning the moving element and excites the induction coil 34 attached on the holding member 3.
The moving elements 4-1, 4-2, . . . 4-n can obtain induced power caused by the magnetic coupling between the power receiving coils 35-1, 35-2, . . . 35-n and the induction coil 34 and in the same time, receive the control signal.
A method for controlling the moving elements 4-1, 4-2, . . . 4-n will be explained with reference to FIG. 10. The induced power S12 generated in the power receiving coil 35 is input to the control signal detecting circuit 38 and the rectifier circuit 36 and a control signal S13 and a DC voltage signal S14 are input to the linear pulse motor driving circuit 37. Then, control signals S15 and S16 excite the moving element driving coils 17a-1 and 17a-2. Thus, the position of each moving element is controlled in the same manner with above.
FIG. 11 shows exemplary signal waveforms of a basic oscillation signal CL of the power supplying and oscillating section 33 and the power signal S11 which has been pulse-width modulated by the positioning command serial pulse signal S10.
While the embodiment in which the power is supplied together with the control signal is explained above, it is conceivable to adopt a method of supplying the power and transmitting the control signal by two line systems as described below. In any case, the more the number of moving elements disposed on the same holding member, the greater the effect of removing the connection cables becomes. While the weight of the moving element increases by adding the power receiving coil 35, the power receiving coil ferrite core 39, the control signal detecting circuit 38, the rectifier circuit 36 and the linear pulse motor driving circuit 37, a light-weight, thin and high-thrust patterning unit may be realized and be put into practical use due to the effect of the patterning unit on an opposing pole structure.
It is noted that beside the non-contact method described above, positioning control by way of wireless control similar to one described above may be implemented by a contact method of supplying signals and power by providing a conductive portion on a part of the holding member and by contacting it with a slip ring provided on the moving element.
FIG. 12 shows an embodiment in which poles of the moving element 4 are disposed so as to face poles at one side of an upper or lower side (upper side in case of the figure) of the stator 18 provided in the knitting width direction in the holding member (not shown).
In the figure, the reference numeral (15) denotes a field magnet, (16a-1, 16a-2) poles of the moving element, and (17a-1, 17a-2) moving element driving coils. Moving rollers 41 are provided before and after the both poles 16a-1 and 16a-2 and are placed on the stator 18 formed so that the moving rollers 41 function also as a guide so as to be able to move the moving element in the knitting width direction. Because an induced power is obtained by the magnetic coupling of the induction coil 34 and the power receiving coil 35, a necessary power is supplied by it. This point is the same with the case in the embodiment in FIG. 8.
FIG. 12 also shows a case in which a microcomputer or a logic circuit is mounted on the moving element 4 to control the moving element 4 thereby reducing the control signals of the induction coil 34 for the correction of position and the like. Accordingly, the figure shows microcomputer chips attached on a substrate PB.
That is, although the case in which the control is made by setting the movement per pulse of the linear pulse motor at the gage pitch (1.411 mm) has been shown in the embodiment of the control method described above, it is desirable to select a control method in which the movement per pulse is set at one-several of 1.411 mm per pulse described above, e.g. one quarter in order to solve the problems of the working precision of the stator, the working precision of the pitch of the knitting needles, the correction of the pitch error, the simplification of the alignment and the increase of the speed. More desirably, the one-two-phase exciting method is adopted to correct the position of the moving element, temperature and individual guide position in unit of 0.176 mm per pulse.
However, if it is set at a plurality of pulses per move of one gage, an amount of information to be transmitted by the induction lines increases four times and in the same time, the processing capacity of the moving element positioning control computer 23 has to be increased four times or more. Further, carrier frequency of the induction line becomes high frequency of more than four times and it becomes difficult to realize it because of the high cost in the aspects of the mounting and processing capacity.
It is preferable, therefore, to adopt the following control method after setting a number of pulses for moving one gage at a plurality of pulses, e.g. four pulses or eight pulses, as shown in the embodiment.
Firstly, the microcomputer is mounted on the moving element 4 to carry out the positioning control individually in order to significantly reduce the amount of information carried by the control signal induction line. Secondly, two lines consisting of the power supplying induction line and the control signal induction line are provided so that resonance frequency can be set in accordance to an inductance of the power supplying induction line without being restricted by the amount of information of the control signal.
The processing capacity is dispersed and the load of the moving element positioning control computer 23 is significantly reduced by adopting this control method.
FIG. 13 shows one example of a control mechanism controlled by the computer mounted on the moving element 4.
It comprises the power receiving coil 35 provided corresponding to the power supplying induction coil 34 secured to the holding member and a signal receiving coil 53 provided corresponding to the control signal induction coil 52 secured to the same holding member together with the power supplying induction coil. An output signal S21 of the power receiving coil 35 is input to a power receiving section 55 to output a controlling power source V5 and a power source Vc for the pulse motor driving circuit 58. Further, an output signal S22 of the control signal receiving coil 53 for shaping the output signal S21 of the power receiving coil 53 and for outputting a control signal synchronizing signal CL is input to the control signal receiving section 56 to be shaped as a serial control signal S23.
FIG. 14 shows each exemplary signal. The serial control signal S23 is output as a sequence consisting of 0 and 1 with respect to the control signal synchronizing signal CL. The signals CL and S23 are input to a positioning control microcomputer section 57. Receiving information necessary for positioning each moving element sent from the pattern controlling and moving element positioning control computer 23, the positioning control microcomputer section 57 develops an exciting signal S24 for the linear pulse motor and a current signal S25 to be output to the pulse motor driving circuit 58. Then, the pulse motor is positioned by means of an A-phase exciting signal S15 and a B-phase exciting signal S16.
FIG. 15 shows an embodiment of the serial control signal S23 transmitted by the control signal induction coil 52. While the method for transmitting and receiving the serial signal is known and its explanation is omitted, the content of the signal will be explained below.
Control codes listed in the lower fields of FIG. 15 are control commands for the moving element and are common to all the moving elements.
The control commands can be roughly divided into two kinds of commands of transmitting control data and of starting the control. The control codes is explained below briefly.
05H Transmit command values: Transmit a movement for positioning, direction, and presence or absence of overlapping to each moving element from pattern data. Transmit once per turn.
01H Start underlap positioning: Execute command of transmitting command value. It is a synchronizing
02H Start overlap positioning: Execute command of transmitting command value. It is a synchronizing signal for starting.
06H Transmit return command value: Used primarily for recovering operation after occurrence of error. Command a movement to be returned.
03H Start positioning of return: Execute command in accordance to return command value.
04H Start adjustment of span: It is a command for starting to control excitation of pulse motor when the position of the stator of the pulse motor is to be adjusted with absolute position detected value. Present position of each moving element is updated.
07H Transmit correction value: Transmit correction value to each moving element. Positioning position is corrected by correcting zero offset values.
08H Transmit control data: Transmit control parameters.
0FH-51H Transmit positioning parameters: Transmit positioning control time with respect to move pulse and current value.
60H-62H Transmit present position of moving element: Transmit absolute detected value to update internal data of moving element.
Mounting the microcomputer in the moving element positioning control section as described above allows the positioning control section and the distributed processing to be realized and the problems to be solved, thus allowing to accommodate with the multi-function of the future, in view of its accommodation to the multiple pulses, to the position correcting function and cordless control and to the multiple moving elements.
FIG. 16 is a block diagram of a control mechanism of the embodiment in which two lines consisting of the power supplying induction coil 34 and the control signal induction coil 52 are provided.
As compared to one described before in FIG. 9, the oscillating section for exciting the induction coil 34 is divided into an oscillating section 51 for exciting the control signal induction coil and an oscillating section 50 for exciting the power supplying induction coil and a control signal S19 output from the moving element positioning control computer 23 is input to the oscillating section 51 to output an oscillating section output signal S20 to be supplied to the control signal induction coil 52. Similarly, a control signal S17 is input to the power supplying oscillating section 50 and an oscillating section output signal S18 which is output as ON and OFF signals is supplied to the power supplying induction coil 34.
Microcomputer positioning control substrates PB-1, PB-2, . . . PB-n are mounted on the moving elements 4-1, 4-2, . . . 4- detecting a temperature of the holding member portion on which the moving elements are mounted and a correction control panel 61 are provided to realize the optimum patterning and positioning control by inputting temperature data S30 and a correction control signal S31 to the moving element positioning control computer 23 to give commands of correction values for the correction of position necessary due to temperature changes and for the adjustment necessary for each individual moving element to the aforementioned moving element correction functions.
FIG. 17 shows one example of a patterning unit constructed by attaching guide bars having a plurality of guide points to the moving elements moved and positioned as described above.
The basic structure of this embodiment is common with the embodiment shown in FIG. 3, so that the same components are designated with the same reference characters and their detailed explanation is omitted. The stator 18 of the linear pulse motor is assembled in the holding member 3 as a guide path and a plurality of moving elements 4 (4-1, 42, 4-2, 4-4, . . . ) are disposed on the same path so that poles 16a and 16b of each moving element face to the poles on both sides of the stator 18 provided in the holding member 3 as the guide path so as to be movable individually in the knitting width direction. Then, guide bars 70 (70-1, 70-2, 70-3 . . . ) on which a plurality of guide points 5 (5-1, 5-2, 5-3, . . . ) are provided are attached to the arbitrary, plural number of moving elements 4 by screw clamp means 71. Each guide point 5 is attached to a desirable position of the guide bar 70 by screws 72.
The moving elements 4 hold the guide bar 70 at least at two points close edge thereof for each guide bar, though it depends on a length of the guide bar 70, i.e. the knitting machine width. The moving elements 4 for holding the guide bar 70 at several points may be provided at adequate intervals depending on the length of the guide bar 70.
When the plurality of guide bars 70 are provided so as to be movable respectively by the moving elements by shifting the attaching positions in the direction of the front and back of the knitting machine, the displacement of each guide bar 70 may be individually controlled readily and quickly. Further, because the plurality of guide bars may be provided individually displaceable within the same guide path, a space margin is created for installing the guide bars and a structure in which a number of guide bars are provided in parallel may be readily realized.
It is noted that although the linear pulse motor driving circuit of the control unit and the moving element driving coils are connected by the signal cables 7 in FIG. 17, it is possible to remove the signal cables like those in FIGS. 9 and 12 to control by way of wireless control also in this embodiment. In this case, it is necessary to provide a unit in which an induction coil, a power receiving coil and current circuit, a driving circuit and a signal detecting circuit are assembled on the upper part of the moving element 4. Further, it is possible to implement the embodiment by disposing the poles of the moving element so as to face to the poles on one side of the stator as in FIG. 12.
Further, beside setting a number of pulses for moving one gage to one pulse, it may be set at a plurality of pulses also in this embodiment. It is also possible to mount a microcomputer on the moving element to position individually and to construct using two lines consisting of the power supplying induction line and the control signal induction line.
According to the inventive patterning unit of the warp knitting machine, a load placed on the moving element bearing is reduced and the thickness of the motor is reduced without reducing thrust of the linear pulse motor to be so that the number of the holding members, which corresponds to a thread guiding reed of the prior art machine, may be increased and the assemble thereof and adjustment, like an alignment with knitting needles, may be made readily.
Further, a leakage magnetic flux may be reduced and the thrust may be uniformed by arranging so that a magnetic path of the magnets runs in the same direction, so that guide points may be positioned stably.
Information for positioning the moving element is incorporated logically in the circuit as moving conditions of positioning control commands by the first control method of the inventive patterning unit, so that it becomes unnecessary to return to the reference position in restarting after power failure, step-out caused by various external noise sources is eliminated and no erroneous operation occurs. Further, it becomes possible to guarantee a short-time and reliable positioning by controlling the exciting position, exciting current and excitation switching timing by parameters given above.
Further, because the restriction on the moving range of the moving element is eliminated in creating a pattern by removing the signal cables connected with the moving elements and by positioning the moving elements by way of wireless control, pattern yarns may be run freely and fully in the knitting machine width, allowing knitting of lace fabrics having a new pattern structure which has been impossible in the past. Further, it allows the machine to be miniaturized, its weight to be reduced and high thrust to be realized, thus contributing to the increase of the speed.
Further, the moving element may be positioned without being restricted by an amount of information of the control signals and the load of the moving element positioning control computer may be reduced, putting the machine into more practical use, by mounting the microcomputer or the logic circuit on the moving element to reduce the control signals transmitted to the induction coil for the correction of the position and the like.
Thus, the patterning unit of the warp knitting machine and the control methods thereof of the present invention allow the problems (1) through (8) described above to be solved and readily enable the patterning and knitting carried out by controlling the move of the moving elements provided with the guide points by utilizing the linear pulse motor. | The present invention provides a patterning unit of a warp knitting machine having a holding member with a stator of a linear pulse motor disposed thereon and a plurality of moving elements provided at arbitrary intervals on the holding member with parts of the moving elements being constructed as guide points. A control method increases reliability and accuracy of positioning the moving elements and eliminates erroneous operation such as step-out by providing a position sensor and by exciting movement of the moving elements on a step by step basis based upon positions of the moving elements sensed by the position sensor. The control method includes providing the moving elements each with a linear motor coil assembly for functioning in conjunction with the stator to move the moving elements along the holding member. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to a beater mill in the grinding chamber of which there rotates a beater rotor which is fitted on its circumference with beater tools and is surrounded by a cylindrical grinding surface adjoined by a coaxial centrifugal classifier. Such beater mills, also referred to as classifier mills, are known in numerous variations having the common feature that the grinding chamber and classifying chamber are mutually separated by a partition, with the oversize particles classified out in the classifying chamber by purposely influencing the classifying air flow being recirculated once again into the grinding chamber.
German Patent 2,444,657, for example, describes such a classifier mill, in which there is arranged between the grinding chamber and classifying chamber a stationary separating disk which forms with the cylindrical grinding surface an annular gap through which the mixture of ground material and air enters the classifying chamber. A spiral flow which produces the classifying effect is imparted there to the flow of ground material by adjustable guide vanes. The oversize particles classified out in this way is recirculated into the grinding chamber through openings that are provided in the separating disk.
German Patent 3,203,324 discloses a classifier mill which is simpler than this and in which only one solid circular disk, which can be adjusted in the axial direction and whose outer rim terminates in the radial direction in front of the beater plates of the beater rotor, is arranged in the region of the housing end wall on the outlet side. The large annular gap created in this way between the disk rim and the housing wall is intended to effect the recirculation into the grinding zone of the oversize particles leaving the grinding surface, it being the case that in the gap which is formed by said circular disk and the housing end wall on the outlet side, the width of which can be adjusted by axial displacement of the circular disk, the fine particles flow off to the central outlet nozzle, and this is additionally supported by stationary guide vanes.
However, as German Patent 1,507,466 shows, the partition between the grinding chamber and classifying chamber can also consist of a circular disk which rotates in common with the beater rotor and whose outer rim forms with the grinding surface an annular gap whose width can be adjusted in order purposely to influence the flow relationships in the classifying chamber.
As may be seen from German Patent 2,122,856, the partition between the grinding chamber and classifying chamber can also be formed by the rotor disk itself, which carries the beater plates and is consequently provided with openings for recirculating into the grinding zone of the oversize particles precipitated in the classifying chamber. The classifying effect is produced there by stationary guide vanes which cooperate with rotating classifier vanes.
It is therefore a common feature of all known classifier mills to recirculate once again into the grinding zone the oversize classified out in the classifying chamber, and this requires quite complicated structural measures, as the cited prior art demonstrates.
SUMMARY OF THE INVENTION
Consequently, it is the object of the invention to integrate the classifying process into the grinding process with a low structural outlay, that is to say not to discharge the material particles from the grinding zone until they have reached the desired degree of fineness.
According to the invention, this object is achieved when the centrifugal classifier is integrated into the grinding zone in such a way that at least one retaining ring whose retaining rim height determines the classifying effect bears against the outlet-side end face of the cylindrical grinding surface.
The retaining ring, which according to the invention is arranged on the outlet-side end face of the grinding surface, denies the flow of ground material moving on a helical path through the grinding gap free outlet from the grinding zone, the retaining ring imparting to said flow a spiral path of motion, which tends radially inwards and resembles an eddy sink whose initial velocity component in the circumferential direction is virtually equal to the circumferential velocity of the beater rotor. As is known for spiral air classifiers, a state of equilibrium is set up on this spiral path of motion between the centrifugal forces, which act on the material particles and are directed radially outwards towards the grinding surface, and the drag forces which tend radially inward toward the central retaining ring outlet. Since, as is known, the drag forces gradually exceed the centrifugal forces as communication progresses, that is to say with decreasing particle size, the spiral flow imparted by the retaining ring discharges from the grinding zone only those particles which have reached a sufficient degree of fineness which, naturally, becomes finer the longer the spiral flow acts on the material particles, that is to say the larger the retaining rim height of the retaining ring. Coarser particles are thus held in the region of the grinding surface until they have reached this degree of fineness. The retaining ring therefore represents, as it were, the outer axial boundary wall of a centrifugal classifier which is integrated into the grinding zone and in which a spiral classifying flow is set up automatically as consequence of the flow of the material to be ground arriving spirally at the retaining ring.
It is possible for a plurality of retaining rings with different retaining rim heights to be set optionally one after another on the outlet-side end wall of the grinding surface, as a result of which the degree of communication can be influenced in steps. In mills whose design parameters and operating parameters are carefully matched by means of tests to the ground material to be processed, this stepwise adjustability of the degree of communication is entirely sufficient in many cases, in particular where robustness of design, ease of replaceability, insensitivity to wear, and simple and cost-effective spares holding are of decisive economic importance.
It is also possible for the retaining rings not located in the operating position to be held in a position of readiness on the inside of the mill housing so that the degree of communication can also be influenced during operation. For this purpose, the retaining rings are additionally provided with control elements which can be actuated outside the mill housing.
In particular for the production of the retaining rings, it is favorable when they are constructed to be plane parallel with the radial plane perpendicular to the axis.
The invention can be particularly advantageously realized in twin-flow beater mills, such as described, for example, in German Patent 1,905,286.
BRIEF DESCRIPTION OF THE APPLICATION DRAWING
The invention is represented in more detail in the application drawing which illustrates, by way of example, a twin-flow beater mill and in which:
FIG. 1 is an axial cross-sectional view of a twin-flow beater mill equipped according to the invention; and
FIGS. 2 and 3 show details on an enlarged scale in the region of the grinding surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
On its front end face, the mill housing 1 has a door 2 that can swivel out and in which an inlet port 3, which merges inside the mill housing 1 into a widening distributor cone 4, is provided for the material to be ground which is fed in an essentially pneumatic fashion.
Supported in a floating mount in the mill housing 1 on the rear housing wall is a beater rotor 5. It consists of a rotor hub 6 which is connected in a rotationally fixed manner to the drive shaft 7. Fixed to the rotor hub 6 is a hub plate 8 which is connected to an annular cover plate 9 by beater plates 10 arranged on the rotor circumference. The outer edges of the beater plates 10 cooperate with a stationary cylindrical grinding surface 11 which concentrically surrounds the beater rotor 5 with a grinding gap a (FIG. 2).
The hub plate 8 forms with the cover plate 9 a guide duct 12, shaped like an annular disk, which has an axial width b and in whose central region the distributor cone 4 opens into the beater rotor 5. In its peripheral region, the guide duct 12 opens out onto the axial center of the grinding surface 11, which is provided with strips or ribs 13 (FIG. 2) that are uniformly distributed over its circumference.
The conveyance of material in the guide duct 12 is additionally further supported by a distribution disk 14 connected to the rotor hub 6.
Bearing against each end face of the grinding surface 11 in each case is a retaining ring 15 which extends axially inwardly and which together form by means of their retaining rim height h (FIG. 3) the lateral, radially outer boundary walls of centrifugal classifiers 16 integrated into the grinding zone. The axially inner walls of the classifying chamber are defined by the plates 8 and 9. The central outlet openings 17 of the centrifugal classifiers are bound by the retaining rim 18 of the two retaining rings 15. Two further retaining rings 15' and 15" with larger retaining rim heights h' and h" are held in a position of readiness in each case on the inside of the end and rear housing walls. All the retaining rings 15, 15' and 15" are provided with a plurality of control elements 19, 19' and 19", respectively, distributed on the circumference, by means of which they can be adjusted in the axial direction from outside and can be locked both in their operating position and in their position of readiness on webs 20 and 21 located outside the mill housing 1.
FIG. 3 shows on an enlarged scale three retaining rings 15, 15' and 15" located in the operating position, and two retaining rings 15 and 15' are illustrated in the operating position in FIG. 2. In both instances, a greater fineness of material is achieved.
Located on both sides of the classifying chambers 16 are annular discharge chambers 22 which are spatially connected to the common ate 23.
The material to be ground is conveyed in inlet port 3 in a pneumatically supported fashion by the air flow produced by the beater rotor 5 into the mill housing 1 where the material passes through the distributor cone 4 into the central re beater rotor 5. There, it impinges on the distribution disk 14, which in addition to the pneumatically effected inflow speed, also further imparts mechanical motive impulses to the material particles and in this way supports the distributing function of the guide duct 12, which has the effect of uniformly loading the grinding surface 11 all round.
The beater plates 10 impart to the material to be ground on the grinding surface 11 a speed in the circumferential direction which, depending on the width a of the grinding gap, is somewhat lower than the circumferential speed of the beater rotor 5. The pneumatic transport of material in the axial direction is superimposed on this circumferential movement of the material to be ground, so as to produce a helical path of motion as a result. Consequently, starting from the axial center of the grinding surface 11, the mixture of the material to be ground and air moves on two oppositely directed helical paths to the two rim zones of the grinding surface 11, where it is denied free outlet from the grinding zone by the retaining rings 15 arranged on both sides of the grinding surface 11. Consequently, the helical path of motion of the mixture of the material to be ground and air merges here into a spiral path of motion tending radially inwards. As is known, material particles that are entrained by the air flow in such spiral paths are acted upon by centrifugal forces which tend to force them radially outwards, that is to say back once again onto the grinding surface. However, these centrifugal forces are opposed by drag forces which, for their part, tend to convey the particles radially inwards, that is to say to the outlet openings 17 formed by the retaining rim 18 of the retaining rings 15. The minimum fineness of material at which the material particles can leave the grinding zone is defined by the state of equilibrium set up on said spiral paths between the centrifugal forces on the one hand, and the drag forces on the other hand.
As illustrated in FIGS. 2 and 3, the degree of fineness of the material to be ground can be increased in steps by setting additional retaining rings 15' and 15" with larger retaining rim heights h' and h", respectively, on the grinding surface 11.
After passing the retaining rim 18 of the retaining rings 15, 15' and 15", the material particles flow off into the lateral annular chambers 22 of the mill housing 1, from where they pass into the common material outlet 23. | The invention relates to beater mills in the grinding chamber of which there rotates a beater rotor which is fitted on its circumference with beater tools and is surrounded by a cylindrical grinding surface adjoined by a coaxial centrifugal classifier. The centrifugal classifier is variably defined by retaining rings having different retaining rim heights, the rings bearing against the outlet-side end faces of the grinding surface so as to determine the classifying effects. | 1 |
BACKGROUND OF THE INVENTION
[0001] a. Field of the Invention
[0002] The present invention is directed toward abrasion resistant sleeves and sleeve assemblies, and toward methods of using them, for a variety of applications including the protection of hydraulic or pneumatic lines, electric wiring, or other critical components exposed to abrasion. More specifically, it relates to single-walled abrasion alert sleeves that may be used individually or embedded one inside another, wherein at least one sleeve is woven from different colored yarns or threads, including protective yarns or threads of a first, base color and indicator yarns or threads of a second, contrasting color.
[0003] b. Background Art
[0004] It is well known that hydraulic and pneumatic lines on pieces of heavy equipment and other machinery move or shift during operation. For example, as hydraulic or pneumatic lines are pressurized and depressurized, they may move laterally or longitudinally, and they may expand or swell and contract or shrink. As the lines move, they may bump against, rub against, or abrade adjacent lines or adjacent portions of the equipment or machinery. The bumping, rubbing, or abrading contact between the lines and each other, or the lines and portions of the equipment or machinery, can unduly shorten the life of the lines. Since worn-out hydraulic lines lead to equipment downtime, which itself may be costly to the equipment owner, and since the hydraulic lines themselves may be expensive to replace, people have sought ways to increase the life of hydraulic lines using various techniques, including more careful placement or routing of the hydraulic lines and various techniques for protecting or shielding the hydraulic lines themselves.
[0005] One of these existing techniques for extending the life of hydraulic lines is to place a protective sleeve around the hydraulic lines themselves for abrasion resistance. These prior art tubular webbing structures, which slide over hydraulic lines, have been constructed from industrial fabrics having threads or yarns of a single color. Although such sleeves are able to protect the hydraulic lines, additional time and effort is required to closely monitor these single-color sleeves for excessive wear so that the sleeves may be replaced before they cease to perform their protective function.
[0006] Multi-walled devices also exist that could be used to protect hydraulic lines. In these latter devices, each single-walled sleeve forming the multi-walled device is constructed from a single color of thread. A multi-walled device may be constructed from one single-walled sleeve made entirely from a first color of thread, and a second single-walled sleeve made entirely from a second color of thread that is different from the first color. Multi-walled sleeves are, however, relatively expensive to make and install. The sleeves that are used to protect the hydraulic lines should be less expensive than the hydraulic lines themselves, and they should be easy to install.
[0007] Thus, there remains a need for a protective device to safeguard hydraulic lines on heavy equipment or other machinery that is relatively inexpensive to manufacture and that facilitates easy monitoring of wear on the protective device itself.
BRIEF SUMMARY OF THE INVENTION
[0008] It is desirable to be able to protect hydraulic lines (and other components that may be subject to abrasion like pneumatic lines, and electrical leads) with a protection device that not only protects the hydraulic lines, but also readily alerts those who use or maintain the equipment or machinery when the protection device is in need of repair or replacement. Accordingly, it is an object of the disclosed invention to provide an improved abrasion protection device.
[0009] The invention comprises a single-walled abrasion alert sleeve wherein the wall is woven from threads or yarns of different colors. For example, an abrasion alert sleeve according to the instant invention may include protective threads or yarns of a base color (e.g., black) interwoven with indicator or warning threads or yarns of a contrasting color (e.g., red or yellow). The protective threads substantially shield or hide the indicator threads when the abrasion alert sleeve is new. As the abrasion alert sleeve protects the hydraulic lines, the protective threads are worn away, and more and more indicator threads become visible over time. In other words, when the protective threads become worn or abraded, the indicator threads of a contrasting color are revealed. The indicator threads thus visually indicate in a relatively easily observable way when the abrasion alert sleeve may fail to protect the hydraulic line and needs to be removed from service. In addition to standalone sleeves, the present invention also comprise abrasion alert sleeve assemblies comprising at least one of these single-walled standalone abrasion alert sleeves used in combination with one or more additional sleeves.
[0010] In one form, the present invention comprises an abrasion resistant device for the protection of a component that would otherwise be exposed to direct abrasion. In this form, the device comprises a single-walled, tubular abrasion alert sleeve woven from longitudinally-extending, protective yarns of a base color interwoven with laterally-extending, indicator yarns of a contrasting color, wherein the base color is different from the contrasting color, and wherein the protective yarns substantially conceal the indicator yarns from view.
[0011] In another form, the present invention is an abrasion alert jacket comprising a single-walled, tubular structure having a longitudinal axis and constructed from threads having at least two contrasting colors to facilitate use of the abrasion alert jacket as a wear indicator. These threads include a first plurality of longitudinally-extending protective threads, the protective threads being of a dominant color and being arranged substantially parallel to the jacket longitudinal axis. The threads also include a second plurality of indicator threads extending substantially perpendicularly to the first plurality of longitudinally-extending protective threads, the indicator threads being of an indicator color and being interwoven with the first plurality of longitudinally-extending protective threads so as to be substantially shielded by and hidden among the first plurality of longitudinally-extending protective threads when the abrasion alert jacket is unworn. The indicator threads are adapted to become visible as the protective threads become worn.
[0012] In yet another form, the present invention comprises a multi-tube, sleeve assembly of concentrically-embedded sleeves for the protection of a critical component that would otherwise be directly exposed to abrasion. In this form, the sleeve assembly comprising an outermost, single-walled sleeve circumscribing a first interior region, the outermost sleeve being constructed from protective threads of a base color and indicator threads of a first contrasting color. The sleeve assembly also comprises an innermost, single-walled sleeve circumscribing a second interior region, the innermost sleeve being located inside the first interior region, and the innermost sleeve being constructed from protective threads of the base color and indicator threads of a second contrasting color, wherein the first contrasting color is different from the second contrasting color, and wherein the critical component resides within the second interior region.
[0013] In still another form, the present invention comprises an abrasion alert sleeve assembly having a-tube-inside-a-tube construction. In this form, the sleeve assembly comprises a first, single-walled, abrasion alert sleeve having a first longitudinal axis and constructed from threads of at least two contrasting colors to facilitate use of the first abrasion alert sleeve as a first wear indicator. The threads of the first abrasion alert sleeve include a first plurality of longitudinally-extending protective threads, the first plurality of protective threads being of a first base color and being arranged substantially parallel to the first longitudinal axis; and a second plurality of indicator threads extending substantially perpendicularly to the first plurality of protective threads, the second plurality of indicator threads being of a first indicator color and being interwoven with the first plurality of protective threads so as to be substantially shielded by and hidden among the first plurality of protective threads when the first abrasion alert sleeve is unworn, and wherein the second plurality of indicator threads are adapted to become more clearly visible as the first plurality of protective threads become worn. In this form, the sleeve assembly further comprises a second, single-walled, abrasion alert sleeve having a second longitudinal axis and constructed from threads having at least two contrasting colors to facilitate use of the second abrasion alert sleeve as a second wear indicator, wherein the second abrasion alert sleeve is embedded within the first abrasion alert sleeve. The threads of the second abrasion alert sleeve include a third plurality of longitudinally-extending protective threads, the third plurality of protective threads being of a second base color and being arranged substantially parallel to the second longitudinal axis; and a fourth plurality of indicator threads extending substantially perpendicularly to the third plurality of protective threads, the fourth plurality of indicator threads being of a second indicator color and being interwoven with the third plurality of protective threads so as to be substantially shielded by and hidden among the third plurality of protective threads when the second abrasion alert sleeve is unworn, and wherein the fourth plurality of indicator threads are adapted to become more clearly visible as the third plurality of protective threads become worn. The first base color may be the same as the second base color.
[0014] In another form, the present invention comprises a multi-walled, abrasion resistant sleeve assembly constructed from a plurality of embedded, single-walled, abrasion alert sleeves including an outermost, single-walled sleeve woven from threads of at least two contrasting colors; and an innermost, single-walled sleeve woven from threads of a single color. This form of the present invention may further comprise at least one intermediate sleeve woven from threads of at least two contrasting colors and inserted between the outermost sleeve and the innermost sleeve. The thicknesses of the sleeves may vary in any desired way, or the sleeves may all have the same thickness.
[0015] The present invention also comprises a method of protecting a critical component in an abusive environment using single-walled, multi-colored, abrasion alert sleeves. In this form, the method comprises the steps of (a) installing a first abrasion alert sleeve over the critical component, the first abrasion alert sleeve comprising a first plurality of protective threads of a first base color and a first plurality of indicator threads of a first warning color, wherein the first plurality of protective threads are woven with the first plurality of indicator threads so as to substantially hide the first plurality of indicator threads; (b) monitoring the first abrasion alert sleeve for the appearance of the first warning color; and (c) removing the first abrasion alert sleeve and installing a replacement abrasion alert sleeve upon the appearance of a substantial amount of the first warning color. The first base color may be, for example, black, and the first warning color may be, for example, yellow or red.
[0016] In yet another form, the present invention comprises a method of protecting a critical component in an abusive environment using an abrasion alert sleeve assembly comprising a plurality of abrasion alert sleeves. This method comprises the steps of (a) installing a first abrasion alert sleeve assembly over the critical component, the first abrasion alert sleeve assembly comprising (1) an outermost, single-walled abrasion alert sleeve, the outermost abrasion alert sleeve comprising a first plurality of protective threads of a first base color and a second plurality of indicator threads of a warning color, wherein the first plurality of protective threads are woven with the second plurality of indicator threads so as to substantially hide the warning color; and (2) an innermost, single-walled abrasion alert sleeve, the innermost abrasion alert sleeve comprising a third plurality of threads of a second base color; (b) monitoring the first abrasion alert sleeve assembly for the appearance of the warning color; and (c) removing and replacing the outermost abrasion alert sleeve upon the appearance of a substantial amount of the warning color.
[0017] In still another form, the present invention comprises a method of protecting a critical component in an abusive environment using an abrasion alert sleeve assembly comprising a plurality of multi-colored, abrasion alert sleeves. This method comprising the steps of (a) installing a first abrasion alert sleeve assembly over the critical component, the first abrasion alert sleeve assembly comprising (1) an outermost, single-walled abrasion alert sleeve, the outermost abrasion alert sleeve comprising a first plurality of protective threads of a first base color and a first plurality of indicator threads of a first warning color, wherein the first plurality of protective threads are woven with the first plurality of indicator threads so as to substantially hide the first plurality of indicator threads; and (2) an innermost, single-walled abrasion alert sleeve, the innermost abrasion alert sleeve comprising a second plurality of protective threads of a second base color and a second plurality of indicator threads of a second warning color, wherein the second plurality of protective threads are woven with the second plurality of indicator threads so as to substantially hide the second plurality of indicator threads; (b) monitoring the first abrasion alert sleeve assembly for the appearance of the first warning color; (c) ordering a replacement sleeve assembly upon the appearance of a substantial amount of the first warning color; (d) monitoring the first abrasion alert sleeve assembly for the appearance of the second warning color; and (e) removing the first sleeve assembly and installing the replacement sleeve assembly upon the appearance of a substantial amount of the second warning color.
[0018] In another form, the present invention comprises a method of controlling inventory of abrasion resistant sleeve assemblies and ensuring timely replacement of worn abrasion resistant sleeve assemblies. This method comprising the steps of (a) installing an abrasion resistant sleeve assembly, the abrasion resistant sleeve assembly comprising embedded abrasion alert sleeves, including (1) an outermost, order-now, abrasion alert sleeve, the outermost abrasion alert sleeve comprising a first plurality of protective threads of a first base color and a first plurality of indicator threads of a first warning color, wherein the first plurality of protective threads are woven with the first plurality of indicator threads so as to substantially hide the first plurality of indicator threads; (2) an innermost, replace-now, abrasion alert sleeve, the innermost abrasion alert sleeve comprising a second plurality of protective threads of a second base color and a second plurality of indicator threads of a second warning color, wherein the second plurality of protective threads are woven with the second plurality of indicator threads so as to substantially hide the second plurality of indicator threads; (b) monitoring the abrasion resistant sleeve assembly during use for evidence of wear manifested as abraded and broken protective threads thereby revealing the warning threads; (c) ordering a new abrasion resistant sleeve assembly upon the appearance of the first warning color; and (d) replacing the abrasion resistant sleeve assembly upon the appearance of the second warning color. The thickness of the abrasion alert sleeves comprising the abrasion resistant sleeve assembly may be adjusted to thereby adjust the protection afforded by the abrasion resistant sleeve assembly.
[0019] In yet another form, the present invention comprises a method of establishing service intervals for abrasion alert sleeve assemblies that are being used to protect a critical component. This method comprising the steps of (a) installing a first abrasion alert sleeve assembly over the critical component, the first abrasion alert sleeve assembly comprising a plurality of single-walled abrasion alert sleeves of approximately the same thickness, including (1) an outermost, single-walled abrasion alert sleeve, the outermost abrasion alert sleeve comprising a first plurality of protective threads of a first base color and a first plurality of indicator threads of a first warning color, wherein the first plurality of protective threads are woven with the first plurality of indicator threads so as to substantially hide the first plurality of indicator threads; (2) a first intermediate, single-walled abrasion alert sleeve, the first intermediate abrasion alert sleeve comprising a second plurality of protective threads of a second base color and a second plurality of indicator threads of a second warning color, wherein the second plurality of protective threads are woven with the second plurality of indicator threads so as to substantially hide the second plurality of indicator threads; (3) a second intermediate, single-walled abrasion alert sleeve, the second intermediate abrasion alert sleeve comprising a third plurality of protective threads of a third base color and a third plurality of indicator threads of a third warning color, wherein the third plurality of protective threads are woven with the third plurality of indicator threads so as to substantially hide the third plurality of indicator threads; and (4) an innermost, single-walled abrasion alert sleeve, the innermost abrasion alert sleeve comprising a fourth plurality of protective threads of a fourth base color and a fourth plurality of indicator threads of a fourth warning color, wherein the fourth plurality of protective threads are woven with the fourth plurality of indicator threads so as to substantially hide the fourth plurality of indicator threads; (b) assessing a wear state of the first abrasion alert sleeve assembly by monitoring the first abrasion alert sleeve assembly for the appearance of at least one of the first warning color, the second warning color, the third warning color, and the fourth warning color; (c) estimating a life expectancy for the first abrasion alert sleeve assembly by monitoring how long it takes for the first warning color to initially appear; (d) adjusting the estimated life expectancy based upon how long it takes for the second and third warning colors to initially appear; (e) ordering a replacement sleeve assembly based upon the estimated life expectancy; and (f) installing the replacement sleeve assembly upon the initial appearance of the fourth warning color.
[0020] The protection afforded by an abrasion alert sleeve assembly according to the present invention may be adjusted or controlled by increasing or decreasing the number of embedded sleeves comprising the abrasion alert sleeve assembly. The protection afforded by the abrasion alert sleeve assembly may also be adjusted or controlled by changing the thickness of the abrasion alert sleeves comprising the abrasion alert sleeve assembly relative to each other.
[0021] The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is an isometric, fragmentary view of an abrasion alert sleeve according to a first embodiment of the present invention.
[0023] FIG. 2 is an enlarged, fragmentary view of the indicated region of FIG. 1 depicting further details of the woven material comprising the abrasion alert sleeve according to the first embodiment.
[0024] FIG. 3 is a further-enlarged, fragmentary, cross-sectional view of the material depicted in FIGS. 1 and 2 taken along line 3 - 3 of FIG. 2 .
[0025] FIG. 4 is a fragmentary view of the abrasion alert sleeve material depicted in FIGS. 1-3 , wherein some of the protective threads or yarns have been abraded or broken thereby revealing more of the indicator threads or yarns.
[0026] FIG. 5 depicts a second embodiment of the present invention, comprising an abrasion alert sleeve assembly formed from four embedded abrasion alert sleeves of similar thickness.
[0027] FIG. 6 depicts a third embodiment of the present invention, comprising an abrasion alert sleeve assembly formed from three embedded abrasion alert sleeves, wherein each sleeve has a somewhat different thickness from each of the other sleeves.
[0028] FIG. 7 is a fragmentary, isometric view of a piece of heavy equipment having hydraulic lines that are protected by abrasion alert sleeves according to the present invention.
[0029] FIG. 8 is an enlarged, fragmentary view of the circled portion of FIG. 7 and depicts a first hydraulic line moving or shifting under the influence of pressure fluctuations relative to a second hydraulic line.
[0030] FIG. 9 is a fragmentary view of a first hydraulic line moving under the influence of pressure fluctuations laterally into and out of bumping contact with a second hydraulic line.
[0031] FIG. 10 is a fragmentary, isometric view depicting abrasion resulting from rubbing contact between two adjacent hydraulic lines.
DETAILED DESCRIPTION OF THE INVENTION
[0032] A number of embodiments of single-walled, abrasion alert sleeves or jackets 10 (see, e.g., FIGS. 1-4 ) and abrasion alert assemblies 12 , 14 (see, e.g., FIGS. 5 and 6 ) comprising a plurality of single-walled abrasion alert sleeves or jackets are disclosed. An advantage of the instant invention over the prior art is that each single-walled abrasion alert sleeve 10 , whether used alone or in combination with other single-walled, abrasion alert sleeves, is constructed from threads having at least two different colors, which facilitates use of the abrasion alert sleeves as wear indicators. Thus, using the abrasion alert sleeves according to the present invention, it is possible to protect hydraulic or pneumatic lines while controlling inventory and ensuring timely replacement of worn sleeves.
[0033] Referring first to FIGS. 1-4 , an abrasion alert sleeve 10 according to a first embodiment of the present invention is described. FIG. 1 is a fragmentary, isometric view of a section of an abrasion alert sleeve or jacket 10 . The abrasion alert sleeve depicted in FIG. 1 comprises longitudinally-extending protective threads 16 that are parallel to a sleeve longitudinal axis 18 . Indicator threads 20 , which are more clearly visible in FIGS. 2-4 , are also present and extend substantially laterally of (i.e., substantially perpendicular to) the protective threads 16 . The orientation and placement of the protective threads or yarns 16 relative to the indicator threads or yarns 20 may be more easily seen in FIGS. 2-4 . In FIG. 2 , which is an enlarged view of the portion of the abrasion alert sleeve 10 circled in FIG. 1 , the relative position of the protective threads 16 and the indicator threads 20 may be more clearly seen. In particular, the protective threads, which are of a “base” or “dominant” color (e.g., black), substantially shield the interwoven indicator threads, which are of an “indicating” or “warning” color (e.g., yellow or red). The base color contrasts with the indicating color. The “base” or “dominant” color is the color that is most visible of the two contrasting colors in a new abrasion alert sleeve. In particular, the abrasion alert sleeve 10 , when new, appears to be of the base color since the indicator threads 20 are not easily seen until the protective threads 16 become worn.
[0034] FIG. 3 is a further-enlarged, fragmentary, cross-sectional view of the material depicted in FIGS. 1 and 2 taken along line 3 - 3 of FIG. 2 . FIGS. 2 and 3 clearly show how the weave pattern is established to hide the indicator threads 20 among the protective threads 16 . Although the indicator threads are slightly visible in a new abrasion alert sleeve, their visibility is hampered by the relative position of the indicator threads 20 relative to the protective threads 16 . As shown in FIG. 3 , the indicator threads are embedded among and shielded by the protective threads, which are woven around the indicator threads. In this configuration, the protective threads protect and substantially hide the indicator threads. Thus, when looking at a new abrasion alert sleeve 10 like the one depicted in FIG. 1 , the observer sees predominately the protective threads 16 having the base color, and the indicator threads 20 having the contrasting color are only partially visible. Since the protective threads shield the indicator threads as the abrasion alert sleeve comes into contact with an abrasive surface, the protective threads 16 absorb the brunt of the impact and wear.
[0035] FIG. 4 is a fragmentary view of the abrasion alert sleeve material depicted in FIGS. 1-3 , wherein some of the protective threads 22 have been abraded or broken thereby revealing more of the indicator threads. Thus, as the hydraulic lines are used, the protective threads 16 of the abrasion alert sleeve ultimately become abraded, damaged, or broken threads 22 . As more and more of the protective threads thus fail or wear out, the previously hidden indicator threads are revealed. As depicted in FIG. 4 , a number of protective threads have been worn through, thereby revealing relatively larger portions of the indicator threads than are visible in a new abrasion alert sleeve 10 . Since the indicator threads 20 are of a contrasting color relative to the protective threads 16 , as more and more of the indicator threads are revealed, it becomes readily apparent to an observer (e.g., someone who maintains the equipment) that the abrasion alert sleeve 10 has started to fail. As discussed further below, replacement abrasion alert sleeves may be ordered and installed based upon timing suggested by how predominant or visible indicator threads have become as the protective threads wear or abrade.
[0036] When using a single-walled abrasion alert sleeve 10 woven from different colored threads, such as the sleeves or jackets just described in connection with FIGS. 1-4 , the sleeves may be more quickly manufactured and may be manufactured at less cost than a multi-walled sleeve. If, however, it remains desirable to have a multi-walled sleeve, such a sleeve may be constructed from a plurality of single-walled abrasion alert sleeves 10 wherein each single-walled sleeve is woven from different colored threads, and/or wherein single-walled sleeves woven from different colored threads are interspersed with single-walled sleeves woven from a single color. FIG. 5 depicts a second embodiment of the present invention, comprising such an abrasion alert sleeve assembly 12 .
[0037] The abrasion alert sleeve assembly 12 depicted in FIG. 5 comprises four embedded abrasion alert sleeves, including an innermost sleeve 24 , an outermost sleeve 26 , a first intermediate sleeve 28 , and a second intermediate sleeve 30 . In the embodiment of the abrasion alert sleeve assembly 12 depicted in FIG. 5 , each of the sleeves 24 , 26 , 28 , 30 is approximately the same thickness as each of the other sleeves. A “pull thread” 32 or “leader yarn” is also visible in FIG. 5 . Since it may be difficult to insert a hydraulic or pneumatic line through the innermost sleeve 24 of the abrasion alert sleeve assembly 12 , the pull thread 32 may be placed in the innermost abrasion alert sleeve 24 during production of the abrasion alert sleeve assembly 12 . This pull thread 32 may be tied or otherwise affixed to the hydraulic or pneumatic hose to be protected to facilitate pulling the hose through the abrasion alert sleeve assembly 12 . Clearly, the abrasion alert sleeve assembly may comprise more or fewer abrasion alert sleeves than the four sleeves that are depicted in FIG. 5 .
[0038] FIG. 6 depicts a third embodiment of the present invention, comprising an abrasion alert sleeve assembly 14 constructed from three abrasion alert sleeves. In this embodiment, the abrasion alert sleeves comprising the abrasion alert sleeve assembly 14 each has a somewhat different thickness compared to each of the other sleeves. In FIG. 6 , the outermost sleeve 34 is the thinnest abrasion alert sleeve, the innermost sleeve 36 is somewhat thicker than the outermost sleeve, and the single intermediate sleeve 38 is the thickest of the three abrasion alert sleeves comprising the depicted abrasion alert sleeve assembly 14 . Clearly, the abrasion alert sleeve assembly may be constructed from more or fewer abrasion alert sleeves, and the thickness of each abrasion alert sleeve may be different from what is depicted in FIG. 6 . For example, the thickest abrasion alert sleeve of the sleeves comprising the abrasion alert sleeve assembly need not be the intermediate sleeve, and the thinnest abrasion alert sleeve need not be the outermost sleeve.
[0039] Through use of the abrasion alert sleeve assemblies 12 , 14 depicted in FIGS. 5 and 6 , a variety of different advantages may be obtained. These abrasion alert sleeve assemblies comprise multi-tube assemblies or concentric-tube assemblies with at least one tube or sleeve inside of another tube or sleeve. The outermost sleeve may be constructed from, for example, protective threads of a base color and indicator threads of a first contrasting color. The intermediate sleeve may be constructed from protective threads of the base color and indicator threads of a second contrasting color. In such a sample abrasion alert sleeve assembly comprising two embedded abrasion alert sleeves, including an outermost sleeve and an innermost sleeve, the appearance of the indicator threads of the first contrasting color may serve as notice that it is time to order a replacement abrasion alert sleeve assembly, but not yet time to replace the abrasion alert sleeve assembly that has begun to wear. Appearance of indicator threads of the second contrasting color (i.e., appearance of the indicator threads comprising part of the innermost abrasion alert sleeve) may serve as an indicator that it is time to replace the now more substantially worn abrasion alert sleeve assembly.
[0040] With the particular tube-inside-a-tube abrasion alert sleeve assembly described in the last paragraph, the user receives multiple benefits. In particular, as the outermost sleeve begins to wear, thereby revealing the indicator threads of the first contrasting color, the user may then place an order for a replacement abrasion alert sleeve assembly. Subsequently, when the indicator threads of the second contrasting color, which comprise part of the innermost abrasion alert sleeve, begin to be revealed in substantial quantities, the user may initiate replacement of the entire abrasion alert sleeve assembly. In the alternative, when the indicator threads of the outermost sleeve begin to be revealed as the protective threads of the outermost abrasion alert sleeve wear, the user may, at that time, replace the outermost abrasion alert sleeve before the innermost abrasion alert sleeve begins to wear. In this latter scenario, the innermost sleeve provides a “backup” or “safety” abrasion alert sleeve that preferably remains unabraded since the outermost sleeve is replaced as soon as it shows significant wear and before the innermost sleeve begins to wear or abrade. In this scenario, since the outermost abrasion alert sleeve is replaced when its indicator threads are sufficiently revealed, and the innermost sleeve is merely a backup protector of the hydraulic or pneumatic lines, the innermost sleeve may even comprise a less expensive sleeve comprised of threads of a single color. Alternatively, protective sleeves constructed from threads of a single color may be interspersed among or between abrasion alert sleeves having indicator threads with contrasting colors woven among protective threads of the base color. Each sleeve of an abrasion alert sleeve assembly may be tacked to one or more adjacent sleeves or left free to move relative to any adjacent sleeve or sleeves.
[0041] As shown in FIG. 6 , the ability to adjust the thickness of each sleeve 34 , 36 , 38 (e.g., by weaving more threads together or by using thicker threads), provides another option for protecting hydraulic or pneumatic lines. For example, if abrasion alert sleeve assemblies 14 take a long period of time to obtain after they are ordered, the relatively thin outermost sleeve 34 depicted in FIG. 6 could serve as an “order now” indicator. When the contrasting indicator threads of the outermost sleeve 34 are noticeably revealed due to abrasion of the protective threads, a replacement abrasion alert sleeve assembly 14 could be ordered. Since we are assuming in this scenario that it takes a relatively long time to manufacture and/or obtain a replacement abrasion alert sleeve assembly 14 , the relatively thinner outermost sleeve 34 results in early order placement and the relatively thicker intermediate sleeve 38 provides the main protection for the hydraulic or pneumatic lines until the replacement abrasion alert sleeve assembly 14 arrives. In this scenario, the innermost sleeve 36 may provide only backup protection in case the abrasion alert sleeve assembly 14 cannot be replaced before the intermediate sleeve 38 also fails.
[0042] Another advantage of abrasion alert sleeve assemblies comprising multiple multi-colored sleeves is that a user can estimate the approximate life of a sleeve assembly by monitoring how long it takes to wear through the individual layers of the abrasion alert sleeve assembly (i.e., by monitoring how long it takes for the indicator threads of individual layers to appear). This “monitoring” is easily done since the indicator threads may be different colored threads from one embedded sleeve to the next. For example, a sleeve assembly could comprise four tubular sleeves placed one inside the other. FIG. 5 depicts such a sample of an abrasion alert sleeve assembly 12 . Each of these four embedded, abrasion alert sleeves 24 , 26 , 28 , 30 could comprise indicator threads of a different color. If one were to monitor how long it takes to wear through the outermost sleeve 26 , it would then be possible to estimate that the entire sleeve assembly 12 would need to be replaced in approximately three times the number of days it took to wear through the first of the four embedded sleeves, assuming the sleeves are of the same thickness. Using that information, a purchaser of replacement sleeve assemblies 12 could better predict when it would be necessary to have a replacement sleeve assembly on hand since one could rapidly assess the “wear state” of the entire sleeve assembly by checking for how many colors and what colors are visible on an installed sleeve assembly.
[0043] FIG. 7 is a fragmentary, isometric view of a piece of equipment 40 (i.e., a forklift) having a plurality of hydraulic lines 42 operatively connected to a lifting mechanism 44 of the equipment. As depicted in FIG. 8 , which is an enlarged, fragmentary view of the circled region of FIG. 7 , each hydraulic line 42 is protected by an abrasion alert sleeve 10 or an abrasion alert sleeve assembly 12 , 14 according to the present invention. As also shown in FIG. 8 , the hydraulic lines move or shift relative to each other and to the equipment to which they are attached as the pressure in the hydraulic lines fluctuates. In particular, FIG. 8 depicts an active hydraulic line 46 next to an inactive hydraulic line 48 , and an arrow 50 represents movement of the active hydraulic line 46 , 46 ′ relative to the inactive hydraulic line 48 . The active hydraulic line is shown in solid lines in a first position 46 relative to the inactive hydraulic line 48 , and the active hydraulic line is shown in phantom in a second position 46 ′ relative to the inactive hydraulic line 48 .
[0044] FIG. 9 is similar to FIG. 8 and again depicts an active hydraulic line 46 , 46 ′ adjacent to an inactive hydraulic line 48 . The active hydraulic line is moving laterally (i.e., side-to-side) under the influence of pressure fluctuations. In particular, the active hydraulic line is depicted in solid lines in a first position 46 relative to the inactive hydraulic line 48 , and the active hydraulic line is depicted in phantom in a second position 46 ′ relative to the inactive hydraulic line 48 . In this figure, movement of the active hydraulic line relative to the inactive hydraulic line is represented by the arrows 52 . As the active hydraulic line moves back and forth in the direction of the arrows between the first position 46 (solid lines) and the second position 46 ′ (phantom lines), the active hydraulic line comes into and out of “bumping” contact with the inactive hydraulic line 48 . During this bumping contact, the abrasion alert sleeves 10 surrounding the hydraulic lines provide protection for the hydraulic lines.
[0045] FIG. 10 is similar to FIGS. 8 and 9 , but is a fragmentary, isometric view of two hydraulic lines 46 , 48 , each protected by an abrasion alert sleeve 10 , in “rubbing” contact with each other. As depicted in FIG. 10 , movement of the active hydraulic line 46 is represented by a two-headed arrow 54 . FIG. 10 shows a mildly-abraded area 56 wherein the protective threads 16 (e.g., FIG. 4 ) have begun to wear. FIG. 10 also shows a heavily-abraded area 58 , wherein more of the protective threads have failed, thereby revealing even more of the contrasting indicator threads 20 (e.g., FIG. 4 ) (represented schematically by the different cross-hatching in this figure). Clearly, the abrasion alert sleeves and sleeve assemblies according to the present invention not only protect the hydraulic lines from each other (as shown in FIG. 10 ), but also protect the hydraulic lines from wear caused by rubbing against adjacent parts of the equipment or machinery with which the hydraulic lines 42 are associated.
[0046] As alluded to above in the discussion of FIGS. 5 and 6 , the present invention also comprises a method of controlling inventory using the contrasting colors of an abrasion alert sleeve 10 and/or the embedded sleeves of an abrasion alert sleeve assembly 12 , 14 , wherein each sleeve of the sleeve assembly has indicator threads of a color that is different from the indicator threads in the other embedded sleeves of the sleeve assembly. For example, an abrasion alert sleeve assembly may comprise an outermost sleeve having blue indicator threads. When the blue indicator threads begin to appear, the person in charge of supplies could order a new abrasion alert sleeve assembly and time the arrival of that new abrasion alert sleeve assembly to be close to the time when an abrasion alert sleeve assembly needs to be replaced. This outermost sleeve of the abrasion alert sleeve assembly thus serves as an “order now” indicator. The innermost abrasion alert sleeve of the abrasion alert sleeve assembly may include indicator threads that are, for example, red. When the red indicator threads begin to be revealed, this could indicate that it is time to replace the abrasion alert sleeve assembly. The innermost abrasion alert sleeve would thus serve as a “replace now” indicator. This technique helps reduce excess inventory since replacement abrasion alert sleeve assemblies are not ordered until their need is imminent (i.e., when the blue threads begin to appear in the above example).
[0047] Although a number of embodiments of this invention have been described with a certain degree of particularity, those skilled in this art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. For example, although two abrasion alert sleeve assemblies are depicted in FIGS. 5 and 6 , abrasion alert sleeve assemblies comprising more or fewer sleeves, or sleeves having different thicknesses or configurations from those depicted, could be made. An important aspect of the abrasion alert sleeve assemblies according to the present invention is that they comprise at least one abrasion alert sleeve constructed from protective threads of a base color and indicator threads of a contrasting color. The above description refers primarily to hydraulic lines, but the devices described herein are equally applicable to pneumatic or other hose assemblies that experience potential abrasion during use. It should be noted that the abrasion alert sleeves and the abrasion alert sleeve assemblies described above are not designed to prevent rupture of hydraulic or pneumatic lines. All dimensional references are only used for identification purposes to aide the reader's understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims. | Abrasion alert sleeves and sleeve assemblies, and methods of using them, are disclosed. The abrasion alert sleeves include protective threads and indicator or warning threads. The protective threads are placed so as to substantially shield or hide the indicator threads unless and until the protective threads become abraded, at which time, the indicator threads become more visible. The abrasion alert sleeves and sleeve assemblies thus provide protection for hydraulic or pneumatic lines, while enabling relatively easy detection of abrasion alert sleeves or sleeve assemblies that need to be replaced due to wear. Various methods for implementing inventory control procedures and replacement procedures are also disclosed. | 5 |
TECHNICAL FIELD
This invention relates to communication switching, and in particular, to an activity transfer of a wireless handset from one wireless base station to another.
BACKGROUND OF THE INVENTION
In prior art wireless communication systems, the implementation for performing an activity transfer such as a handoff was as follows. When the cell-site receiver handling a call from a wireless telephone noticed that the received signal strength from the wireless telephone fell below a predetermined threshold value, the cell site asked a system controller controlling the overall wireless system to determine if a neighboring cell site was receiving the wireless telephone's signal at an adequate signal strength. The system controller in response to the current cell site inquiry sent messages to the neighboring cell sites with a handoff request. Each neighboring cell site scanned for the signal from the wireless telephone on the channel specified by the system controller. When one of the neighboring cell sites reported an adequate signal level to the system controller, the system controller implemented the handoff. This method of determining neighboring cell-sites performs well for conventional cellular systems in which the number of cell sites is reasonably small, and each cell site covers a large geographical region. Because each cell site covers a large geographical region, the number of handoffs that occur is reasonably low.
Whereas this technique of performing handoff has worked well for large cellular telephone systems, in large personal communication systems (PCS), the technique has not been as effective in all situations. The reason is that within a large PCS system, there are potentially hundreds of cell sites each having an extremely small geographical area. In addition, PCS system uses high transmission frequencies and low transmission power resulting in frequent handoffs. Another problem in certain large PCS systems is that they are in office buildings where there are many obstructions, also the physical destination of the wireless handset's user plays a important role in the handoff process. For example, if the handset is moving down a particular hallway in a given direction, then the handoff should be to the next cell site that can handle that hallway in that direction. Note, because of the power and transmission frequencies or obstructions this desired cell site may not be the closest geographical cell site to the hallway. Because of the need to do frequent handoffs for each individual active wireless telephone and the extremely large number of cell sites, the system controller experiences a large real time processing load from performing handoffs. In addition, the PCS system is distinguished from a cellular telephone system in that a cellular telephone system may have each cell site surrounded by only three other cell sites; whereas, the PCS system normally will have each cell site having seven to 32 possible neighbors that may be candidates for a handoff. Further, because of the large number of cell sites in a PCS system, it is very difficult for a system administrator to hand specify for each cell site what are the possible candidate cell sites for handoffs let alone determine the best candidate cell sites based on user traffic patterns. In addition, PCS systems are characterized by constant addition and removal of cell sites.
It is clear that a problem exists with the present method for doing handoffs in large PCS systems since requiring each of the neighboring cell sites to monitor the wireless handset and report back to the system controller places a large real time processing burden on the system controller.
SUMMARY OF THE INVENTION
The foregoing problem is solved, and a technical advance is achieved by an apparatus and method in which a system controller uses dynamic learning techniques to determine a subset of neighboring cell sites to which an activity transfer should be attempted. Advantageously, an activity transfer can be a handoff or registration. This dynamic learning for each cell site can be done for all users or may be customized for each individual user. Advantageously, the neighboring cell sites that should be chosen for an activity transfer are specified for each cell site. The specified neighboring cell sites are determined by the dynamic learning process. In a first embodiment, the dynamic learning is accomplished by accumulating statistical data that defines the average call duration of each of the selected neighboring sites after an activity transfer to each. Advantageously, this average duration can include the total call duration for two subsequent activity transfers. In addition to choosing from the subset of known neighboring cell sites, the system controller randomly chooses a small subset of the remaining cell sites in the system as potential activity transfer target cell sites in order to learn new neighboring cell sites.
In a second embodiment, the dynamic learning is accomplished by accumulating statistical data that defines the maximum transmission power from the base station to which a handset was transferred. An average maximum power number is maintained for each cell for each of the cells to which that cell has done an activity transfer. When an activity transfer must be done, the target having the highest average maximum power number is selected.
In a third embodiment, the duration of the low power transmission level of the base station from which the handset had just been transferred is timed. If the duration is less than a predefined number, it is assumed that a null had occurred, and that fact is stored for that cell. This information is used to detect multipath fading and to prevent premature handoffs when multipath fading occurs. Subsequently, a transfer is delayed for a cell having a large average number of nulls.
Other and further aspects of the present invention will become apparent during the course of the following description and by reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1-3 illustrate a wireless telecommunication switching system embodying the inventive concept;
FIGS. 4-8 illustrate tables that are used to collect the average duration of calls after a handoff;
FIGS. 5 and 6 illustrate tables that are used to maintain call duration statistics for active calls;
FIGS. 9-12 illustrate the operations performed by a system controller;
FIG. 13 illustrates, in block diagram form and greater detail, the wireless telecommunication system of FIGS. 1-3;
FIG. 14 shows a wireless telecommunication system implementing a second embodiment;
FIG. 15 illustrates a wireless handset;
FIG. 16 illustrates a table utilized in the second embodiment of the invention;
FIG. 17 illustrates the steps performed by a wireless handset utilized in the second embodiment of the invention;
FIG. 18 illustrates the steps performed by a system controller utilized in the second embodiment of the invention;
FIG. 19 illustrates a table utilized in the third embodiment of the invention;
FIG. 20 illustrates the steps performed by a wireless handset utilized in the third embodiment of the invention; and
FIG. 21 illustrates the steps performed by a system controller utilized in the third embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a wireless telecommunication system having a plurality of wireless cell sites (also referred to as cells) which are cells 101-116. This plurality of cells are providing service for wireless handsets such as wireless handset 117. Each cell consists of a base station which is not illustrated in FIG. 1 but is illustrated in detail in FIG. 13. The cells illustrated in FIG. 1 are under control of system controller 118. The geographical area covered by the cells is illustrated as being a circle; however, one skilled in the art would immediately recognize that the geographical area covered by each cell could be of a different configuration. System controller 118 controls the operation of the cells by controlling the base stations via communication links not illustrated in FIG. 1.
To understand the operation of the wireless communication system of FIG. 1, in accordance with a first embodiment of the invention, consider the following example. This example uses a handoff as the activity transfer being performed. Cell 101 has overlapping areas with cells 102-109. However, due to the traffic flow within the building which is serviced by the wireless communication system, users of wireless handsets do not in general leave cell 101 and enter cells 106-109. The normal traffic pattern is to leave cell 101 and enter cells 102-104. Cell 101 is currently active on a call with wireless handset 117. In the prior art, when the base station of cell 101 recognized that wireless handset 117 was leaving cell 101 due to a change in transmission signal strength, the base station informs system controller 118 of this fact. The base station of cell 101 realizes that wireless handset 117 is leaving its cell area as the signal strength of the transmission from wireless handset 117 goes below an acceptable level. System controller 118 then looks in a table associated with cell 101 to determine target cells. In the present example, the target cells are cells 102 through 109. System controller 118 requests that the base station in each of the target cells monitor transmission signal from wireless handset 117 for an adequate transmission signal. Each base station then must report back to system controller 118. Although, the wireless telecommunication system of FIG. 1 is illustrated as having a fairly small number of cells, in general, such a wireless telecommunication system has hundreds of cells. There are a large number of cells reporting back whether or not they were receiving the signal from a wireless handset in the process of doing a handoff at any given time. Hence, handoffs place a large real time processing load on system controller 118.
In accordance with the invention, when wireless handset 117 starts to move out of cell 101, system controller 118 selects a subset of cells 102-109 to interrogate the signal strength of wireless handset 117 to determine to which cell the handset should be handed off. In addition, system controller 118 randomly picks two other cells from the remaining cells illustrated in FIG. 1 to also interrogate the transmission signal strength of wireless handset 117. This is done so that system controller 118 can determine if the other cells can also be considered target cells from cell 101. The randomly selected cells are used to determine if indeed there are new cells that now can be considered target cells from cell 101. Relocation of base stations, new base stations, and structural changes in a building can result in new target cells. Note, in certain building environments, a structural change can be the moving of a shelf resulting in one cell becoming a potential target for another cell.
In the present example, system controller 118 accesses table 1 to determine the three target base stations of base station 101 which have the highest average call duration for handoffs. System controller 118 selects target base stations 102, 103, and 104 based on the average call durations illustrated in lines 401-403, respectively. System controller 118 then requests that these selected base stations and two randomly chosen base stations interrogate the signal transmission strength from wireless handset 117. Assuming that target base station 102 has an adequate signal strength, it will be selected for the handoff on the basis that its average call duration time is two minutes after a handoff from base station 101. In the present example, it is assumed that wireless handset 117 had been actively engaged in a call for one minute on base station 101 before the handoff occurred. When the handoff occurs to base station 102, table 2 illustrated in FIG. 5 has entry 501 inserted. Line 501 illustrates that the current base station is 102. The first previous/last base station is base station 101 and that the call duration had been one minute on base station 101.
The present example assumes that after wireless handset 117 has been active on base station 102 for 1.3 minutes, base station 102 determines that the signal strength from wireless handset 117 requires another handoff. Base station 102 makes a handoff request to system controller 118. System controller 118 accesses table 1 of FIG. 4 and determines from lines 408-411 that the target base stations for base station 102 are base stations 101, 103, and 112. System controller 118 requests that these base stations interrogate the signal transmission strength of wireless handset 117. Assuming that the transmission strength determined by base station 112 is adequate, system controller 118 selects base station 112 for the handoff based on the fact that its average call duration time is greater than the other two base stations. When the handoff occurs to base station 112, entry 501 is removed from table 2, and entry 601 is added to table 2 as illustrated in FIG. 6. When subsequently base station 112 hands off wireless handset 117 to cell 111, the statistics in line 601 will be used to update the average call duration time given in line 401 of FIG. 4 where base station 102 is the target for base station 101. This updated material is illustrated in table 1, line 701 of FIG. 7. The average duration of line 701 is the total duration of the call as handled by base station 101 and 102 and is 2.3 minutes. This results in a new average call duration of 2.03 in line 701.
If the call is terminated after being handed off to base station 102 after 1.3 minutes, the average call duration utilized to update table 1 of FIG. 7 is 2.5 minutes with an extra 0.2 minutes being added to emphasize that base station 102 may be a final destination for users traveling through base station 101.
If on the other hand, system controller 118 had not been able to perform a successful handoff from base station 102 upon being requested to do so, the total time utilized for the call to update table 1 of FIG. 7 is 2.1 minutes with 0.2 minutes being subtracted to emphasize that base station 102 may not be a good target base station for base station 101.
The present example has been based on the configuration of cells as illustrated in FIGS. 1 and 2. If the cell configuration changes due to a relocation of base station 112 as illustrated in FIG. 3, system controller 118 learns about the fact that cell 112 is now a target for cell 101 when cell 112 is randomly selected for the handoff. When this occurs, table 1 is updated as illustrated in FIG. 8 where base station 112 in line 801 has replaced the entry for base station 109 in line 407 of FIG. 4.
The operations performed by system controller 118 are illustrated in greater detail in FIGS. 9-12. When the operation of system controller 118 is initially started, control is transferred from block 901 to decision block 902. The latter decision block determines if a handoff request is being received from a wireless handset. If the answer is no, control is transferred to decision block 1201 of FIG. 12. If the answer is yes in decision block 902, control is transferred to block 903 which selects the three highest rated base stations that are target stations for the current base station serving the wireless handset from table 1. The highest rated base stations are those having the longest average call duration. From block 903, control is passed to block 904. Block 904 then selects at random two other base stations from the wireless telecommunication system as illustrated in FIG. 3. Note, in both blocks 903 and 904, a base station is not selected as a target unless it has at least one idle channel to perform the handoff. After execution of block 904, control is transferred to block 906 which sends messages to the selected base stations requesting that the wireless handset's transmission signal strength be interrogated. Next, decision block 907 determines if any of the selected base stations are detecting an adequate signal strength from the wireless handset. If the answer is no in decision block 907, this means that a handoff has failed for the current base station, and control is transferred to block 1101 of FIG. 11. If the answer is yes in decision block 907, control is transferred to block 908 which sends a message to the base station that has the highest rating and is receiving adequate signal strength to perform the handoff. After execution of block 908, control is transferred to block 1001 of FIG. 10.
FIG. 10 illustrates the operations for updating table 2 when a successful handoff has been performed. In block 1001, table 2 is accessed using the base station number from which the handoff has just been performed. This base station number is denoted as "current base station number". The base station to which the handoff was done is referred to as the "new base station". Control is then passed to decision block 1002, it determines whether there are two entries listed for the line associated with the current base station number in table 2. If the answer is no, control is transferred to block 1007. In the previous example this is illustrated by line 501 of FIG. 5. Block 1007 removes the current entry from table 2 which in the previous example results in the removal of line 501. Block 1008 then adds a new entry in table 2 for the new base station. In the previous example this is illustrated as line 601 of FIG. 6.
Returning to decision block 1002, if the answer is yes in decision block 1002, control is transferred to block 1003. In the previous example, this operation is performed when a handoff was done from base station 112 to base station 111. Block 1003 updates the average call duration for the second last base station in table 1 by averaging the present call duration into the number currently present in table 1. In the example, this is illustrated when line 701 of FIG. 7 is updated for base station 101. After execution of block 1004, the current entry is removed from table 2, and a new entry is made into table 2 for the new base station by block 1006. From both blocks 1006 and 1008, control is transferred back to decision block 902 of FIG. 9.
Returning to decision block 907 of FIG. 9, if the answer is no, this indicates the handoff failed to the target base station, and control is transferred to block 1101 of FIG. 11. Block 1101 accesses table 2, and decision block 1102 determines if there are two entries in the line associated with the current base station. If the answer is no, then the average call duration for the base station identified as the first last base station in table 2 is performed in table 1. Note, the the call duration listed for the first last base station in table 2 is averaged into the entry in table 2 minus a predefined value. This predefined value may advantageously be 0.2 seconds. After execution of block 1107, block 1108 removes the entry for the current base station from table 2 and transfers control back to decision block 902 of FIG. 9. Returning to decision block 1102, if the answer is yes, control is transferred to block 1103 which updates the average call duration for the second last base station in table 1 again subtracting from the present call duration given in table 2 the predefined value. Block 1104 then updates the average call duration for the first last base station of table 2 in table 1 again subtracting the predefined value from the average time duration listed in table 2. Finally, block 1106 removes the entry for the current base station from table 2 before transferring control back to decision block 902 of FIG. 9.
Returning to decision block 902 of FIG. 9, if a handoff is not being requested by the station set, control is transferred to decision block 1201 of FIG. 12. If the operation is not a call hangup by a wireless handset, control is transferred from decision block 1201 to block 1202 for normal processing. If a wireless handset has terminated a call by hanging up, control is transferred to block 1203 which accesses table 2 for the current base station. Decision block 1204 then determines whether there are two entries for the current base station in table 2. If the answer is no, blocks 1209 and 1211 perform the same operations as blocks 1107 and 1108 of FIG. 11 with the exception that the predefined value is added to the present call duration rather than being subtracted. If the answer in decision block 1204 is yes, blocks 1206-1208 perform the same operations as blocks 1103-1106 of FIG. 11 with the exception that the predefined value is added to the present call duration rather than being subtracted. After execution of either block 1208 or 1211, control is transferred back to decision block 902 of FIG. 9.
FIG. 13 illustrates, in block diagram form, the wireless telecommunication system illustrated in FIGS. 1-3. System controller 118 is under the control of processor 1302 which executes programs and utilizes data stored in memory 1301. For example, memory 1301 stores tables 1 and 2. System controller 118 interfaces to public network 1308 via interfaces 1304. System controller 118 is interconnected to base stations 101-116 via links 1321-1322 which terminate on interfaces 1306-1307. The switching of audio and data received via interfaces 1306-1307 is performed by switching network 1303 under control of processor 1302. Base station 101 illustrates in greater detail the composition of a base station. Each base station comprises a plurality of radio units 1318-1319 that are under the control of base controller 1309. Base controller 1309 is responsive to the message requesting that a wireless handset's transmission signal strength be interrogated to adjust the frequency of RF transceiver 1313 to the channel used by the wireless handset by controlling frequency synthesizer 1312 via time domain duplexer 1311 and bus 1310. Signal strength monitor 1314 reports the relative signal strength of the wireless handset to base controller 1309 via bus 1310.
Consider now a second embodiment of the invention. FIG. 14 illustrates path 1404 which is a path that is traveled frequently by users of the wireless telecommunication system. For example, this could be the main path to the cafeteria or other such facility. When wireless handset 1406 entered cell 1402 it was handed off to cell 1402. As illustrated in FIG. 14, wireless handset 1406 is now at the boundary of cell 1402 and must be handed off to either cell 1403 or 1401. Since wireless handset 1406 is closer to the center of cell 103, the normal choice would be to hand wireless handset 1406 off to cell 1403. However, wireless handset 1406 is moving away from the center of cell 1403 and towards the center of cell 1401. Hence, cell 1401 is the best cell for the hand off of wireless handset 1406. This second embodiment is directed towards detecting and allowing the dynamic learning within system controller 1408 to account for paths such as path 1404. When wireless handset 1406 is handed off to cell 1401, wireless handset 1406 continues to measure the received transmission power from cell 1401. After wireless handset 1406 is handed off to another cell, wireless handset 1406 communicates the maximum transmission power that was detected while in cell 1401 to system controller 1408. Similarly, when wireless handset 1406 is handed off to cell 1403, it also measures the maximum power that was received. System controller 1408 maintains an average power for each cell to which another cell can hand off. For example, cell 1402 has a table associated with it that indicates the average of the maximum transmission power that had been detected by handsets being handed off from cell 1402 to cells 1403 and 1401. Using this average power information, system controller 1408 determines the cell to which the handoff is to occur based on the maximum average power that had been previously detected in handoffs to that cell in the same manner that was previously described with respect to FIG. 9. The first embodiment is applied to processing registration in a similar manner as handoffs. An exception is that for registrations decision block 1201 will detect when the wireless handset is inactive rather than when the call has been terminated.
In the second embodiment, it is assumed that wireless handset 1406 is as illustrated in FIG. 15. Handset 1406 is implementing a wireless protocol that allows wireless handset 1406 to maintain a wireless signal link with system controller 1408 via the base stations in the cells. One air interface that can be used is the Japanese PHS protocol as set forth in "User-Network Interface and Inter-Network Interface Standards for PHS", the Telecommunication Technology Committee, 1995, and "Personal Handy Phone System RCR Standard", Version 1, RCR STD-28, Dec. 20, 1993. The message set of the PHS protocol is similar to the ISDN message set. In the second and third embodiment, only the signal protocol of PHS protocol is used and not the handoff method of the PHS protocol. Control unit 1501 of wireless handset 1406 uses user information messages to communicate the transmission power to system controller 1408. At regular intervals, control unit 1501 records the maximum transmission power being received from cell 1401 using signal strength monitor 1502. When wireless handset 1406 is handed off to another cell from cell 1401 or the call terminates, control unit 1501 transmits the maximum transmission power that had been received while wireless handset 1406 was active on a call with cell 1401. For the present example, FIG. 16 illustrates in table 3 the results of handoffs from cell 1402 to cells 1401 and 1403. When a handset is handed off from one cell to another cell, system controller 1408 is responsive to the message defining the maximum transmission power experienced by the wireless handset for the cell handing off to update a table such as illustrated in FIG. 16 for the cell that had done the previous hand off.
FIG. 17 illustrates the operations performed by wireless handset in implementing the second embodiment. When a handoff occurs, block 1701 measures the transmission power of the base station to which the wireless handset has just been handed off. In addition, block 1701 stores this value for the transmission power before transferring control to decision block 1702. Decision block 1702 determines if the call has been terminated. If the answer is yes, the operations illustrated in FIG. 17 are done, and block 1711 causes the handset to perform normal operations. If the decision in decision block 1702 is no, decision block 1705 determines if a handoff has occurred. If a handoff has not occurred, control is transferred to decision block 1706 which determines if a predefined amount of time has elapsed. If the answer is yes, block 1707 measures the transmission power of the base station. Then, decision block 1708 determines if the measured transmission power is greater than the value of transmission power that is stored. If the answer is yes, block 1709 replaces the previously stored transmission power with the measured transmission power before returning control to decision block 1702. If the answer in decision blocks 1706 or 1708 is no, control is returned to decision block 1702. Returning to decision block 1705, if a handoff has occurred, control is transferred to block 1703 which transmits the stored transmission power to the system controller and resumes normal operations by execution of block 1704.
FIG. 18 illustrates the operations performed by system controller 1408 of FIG. 14. When a maximum power message is received from a wireless handset by block 1801, block 1802 accesses table 3 of FIG. 16 and obtains the number of handoffs and the average maximum power for the present base station. In table 3, the present base station is denoted as the target base station number. The base station from which the last handoff occurred is denoted as the current base station number in table 3. Block 1803 then calculates a new average maximum power, and block 1804 inserts this new average maximum power number into table 3. Operations are terminated by execution of block 1806. The second embodiment is applied to processing registrations in a similar manner as handoffs. The exceptions are that for registrations decision block 1702 detects when the wireless handset is inactive rather than when the call has been terminated and decision block 1705 detects a new registration rather than a handoff.
A third embodiment is directed to the problem of solving multipath fading. Multipath fading is caused when the handset is receiving the transmission signal from the base station but that signal is taking a number of paths to the handset. At a certain point, the signals from these paths cancel each other out. The point at which this occurs is called a null. At the frequencies used by PCS handsets, these null points often are only a few inches in distance but can cause a handset to do a handoff to a base station that actually has weaker overall transmission power than the base station which was experiencing the multipath fading. The third embodiment is directed to detecting paths such as path 1404 that experience multipath fading for example from the base station of cell 1401. This is done by the wireless handset continuing to monitor the transmission power of the base station from which the handset had just been handed off for a predefined period of time. If the transmission power returns to an acceptable communication level, the wireless handset utilizes a facility message to transmit that a null occurred to system controller 1408. System controller 1408 maintains a table for each cell such as illustrated in FIG. 19. For each pair of current base station numbers and target base station numbers in table 4 of FIG. 19, system controller 1408 maintains an average number of nulls that have been detected per handoff. Using this average number of nulls, system controller 1408 determines whether to delay the handoff for a predefined time. Advantageously, this predefined amount of time is two seconds. System controller 1408 delays the handoff if the average number of delays is greater than a second predefined number. Advantageously, this second predefined number is 0.5. It is assumed that the wireless handset illustrated in FIG. 15 is utilized. In this case, control unit 1501 monitors the power transmission strength utilizing signal strength monitor 1502. In the PHS protocol, control unit 501 does this by monitoring the previous base station in the paging channel.
FIG.20 illustrates the operations performed by wireless handset in implementing the third embodiment of the invention. After a handoff has occurred, decision block 2000 waits for a predefined amount of time to elapse, and then, transfers control to block 2001. Block 2001 measures the transmission power of the previous base station. Decision block 2002 then determines if the measured power is greater than the handoff threshold power. If the answer is yes, block 2003 transmits a null occurred message to system controller 1408, and block 2004 returns the handset to normal operations.
FIG. 21 illustrates the operations performed by system controller 1408 in implementing the third embodiment. Block 2101 transfers control to block 2102 when a null occurred message is received from the wireless handset. Block 2102 accesses table 4 of FIG. 19 utilizing the present base station as the target base station number and the previous base station as the current base station number. Block 2103 calculates a new average number of nulls utilizing the number of handoffs and the average number of nulls. Block 2104 then stores this new average number of nulls in table 4 before block 2106 returns the system controller to other operations. The third embodiment is applied to processing registrations in a similar manner as handoffs.
It is to be understood that the above-described embodiments are merely illustrative of the principles of the invention and that other arrangements may be devised by those skilled in the art without departing from the spirit and scope of the invention. In particular, it would be apparent to one skilled in the art that the three different embodiments could be combined together. Also, one skilled in the art could readily envision how to adapt the principles of the invention to arrangements where the wireless handset controlled the handoff. | Using dynamic learning techniques by a system controller to determine a subset of neighboring cell sites to which an activity transfer should be attempted. An activity transfer can be a handoff or registration. The neighboring cell sites that should be chosen for an activity transfer are specified for each cell site. The specified neighboring cell sites are determined by the dynamic learning process. In a first embodiment, the dynamic learning is accomplished by accumulating statistical data that defines the average call duration of each of the selected neighboring sites after an activity transfer to each. Advantageously, this average duration can include the total call duration for two subsequent activity transfers. In a second embodiment, the dynamic learning is accomplished by accumulating statistical data that defines the maximum transmission power from the base station to which a handset was transferred. In a third embodiment, the duration of the low power transmission level of the base station from which the handset had just been transferred is timed. If the duration is less than a predefined number, it is assumed that a null had occurred, and that fact is stored for that cell. This information is used to detect multipath fading and to prevent premature handoffs when multipath fading occurs. Subsequently, a transfer is delayed for a cell having a large average number of nulls. | 8 |
PRIORITY CLAIM AND CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of patent application Ser. No. 12/540,398 filed Aug. 13, 2009 which is a continuation in part of U.S. patent application Ser. No. 11/749,615 filed May 16, 2007 and a continuation in part of U.S. patent application Ser. No. 12/355,145 filed Jan. 16, 2009 the entire contents of these applications are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention is directed to the field of pedicle screws, and in particular, to a pedicle screw implant system adapted for use as a polyaxial, mono-axial with range limiting or as a fixed spinal implant with top or side loading for a connector rod.
BACKGROUND OF THE INVENTION
[0003] The use of pedicle screw fasteners is well known for their use with spinal fixation systems. In the field of spinal pathologies, spinal fixation systems represent a major medical breakthrough. Surgically implanted fixation systems are commonly used to correct a variety of back structure problems, including those which occur as a result of trauma or improper development during growth. A commonly applied fixation system includes the use of one or more connecting rods aligned in a desired orientation with respect to a patient's spine for stabilization of the spine. The pedicle screw provides anchoring of the fixation system wherein a series of connectors are used to rigidly link rods and the anchors.
[0004] Common to all spinal implant systems is the necessity for proper anchoring to the bone so as to provide support for the aforementioned components. The use of a polyaxial design pedicle screw has proven very effective in allowing a surgeon the flexibility to secure an installation with minimal strain on the individual. However, one of the problems with a polyaxial pedicle screw is the lack of a stabilized angular placement position during installation. Once a polyaxial pedicle screw is inserted into the bone, the connector component portion has yet to receive a connecting rod leaving the connector assembly free to move around or fall over making it difficult for the surgeon to grasp while in the midst of surgery. This problem is compounded by the need to align multiple component heads for receipt of a connecting rod. Another problem with the prior art is the inability to use various size anchoring screws in combination with a common saddle larger saddle which leads to assembly integrity over a large range of installation considerations.
[0005] A conventional polyaxial bone screw typically consists of a single shaft with a coarse thread at one end for threading into the bone. A spherical ball is positioned at an opposite end for coupling to a connecting member. For example, a number of patents exist for bone screw anchoring assemblies that include a U-shaped connector element which acts as a saddle for attachment to an alignment rod. U.S. Pat. No. 5,133,717 sets forth a sacral screw with a saddle support. Disclosed is the use of an auxiliary angled screw to provide the necessary support in placing the screw in an angular position for improved anchoring.
[0006] U.S. Pat. No. 5,129,900 sets forth an attachment screw and connector member that is adjustably fastened to an alignment rod. An oblong area provided within each connector member allows minute displacement of the alignment rod.
[0007] U.S. Pat. No. 4,887,595 discloses a screw that has a first externally threaded portion for engagement with the bone and a second externally threaded portion for engagement with a locking nut. The disclosure illustrates the use of a singular fixed shaft.
[0008] U.S. Pat. No. 4,946,458 discloses a screw which employs a spherical portion which is adapted to receive a locking pin so as to allow one portion of the screw to rotate around the spherical portion. A problem with the screw is the need for the locking pin and the inability of the base screw to accommodate a threaded extension bolt.
[0009] U.S. Pat. No. 5,002,542 discloses a screw clamp wherein two horizontally disposed sections are adapted to receive the head of a pedicle screw for use in combination with a hook which holds a support rod at an adjustable distance.
[0010] U.S. Pat. No. 4,854,304 discloses the use of a screw with a top portion that is adaptable for use with a specially designed alignment rod to permit compression as well as distraction.
[0011] U.S. Pat. No. 4,887,596 discloses a pedicle screw for use in coupling an alignment rod to the spine wherein the screw includes a clamp permitting adjustment of the angle between the alignment rod and the screw.
[0012] U.S. Pat. No. 4,836,196 discloses a screw with an upper portion designed for threadingly engaging a semi-spherical cup for use with a specially designed alignment rod. The alignment rod includes spaced apart covertures for receipt of a spherical disc allowing a support rod to be placed at angular positions.
[0013] U.S. Pat. No. 5,800,435 sets forth a modular spinal plate assembly for use with polyaxial pedicle screw implant devices. The device includes compressible components that cooperatively lock the device along included rails.
[0014] U.S. Pat. No. 5,591,166 discloses an orthopedic bone bolt and bone plate construction including a bone plate member and a collection of fasteners. At least one of the fasteners allows for multi-angle mounting configurations. The fasteners also include threaded portions configured to engage a patient's bone tissue.
[0015] U.S. Pat. No. 5,569,247 discloses a multi-angle fastener usable for connecting a patient bone to other surgical implant components. The '247 device includes fastening bolts having spherical, multi-piece heads that allow for adjustment during installation of the device.
[0016] U.S. Pat. No. 5,716,357 discloses a spinal treatment and long bone fixation apparatus. The apparatus includes link members adapted to engage patient vertebrae. The link members may be attached in a chain-like fashion to connect bones in a non-linear arrangement. The apparatus also includes at least one multi-directional attachment member for joining the link members. This allows the apparatus to be used in forming a spinal implant fixation system.
[0017] Another type of spinal fixation system includes rigid screws that engage the posterior region of a patient's spine. The screws are designed with rod-engaging free ends to engage a support rod that has been formed into a desired spine-curvature-correcting orientation. Clamping members are often used to lock the rod in place with respect to the screws. Instead of clamping members, other fixation systems, such as that disclosed in U.S. Pat. No. 5,129,900 employs connectors that join the support rods and anchoring screws. The connectors eliminate unwanted relative motion between the rod and the screws, thereby maintaining the patient's spine in a corrected orientation.
[0018] Other spinal fixation systems employ adjustable components. For example, U.S. Pat. No. 5,549,608 includes anchoring screws that have pivoting free ends which attach to discrete rod-engaging couplers. As a result, the relative position of the anchoring screws and rods may be adjusted to achieve a proper fit, even after the screw has been anchored into a patient's spinal bone. This type of fixation system succeeds in easing the rod-and-screw-linking process. This adjustment capability allows the screws to accommodate several rod paths.
[0019] U.S. Pat. No. 7,445,627 discloses a fastener and a bone fixation assembly for internal fixation of vertebral bodies. According to one exemplary embodiment, a tulip assembly is employed; the tulip assembly includes a non-circular surface disposed on its outer surface. A fastener is coupled to the tulip assembly and positionable to retain the tulip assembly on the head of a screw. A cap having an outer surface and a plurality of inner protrusions mateably connects to the non-circular surface on the tulip body to compress the tulip assembly to secure a rod.
[0020] U.S. Publication No. 2008/0177322 discloses a spinal stabilization system that includes bone fastener assemblies that are coupled to vertebrae. Each bone fastener assembly includes a bone fastener and a collar. The bone fastener has a head portion having at least a first cross-sectional shape in a first plane, and a second cross-sectional shape in a second plane. The collar has a circular opening in the bottom, with a relief extending from the circular opening. The second cross-sectional shape of the bone fastener is keyed to the opening to permit insertion of the bone fastener into the collar assembly from the bottom. After insertion, the bone fastener is rotated to prohibit removal of the bone fastener from the collar. The collar can then be rotated and/or angulated relative to the bone fastener. An elongated member can be positioned in the collar and a closure member is then used to secure the elongated member to the collar.
[0021] U.S. Publication No. 2006/0241599 discloses a polyaxial fixation device having a shank with a spherical head formed on a proximal end thereof, and a receiver member having an axial passage formed therein that is adapted to polyaxially seat the spherical head of the shank. The polyaxial bone screw further includes an engagement member that is adapted to provide sufficient friction between the spherical head and the receiver member to enable the shank to be maintained in a desired angular orientation before locking the spherical head within the receiver member.
[0022] U.S. Publication No. 2006/0235392 discloses a system for connecting a fastener element (e.g., a pedicle screw) relative to a rod for the purposes of vertebral fixation. The system may permit multi-axial movement between the fastener element and the rod. Further, the system may permit the angular relationship between the fastener element and the rod to be held in a desired orientation.
[0023] U.S. Publication No. 2006/0155277 discloses an anchoring element for securing a rod on a vertebra, that comprises a retaining means for receiving the rod, a safety element placed on the retaining means, a securing element which can be placed on the body of the vertebra, and a clamping device which is arranged between the retaining means and the securing element. The clamping device includes a ring-shaped mount, a partially conical-segment shaped bearing and an intermediate element which is embedded in the mount and which engages the bearing, whereby the mounting is moveable in a removed state in relation to the bearing, whereas the mount is maintained in a clamped state on the bearing by means of the intermediate element. The mount is rigidly connected to the retaining means and the bearing is rigidly connected to the securing element.
[0024] U.S. Publication No. 2006/0149240 discloses a polyaxial bone screw assembly that includes a threaded shank body having an upper capture structure, a head and a multi-piece retainer, articulation structure. The geometry of the retainer structure pieces correspond and cooperate with the external geometry of the capture structure to frictionally envelope the retainer structure between the capture structure and an internal surface defining a cavity of the head. The head has a U-shaped cradle defining a channel for receiving a spinal fixation or stabilization longitudinal connecting member. The head channel communicates with the cavity and further with a restrictive opening that receives retainer pieces and the capture structure into the head but prevents passage of frictionally engaged retainer and capture structures out of the head. The retainer structure includes a substantially spherical surface that mates with the internal surface of the head, providing a ball joint, enabling the head to be disposed at an angle relative to the shank body.
[0025] U.S. Pat. No. 6,716,214 discloses a polyaxial bone screw having a bone implantable shank, a head and a retaining ring. The retaining ring includes an outer partial hemispherical surface and an inner bore with radially extending channels and partial capture recesses. The shank includes a bone implantable body with an external helical wound thread and an upwardly extending capture structure. The capture structure includes at least one spline which extends radially outward and has a wedged surface that faces radially outward therefrom. The capture structure operably passes through a central bore of the retaining ring while the spline passes through a suitably shaped channel so that the spline becomes positioned above the head, at which time the shank is rotated appropriately and the shank is drawn back downwardly so that the spline engages and seats in the capture recess. The head includes an internal cavity having a spherical shaped surface that mates with the ring surface and has a lower restrictive neck that prevents passage of the ring once the ring is seated in the cavity.
[0026] U.S. Pat. No. 6,565,567 discloses a pedicle screw assembly for use with a rod for the immobilization of bone segments. The assembly is comprised of a screw, a polyaxial housing for receiving the screw, a washer, a set screw, and a cup-shaped cap. The lower portion of the housing terminates in a reduced cross-sectional area, which engages the bottom of the screw head. When the screw is placed inside the polyaxial housing and the screw is secured into the bone, the polyaxial housing is pivotable with three degrees of freedom. The housing includes a top portion with a pair of upstanding internally threaded posts. A washer is inserted between the head of the screw and the rod. A cap, having a bottom, with a pair of posts accommodating openings and a lateral cross connector, is placed over the posts so that the cross connector engages the rod. The cross connector and washer have concave generally semi-cylindrical rod engaging surfaces to prevent the rod from rotating or sliding within the housing once the set screw is tightened. A set screw is threaded into the housing posts to secure the rod within the housing. The washer has a roughened lower surface which, in conjunction with the reduced cross-sectional area at the bottom of the housing, securely clamps and locks the housing to the screw head when the set screw is tightened.
[0027] U.S. Pat. No. 5,501,684 discloses an osteosynthetic fixation device which consists of a fixation element which has a conical head section and an anchoring element abutting it which is for attachment into the bone. The fixation device also consists of a spherically formed, layered, slotted clamping piece which has a conical borehole for installation of the conical head section, and which is meant for locking within a connecting piece equipped with a spherically shaped layered borehole. Fixation piece has an axially arrayed tension element, permitting axial displacement and wedging of conical head section in the borehole that corresponds with it. The fixation device is appropriate for use as a plate/screw system, an internal or external fixator, and in particular for spinal column fixation.
[0028] U.S. Pat. No. 4,693,240 discloses a bone pin clamp for external fracture fixation. The apparatus comprises rotation, slide and housing elements nested one within the next, each such element having an aperture to receive a pin therethrough, and the rotation and slide elements respectively affording pin adjustment in azimuth and zenith, and in height, relative to the housing element. A locking mechanism including a common actuator member is operable simultaneously to lock the pin and rotation and slide elements in the housing element. In a preferred form, the housing element serves as a cylinder with the slide element as a keyed piston therein, and the rotation element is a disc located between a screw and annular thrust members engaged in the piston, the piston and disc being split respectively to lock by expansion and compaction under screw action towards the thrust members.
[0029] U.S. Pat. No. 4,483,334 discloses an external fixation device for holding bone segments in known relation to each other. The device includes a pair of bone clamp assemblies each secured to bone pins extending from the bone segments, a bridge extending between the pin clamp assemblies, and a specialized high friction universal assembly connecting the bridge to each of the pin clamp assemblies.
[0030] U.S. Pat. No. 4,273,116 discloses an external fixation device for reducing fractures and realigning bones that includes sliding universal articulated couplings for enabling easy adjustment and subsequent locking of connections between Steinmann pins and tubular tie-rods. The couplings each include a split, spherical adapter sleeve which is embraced by the matching inner surface of an open ring portion of a coupling locking clamp having clamp lugs tightenable against a block by means of a nut-and-bolt assembly. Further nut-and-bolt assemblies are disposed in elongated slots in the blocks and cooperate with associated clamping members to clamp the Steinmann pins to the blocks after adjustment in two orthogonal directions and optional resilient bending of the pins.
[0031] U.S. Pat. No. 6,672,788 discloses a ball and socket joint incorporating a detent mechanism that provides positive biasing toward a desired position. The ball and socket joint can be used in flexible supports that hold and support items such as lamps, tools and faucets. The detent mechanism comprises two corresponding parts, one in the ball portion and the second in the socket portion of the joint. The first detent part is a protrusion of some type and the second detent part is a groove or indentation that is adapted to accept and engage the protrusion. If the ball contains the detent protrusion, then the socket contains the detent indentation. And conversely, if the socket contains the detent protrusion, then the ball contains the detent indentation. The detent tensioning force can be provided by a spring or a spring band, the characteristics of the material from which the joint is made, or by some other similar tensioning device.
[0032] U.S. Publication No. 2003/0118395 discloses a ball and socket joint, which has a housing, a ball pivot mounted pivotably in the housing, and a sealing bellows, which is fastened to the housing and is mounted on the ball pivot slidably via a sealing ring provided with two legs. A first leg of the two legs is in contact with the ball pivot under tension and the second leg meshes with the wall of the sealing bellows. The second leg is, furthermore, fastened in an anchoring ring arranged at least partially in the wall of the sealing bellows.
[0033] U.S. Pat. No. 4,708,510 discloses a ball joint coupling assembly that permits universal movement and positioning of an object with respect to a vertical support shaft. Quick release/lock action is provided by a ball joint assembly having a housing in which a ball and piston are movably coupled. The ball is captured between annular jaw portions of the housing and piston, with locking action being provided by gripping engagement of the piston jaw portion and the housing jaw portion. The ball member is gripped in line-contact, compressive engagement by the annular edges of the piston jaw and housing jaw on opposite sides of the ball. The piston is constrained for axial movement within the housing with locking engagement and release being effected by rotation of a threaded actuator shaft.
[0034] U.S. Pat. No. 3,433,510 discloses a swivel structure for rigidly joining first and second parts together. A first member is connected to the first part and a second member is connected to the second part. An intermediate hollow member interconnects the first and second members together. An enlarged outer end portion is provided on the first member and includes a plurality of locking means thereon. Means are provided on the second member for engaging one of the locking means. Means are provided for threadably joining the hollow member and the second member together. A slot is provided in the hollow member and includes an enlarged entrance which passes the enlarged outer end portion and which also includes a restricted opening opposite the threaded joining of the hollow member and the second member together. The portion surrounding the restricted opening opposes the forces imparted against the outer end portion as the second member is threadably joined to the hollow portion and bears against the outer end portion.
[0035] U.S. Patent Publication No. 2008/0269809 discloses a bottom loading pedicle screw assembly. The device includes a pedicle screw and a connector member. The pedicle screw includes a threaded lower portion while the upper portion includes a groove sized to accept a clip member. The clip member includes a spherical outer surface. In operation the clip is placed within the groove and the assembly is pressed through the opening in the bottom of the connector member. While the device is bottom loading, the device will separate when the pedicle screw is aligned with the connector member. The construction of the clip member allows the clip to collapse sufficiently to pass back through the opening when the screw is positioned in alignment with the connector, requiring the connection to bone be placed at an angle with respect to the connector for proper operation.
[0036] Various attempts have also been made for placing of a connecting rod along a side entry chamber. U.S. Pat. Nos. 5,669,911; 5,817,094 and 5,690,630 discloses a polyaxial pedicle screw having a side loading channel with an external nut fastened to the connector for securing a rod to the screw.
[0037] U.S. Pat. No. 6,063,090 discloses a device for connecting a longitudinal support to a pedicle screw. One embodiment including a sidewardly open channel for receipt of a longitudinal support; the device employs a clamping element having a hollow truncated cone shape with a plurality of slots, the element used in securing the fastener in the tapered opening.
[0038] U.S. Pat. No. 7,022,122 discloses a device for connecting a longitudinal bar to a pedicle screw. The device including an adjusting nut for securing the spherical head of a pedicle screw with the longitudinal bar.
[0039] Thus, what is needed is a pedicle screw system that can be adapted for use in a spinal fixation system that includes a thread thru assembly allowing different sized anchoring screws to be coupled to a single size connector, and an assembly that maintains the connector member in position to assist a surgeon during installation. The pedicle screw system to include a polyaxial and monoaxial configuration, as well as fixed angular positioning therebetween. In addition, the pedicle screw system to include side loading and top loading.
SUMMARY OF THE INVENTION
[0040] The present invention is a pedicle screw system that allows for securement to a bone screw in either a polyaxial, monoaxial, fixed or range limiting attachment. In the preferred embodiment the threads of a pedicle screw can pass thru a lower section of a connecting member during manufacturing which permits the manufacturer to use a range of different size shanks and threads while using a common connector member to lower inventory costs. The system also provides for using oversized pedicle screws for a given connector member to provide a low profile assembly. In addition, the system includes a means for applying tension to the pedicle screw anchoring member that allows the connector to be desirably positioned relative to the screw to assist in surgical assembly of the system.
[0041] The bone screw has a threaded shank extending outwardly from a spherical ball for use in anchoring to the spine and a connector member that includes a socket constructed and arranged to accept the spherical ball. In the disclosed embodiment, the connector member is illustrated as a U-shaped or side loading connector member having a lower receptacle that operates as a socket for housing a retainer ring. The socket is receptive to the spherical ball which is inserted through the top of the connector during a manufacturing step. The retainer ring is biased against an upper component of the connector member and engages the spherical ball so as to keep the connector member in position during installation and prior to installation of the connector rod. A surgeon can easily move the connector member into a preferred position and the biasing member keeps sufficient tension on the retainer ring so as to maintain the connector in a position for proper placement of the connecting rod. This facilitates easier installation of the connecting rod by maintaining the proper angle of the saddle also allowing the surgeon to align additional screws on adjacent vertebra and/or bone structures.
[0042] The retaining ring may have a concave spherical shape that cooperates with a spherical head portion on the bone screw allowing the bone screw to operate in a polyaxial manner. Alternatively the retaining ring may include a partial spherical cavity shaped to cooperate with a partially spherical head portion to cause the bone screw to operate in a monoaxial range of motion or further include angular construction so as to limit the range of motion to a reduced or fixed angular displacement. Alternatively, the head portion of the bone screw may be shaped to cause range limitation in accordance with the shape of the retaining ring.
[0043] A fastener member, such as a set screw or nut, is utilized to press the retaining ring into contact with the spherical or partially spherical head while simultaneously causing the lower split ring to engage a lower portion of the ball as it wedges between the ball and the inner surface of the connector member immobilizing the connection.
[0044] The connector members are substantially rigid structures adapted to link an associated anchoring assembly with one of the stabilizing rods. The stabilizing rods may be rigid or dynamic members shaped to form a spine-curvature-correcting and/or immobilizing path. Attaching each anchoring assembly, via connectors, to a stabilizing rod forces a patient's back into a surgeon-chosen shape. Stabilizing rods may be used singly, or in pairs, depending upon the type of correction required. The rods vary in size, but typically extend between at least two vertebrae.
[0045] Accordingly, it is an objective of the present invention to teach the use of a pedicle screw system for posterior fixation having a common connector for use with different sized threaded shanks and thread types, which lowers inventory requirements and provides the surgeon with a uniform connector.
[0046] It is another objective of the present invention to disclose the use of a pedicle screw having a biasing member to supply a tension between the anchoring member and the connector member, the tension facilitates installation by maintaining the connector component in an angular placement position as desired by the surgeon prior to assembly of the rod member.
[0047] It is another objective of the present invention to teach the use of a bone screw assembly having a connector assembly that provides a thread through lower portion and a heavy side-walled upper portion that does not include thread through to provide a greater safety factor when a set screw fastener is employed to avoiding splaying.
[0048] Another objective of the present invention to teach the use of a polyaxial bone screw assembly that is adapted to utilize multiple connector rod member diameters.
[0049] Still another objective of the present invention to teach the use of a retainer ring member for use in conjunction with a U-shaped saddle or side loading saddle to obtain a three point fixation between a fastener set screw and the saddle.
[0050] Yet another objective of the present invention to teach the use of a polyaxial bone screw assembly that allows 60 degrees of conical polyaxial motion.
[0051] It is yet another objective of the present invention to provide a simple spinal fixation system having only a few components for use in assembly and limiting component parts needed during assembly by use of a common connector.
[0052] Still another objective of the invention is to teach a motion limiting pedicle screw assembly.
[0053] Still yet another objective of the present invention is to teach a pedicle screw assembly that utilizes a cooperating retaining ring and bone screw head to provide a pedicle screw that can be fixed, monoaxial or polyaxial in movement.
[0054] Still yet another objective of the present invention is to teach a pedicle screw assembly that that utilizes a cooperating retaining ring and bone screw head to provide a pedicle screw having a fixed or predetermined angular displacement.
[0055] Still another object of the invention to teach the use of a bone screw assembly having a connector assembly that provides a pass through non threaded lower portion with at least one groove on the spherical seat surface to provide improved friction gripping between the spherical seat surface and the spherical head of the pedicle screw.
[0056] 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 objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 is depiction of the instant invention having a U-shaped connector with a polyaxial assembly;
[0058] FIG. 2 is depiction of the instant invention having a U-shaped connector with a monoaxial assembly;
[0059] FIG. 3 is side view depiction of the range of motion for instant invention having a U-shaped connector with either a polyaxial or monoaxial assembly;
[0060] FIG. 4 is depiction of the instant invention having a side loading connector with a polyaxial assembly;
[0061] FIG. 5 is depiction of the instant invention having a side loading connector with a monoaxial assembly;
[0062] FIG. 6 is side view depiction of the range of motion for instant invention having a side loading connector with either a polyaxial or monoaxial assembly;
[0063] FIG. 7 is a perspective view of the pedicle screw apparatus without a rod or set screw;
[0064] FIG. 8 is a cross section view of the thread thru pedicle screw apparatus;
[0065] FIG. 9 is a cross sectional side view in an exploded manner depicting a bone screw with a thread thru lower element of a connector;
[0066] FIG. 10 is a cross sectional side view of a bone screw partially threaded into a lower element of a connector;
[0067] FIG. 11 is a cross section side view of a bone screw threaded into a lower element of a connector;
[0068] FIG. 12 is an exploded cross section view of the U-shaped pedicle screw apparatus;
[0069] FIG. 13 is a perspective view of the biasing spring;
[0070] FIG. 14 is a top perspective view of the retainer ring element;
[0071] FIG. 15 is a bottom perspective view of the retainer ring element;
[0072] FIG. 16 is a perspective view of the set screw;
[0073] FIG. 17 is a cross section view of the assembled connector for a polyaxial assembly;
[0074] FIG. 18 is a top perspective view of the limiting retainer ring element;
[0075] FIG. 19 is a bottom perspective view of the limiting retainer ring element;
[0076] FIG. 20 is a pictorial view depicting monoaxial range of motion;
[0077] FIG. 21 is a side view of a monoaxial bone screw and retaining ring;
[0078] FIG. 22 is a perspective view of a monoaxial bone screw and retaining ring;
[0079] FIG. 23 is a perspective view of a monoaxial bone screw;
[0080] FIG. 24 is a perspective view of a monoaxial bone screw and retaining ring of an alternative embodiment;
[0081] FIG. 25 is a bottom perspective view of a limiting retainer ring element;
[0082] FIG. 26 is a side view of a limiting retainer ring element;
[0083] FIG. 27 is a perspective view of a monoaxial bone screw;
[0084] FIG. 28 is a perspective view of a monoaxial bone screw and retaining ring of an alternative embodiment;
[0085] FIG. 29 is a bottom perspective view of a limiting retainer ring element;
[0086] FIG. 30 is a perspective view of a monoaxial bone screw and retaining ring of an alternative embodiment;
[0087] FIG. 31 is a side view of a monoaxial bone screw and retaining ring of an alternative embodiment;
[0088] FIG. 32 is a side view of a limiting retainer ring element;
[0089] FIG. 33 is a perspective view of a monoaxial bone screw;
[0090] FIG. 34 is a pictorial view depicting monoaxial range of motion;
[0091] FIG. 35 is a cross section view of the assembled connector for a monoaxial assembly;
[0092] FIG. 36 is a side view of a side loading connector;
[0093] FIG. 37 is a pictorial view depicting side loading polyaxial range of motion;
[0094] FIG. 38 is a cross sectional side view of a polyaxial side loading connector;
[0095] FIG. 39 is a pictorial view depicting side loading monoaxial range of motion;
[0096] FIG. 40 is a cross sectional side view of a polyaxial side loading connector.
[0097] FIG. 41 is a perspective view showing the range of various sized pedicle screws and tulip heads including lumber thoracic spine sizing and cervical-thoracic spine sizing.
[0098] FIG. 42 is a cross sectional view of a polyaxial screw having a groove formed in the spherical seat surface.
[0099] FIG. 43 is an enlarged detailed view of the spherical seat surface shown in FIG. 42 as detail A.
[0100] FIG. 44 is a perspective view of the spherical seat surface having a single gripping groove.
[0101] FIG. 45 is a perspective view of the spherical seat surface having two gripping grooves.
[0102] FIGS. 46 and 47 are perspective views of the spherical seat surface having three gripping grooves.
[0103] FIG. 47 is a cross sectional view of a monoaxial screw having a spherical seating surface with a gripping groove formed therein.
[0104] FIG. 49 is a cross sectional view of the screw shown in FIG. 48 rotated ninety degrees.
[0105] FIG. 50 is a diagrammatic representation of the monoaxial path of the screw shown in FIGS. 47 and 48 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0106] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0107] Referring generally to the Figures, disclosed is an exemplary embodiment of the thread thru polyaxial pedicle screw system for use in a spinal fixation system. The pedicle screw system ( 10 ) is based on an anchoring member formed from a bone screw ( 12 ) including a shank ( 14 ) with at least one helical thread ( 16 ) formed along the length thereof. It is important to note that the proportions of the bone screw depicted are for illustrative purposes only and variations in the length of the shank, diameter of the screw, thread pitch, thread length, number of thread leads, shank induced compression and the like may be varied without departing from the scope of the invention. As will be further described later in this specification, unique to invention is the ability to use various shank widths and thread sizes with the same connector which reduces the manufacturing inventory. At the upper end ( 20 ) of the shank ( 14 ) is a ball shaped spherical connector ( 18 ) having a predetermined diameter. The diameter of the spherical connector ( 18 ) and the width of the shank ( 20 ) control the angular positioning (A) of about 60 degrees that the shank has of conical polyaxial motion in relation to the connector assembly ( 30 ).
[0108] FIG. 1 depicts a connector assembly ( 30 ) that is U-shaped and includes an upper connector member ( 31 ) and a lower connector member ( 33 ) having a polyaxial bone screw with movement depicted throughout a radius (R) which is controlled by a retainer ring construction ( 42 ), described in detail later in this specification, or by construction of the ball shaped connector ( 18 ). The angular positioning of the bone screw having a predetermined angular displacement (A).
[0109] FIG. 2 depicts a monoaxial bone screw having a mono angular predetermined angular displacement (A). FIG. 3 depicts a side view of either FIG. 1 or FIG. 2 wherein the predetermined angular displacement (A) is controlled by a retainer ring construction ( 42 ) or by construction of the ball shaped connector ( 18 ), described in detail later in this specification.
[0110] FIG. 4 depicts a connector assembly ( 130 ) that allows for side loading and includes an upper connector member ( 131 ) and a lower connector member ( 133 ) having a polyaxial bone screw with movement depicted throughout a radius (R) which is controlled by a retainer ring construction ( 42 ), described in detail later in this specification, or by construction of the ball shaped connector ( 18 ). The angular positioning of the bone screw having a predetermined angular displacement (A). The connector ( 131 ) is in receipt of a connecting rod 70 .
[0111] FIG. 5 depicts a monoaxial bone screw having a mono angular predetermined angular displacement (A). FIG. 6 depicts a side view of either FIG. 4 or FIG. 5 wherein the predetermined angular displacement (A) is controlled by a retainer ring construction ( 42 ) or by construction of the ball shaped connector ( 18 ), described in detail later in this specification.
[0112] As shown in FIGS. 7 , 8 and 12 , the U-shaped connector 30 has an upper connector member ( 31 ) with a substantially circular side wall ( 32 ) divided by a pair of U-shaped openings ( 49 ) forming an upstanding first interior side wall ( 34 ) and second interior side wall ( 36 ). A portion of each said side wall is threaded ( 54 ) for receipt of a set screw used in securing a rod within the connector. The connector assembly is sized to cooperate with the retaining ring ( 42 ) for receipt of various sized rods, as well as limiting the range of motion of between the connector ( 30 ) and the screw ( 12 ). A driver receptacle ( 22 ) is located along the upper end ( 20 ) of the spherical connector for use in installing the bone screw. It should be noted that the driving receptacle may be any shape, male or female, suitable for cooperation with a driving tool to rotate the bone screw into its final position.
[0113] The upper connector member ( 31 ) preferably includes a shoulder ( 92 ) on the bottom surface thereof for location of the lower connector member ( 33 ) forming a socket area ( 44 ) for receipt of a retainer ring ( 42 ) there between. The socket area ( 44 ) is constructed and arranged to cooperate with the spherical ball connector on the bone screw and is further designed to prevent rotation of the retainer ring ( 42 ) thereby maintaining the saddle surface area in alignment with the U-shaped opening. Alignment is maintained by inset side walls ( 45 , 46 ) which operate in conjunction with side walls ( 43 , 48 ) of the retainer ring ( 42 ).
[0114] The lower connector member ( 33 ) also includes a shoulder ( 96 ) that is constructed and arranged to cooperate with shoulder ( 92 ) to maintain alignment of the two components. The lower connector member ( 33 ) includes a substantially spherical shaped receptacle ( 38 ) which operates in conjunction with the upper component member to house the retainer ring ( 42 ) used to engage the spherical ball ( 18 ). The shoulders ( 92 ) and ( 96 ) are utilized to align the components and the upper and lower connector members, once assembled the connector members are laser welded together. It should be noted that other suitable methods or techniques of attaching the upper and lower connector members together may be utilized without departing from the scope of the invention, such methods may include, but should not be limited to spot welding, threads, adhesives, pins swaging, solder, interference fits and suitable combinations thereof.
[0115] The retainer ring ( 42 ) is positioned within the lower receptacle ( 38 ) with an upper edge ( 52 ) positionable within the cavity formed by side wall ( 41 ); the retaining ring side wall ( 43 ) cooperates with side wall ( 41 ) of the cavity to prevent rotation of the retaining ring. The inner surface ( 56 ) of the retaining ring has a spherical diameter and provides for self centering by engaging of the outer surface of the spherical connector ( 18 ). The upper surface ( 53 ) of the retaining ring ( 42 ) includes a concave cylindrical surface for cooperation with the connecting rod ( 70 ). The cylindrical surface provides additional surface area for contact with the connecting rod and may include a knurled or otherwise modified surface finish adapted to enhance gripping power between the rod and the connecting assembly ( 30 ). The retaining ring ( 42 ) includes a biasing member to cause a tension from the retaining ring ( 42 ) to the spherical ball ( 18 ). In the preferred embodiment the biasing member is coil springs ( 102 ) that are located to cooperate with spring pockets ( 100 ) positioned in the upper connector member to locate and contain coil springs ( 102 ). The spring members bias the retaining ring toward the opening ( 50 ) of the lower receptacle. It should be noted that while springs are depicted, the biasing member can be a polymer or any other resilient material that can be use to apply a light pressure onto the retaining device to maintain a separation. Once the anchoring member is secured to the bone, a rod placed within the connector assembly fits within the U-shaped saddle ( 49 ) and is placed on the surface ( 53 ) of the retainer ring. The set screw ( 80 ) is threaded onto the threads ( 54 ) of the upper connector ( 31 ) wherein the rod forces the retainer ring ( 42 ) onto the spherical ball connector ( 18 ) locking the assembly into a fixed position. Alternatively the upper connector member can include the use of the well know faster type wherein the upper connector member had an external thread and the fastener element would be a nut having internal threads.
[0116] The surface ( 53 ) of the retainer ring ( 42 ) includes a clamp angle that provides positive contact with the rod connection member along multiple points with the exact point position dependant upon the diameter of the connecting rod. A third point is supplied by the bottom of the set screw ( 80 ) creating three point securement when used with any diameter rod. A driver receptacle ( 83 ) is located along the upper end of the set screw ( 80 ) for use in installing, the driving receptacle may be any shape, male or female, suitable for cooperation with a driving tool to rotate the set screw into its final position.
[0117] The pedicle screw system ( 10 ) is a pass through along a portion of the device allowing a larger bone screw to be used without increasing the size of the connector. FIGS. 9-11 depict the steps of selecting an anchoring member having a threaded shank ( 16 ) of an elected size for a particular installation. The shank may be small or large, the threads may be small or large, or any combination therebetween. The threaded shank) is inserted into the opening ( 50 ) of the lower connector member ( 33 ), the lower connector member having a centrally disposed aperture which is constructed and arranged to allow the threaded shank to pass through. The lower connector member ( 33 ) includes a pass through thread ( 103 ) which allows the larger threaded shanks to pass through by matching the threaded shank with the pass through thread. In operation, an oversized bone screw can be installed by use of a helical rotation ( 107 ) wherein the bone screw is threaded through the member ( 33 ). The pass through thread ( 103 ) having a helical assembly groove to match the bone screw threads. The connector remains the same size and is situated in the socket ( 96 ), the design allowing a variety of anchor screws to be inventoried yet only one size connector assembly needs to be inventoried. It should be noted that the spherical head ( 20 ) of the bone screw engages the thread of the lower connector in a uniform manner wherein the edge of the thread provide a superior edge for gripping of the head.
[0118] Once the anchoring screw is positioned, the retainer ring is placed in the socket ( 96 ), the retainer ring ( 42 ) having a lower spherical surface ( 56 ) positionable along an upper surface of the spherical connector ( 18 ), the upper surface ( 53 ) of the retainer ring constructed and arranged to receive a connecting rod. A clearance aperture ( 61 ) allows passage of a driver for use in securing to the bone screw fastener ( 22 ). The spring member ( 102 ) is attached to the upper connector ( 31 ) having the spring pockets ( 100 ). The upper connector member is then coupled, or welded as previously mentioned, to the lower connector member engaging the springs to bias the retainer ring against the anchoring member.
[0119] Now referring to FIGS. 18-35 set forth is an embodiment of the limiting retainer ring element ( 142 ) for limiting the movement of an anchoring screw in a monoaxial direction. A first embodiment employs a shaped cavity within the retainer ring; a second embodiment employs a shaped spherical head on an anchoring screw. It will be obvious to one skilled in the art that either embodiment accomplishes the inventor's goals, as would a combination of the embodiments. The retainer ring ( 142 ) includes an upper wall ( 144 ) for use in cooperating with the side wall of a connector cavity to prevent rotation of the retaining ring. The inner surface ( 156 ) of the retaining ring has a spherical diameter and provides for self centering by engaging of the outer surface of the spherical connector ( 160 ). The upper surface ( 153 ) of the retaining ring ( 142 ) includes a concave cylindrical surface for cooperation with a connecting rod. The cylindrical surface provides additional surface area for contact with the connecting rod and may include a knurled or otherwise modified surface finish adapted to enhance gripping power between the rod and the connecting assembly. A lower portion ( 147 ) of the retaining ring ( 142 ) includes a shape adapted for placement over a shaped spherical connector ( 160 ) which in a first embodiment includes a recessed area ( 162 ) having a substantially flat abutment surface ( 164 ). The lower portion ( 147 ) of the retaining ring limiting range of monoaxial movement in accordance with the angle of the lower portion ( 147 ) in respect to the flat abutment surface ( 164 ).
[0120] In an alternative embodiment the lower portion ( 147 ) of the retaining ring ( 142 ) includes a shape adapted for placement over a shaped spherical connector ( 170 ) which in this embodiment includes a recessed area ( 172 ) having a substantially flat abutment surface ( 174 ). The lower portion ( 147 ) of the retaining ring limiting range of movement to and angle set by B which in this embodiment is zero, however, changing of angle B on the retainer ring or the spherical head would allow for monoaxial range of motion.
[0121] As previously mentioned, the spherical head of the bone screw may include a variation of the above embodiments. FIGS. 29-23 depict the lower portion ( 177 ) of the retaining ring ( 178 ) to include a shape adapted for placement over a shaped spherical connector ( 180 ) which in this embodiment includes a recessed area ( 172 ) having an angled abutment surface ( 184 ). The lower portion ( 177 ) of the retaining ring limiting range of movement to and angle set by C which in this embodiment is zero, however, changing of angle C on the retainer ring or the spherical head would allow for monoaxial range of motion.
[0122] As shown in FIG. 35 , the U-shaped connector 230 has an upper connector member ( 231 ) and a lower connector member ( 233 ). A portion of each said side wall is threaded ( 254 ) for receipt of a set screw ( 260 ) used in securing a rod ( 262 ) within the connector. The connector assembly is sized to cooperate with the retaining ring ( 142 ) for receipt of various sized rods, as well as limiting the range of motion of between the connector ( 230 ) and the screw ( 212 ). The screw ( 212 ) includes recessed areas for receipt of the retainer ring ( 142 ) for limiting the range of motion in a monoaxial direction and with a limit as to displacement by surface ( 147 ). Biasing springs ( 102 ) place a constant pressure upon the retainer ring which frictionally engages the head of the spherical screw.
[0123] FIG. 36 is a side view of a side loading connector assembly ( 300 ) depicting the placement of rod ( 302 ). The insertion of the rod ( 302 ) along the side allowing for certain advantages in various surgeries. The strength of the connector has been found to be the same as a top loading connector. FIG. 38 is a cross sectional side view of a polyaxial side loading connector having an upper connector member ( 306 ) that is welded to the lower connector member ( 308 ) thereby allowing the larger bone screw and spherical head ( 310 ) to be placed therein. The upper connector ( 306 ) member being generally C shaped having a top annulus portion ( 320 ) and a bottom annulus portion ( 322 ). The top annulus ( 320 ) includes internally directed threads that operatively engage a set screw for securing the rod ( 302 ) to the retainer ( 42 ) and the spherical head ( 310 ). The top annulus portion ( 320 ) is formed integrally with the bottom annulus portion ( 322 ) and a side wall ( 324 ). Side wall ( 324 ) circumscribes less than half of the circumference of said top and bottom annulus portions. The retaining ring ( 42 ) is again preloaded with the biasing member springs ( 102 ) to assist in maintaining the bone screw in position during installation. It should be noted that the removal of the biasing member would not defeat this invention as the biasing member is simply a benefit for the surgeon during installation and the lack of the biasing springs would simply require the holding of the connector while positioning of the connecting rod.
[0124] FIG. 40 is a cross sectional side view of a monoaxial side loading connector. In this embodiment the upper body element ( 326 ) is again welded to the lower body element ( 338 ) thereby allowing the larger bone screw and spherical head ( 160 ) to be placed therein. The retaining ring ( 142 ) is preloaded with the biasing member springs ( 102 ) to assist in maintaining the bone screw in position during installation. The shape of the retainer ring operatively associated with the shape of the recessed area of the bone screw to allow movement only in a monoaxial direction.
[0125] It should be noted that while the springs ( 102 ) are illustrated as coil springs, any spring or resilient type member suitable for displacing the retaining ring may be utilized without departing from the scope of the invention. Such spring or resilient members may include, but should not be limited to, Belleville type springs, leaf springs, polymeric members and suitable combinations thereof. It should also be noted that the recessed area or the flat portions on the sides of the spherical head may be displaced angularly to provide an assembly that provides a fixed angularly displaced connector or an angularly displaced connector with a limited range of monoaxial movement.
[0126] FIG. 41 is a perspective view showing the range of various sized pedicle screws and tulip heads including lumber thoracic spine sizing and cervical-thoracic spine sizing. The five larger screws as shown are lumber-thoracic spine sizing. The largest screw is 55 mm and uses an 8.5 mm tulip, the next smaller size screw is 45 mm and uses a 7.5 mm tulip, the next smaller screw is 40 mm and uses a 6.5 mm tulip, the next smaller screw is 35 mm and uses a 5.5 mm tulip and next smaller screw is 25 mm and uses a 4.5 mm tulip. These lumber thoracic screws use a 5.5 mm rod. The three smallest screws as shown are cervical thoracic spine sizing. The largest of this group is 18 mm with a 4.5 mm tulip, the next smaller screw is 14 mm with a 4.0 mm tulip and the smallest screw is 10 mm with a 3.5 mm tulip. These cervical thoracic screws utilize a 3.5 mm rod. The cervical thoracic spine sized screws are approximately two thirds the size of the lumbar thoracic sized screws. With the smaller sized screws the geometric relationship between the screw and the tulip is such that need for threading the screw through the lower member is eliminated. However it has been found that the utilization of at least one groove on the spherical bearing surface seat is very beneficial in gripping and locking the pedicle screws spherical head to the spherical bearing seat.
[0127] The tulip connector assembly shown in FIG. 42 includes an upper connector member 431 and a lower connector member 433 . The lower connector member is formed as an annulus and includes an aperture 440 . In this configuration the outer diameter of the threaded shank is smaller than the diameter of aperture 440 . The lower connector member has a spherical bearing surface 458 that will cooperate with the spherical head 20 on the anchoring screw. The threaded shank is inserted into the lower connector member 433 and through aperture 440 . Since the outer diameter of the threaded shank is smaller than the diameter of the aperture 440 the screw will pass through the aperture without the aid of screw threads and the spherical head 20 of the anchoring member can be positioned to cooperate with the spherical bearing seat surface 458 of the lower connector member 433 . A retainer ring 442 having a lower spherical surface 456 is resiliently mounted within in a cavity of the upper connector by a biasing member 402 shown in this configuration as a plurality of coil springs. The lower connector member 433 includes spherical seat bearing surface 458 . The spherical head of the screw cooperates with spherical bearing surfaces 456 and 458 to permit polyaxial motion of the connector assembly relative to said anchoring member. The upper and lower connector members 431 and 433 are secured to one another using any one of the suitable techniques previously described. This screw can also be used in conjunction with a side loading connector assembly such as that disclosed in FIGS. 36-38 . In this instance the upper connector member would be generally C shaped having a top annulus portion and a bottom annulus portion. The top annulus includes internally directed threads that operatively engage a set screw for securing the rod to the retainer and the spherical head. The top annulus portion is formed integrally with the bottom annulus portion and a side wall. Side wall circumscribes less than half of the circumference of said top and bottom annulus portions. Located on spherical bearing seat surface 458 is a gripping and locking groove 470 .
[0128] FIG. 43 is an enlarged view of the encircled detail area shown in FIG. 42 . The groove 470 circumscribes a minor portion of the circumference of the spherical bearing seat surface 458 . The groove 470 starts at a zero depth at a lower portion 474 of the spherical bearing surface 458 . The grove 470 penetrates to the design depth as it approaches the upper portion 476 of the spherical bearing seat surface 458 . The helical groove 470 is used as an additional aid in locking the spherical head of a screw in its polyaxial position. The groove provides additional points and edges for friction gripping. Under high locking forces the groove also provides a flexing interface for the spherical seat surface to deform and better mate to the spherical head of the screw.
[0129] FIG. 44 is a perspective top view of the lower connector member 433 with a single groove 470 on the spherical bearing seat surface 458 . FIG. 45 is a perspective top view of an alternative embodiment wherein lower connector member 433 has a pair of grooves 471 and 472 formed on the spherical bearing seat surface 458 . FIG. 46 is a perspective top view of a third embodiment wherein the lower connector member 433 includes three grooves 473 , 474 and 475 each circumscribing only a minor portion of the bearing seat surface 458 . FIG. 47 is a cross sectional view of the embodiment shown in FIG. 46 .
[0130] FIGS. 48 and 49 show different cross sectional views of an embodiment similar to that shown and described in FIG. 42 however in this embodiment the motion of the connector assembly relative to said anchoring member is limited to either mono axial movement or a fixed relative position. The connector assembly ( 530 ) has an upper connector member ( 531 ) and a lower connector member ( 533 ). A portion of each said side wall of the upper connector member is threaded for receipt of a set screw ( 506 ) used in securing a rod ( 504 ) within the connector assembly ( 530 ). The connector assembly ( 530 ) is sized to cooperate with the retaining ring ( 542 ) for receipt of various sized rods, as well as limiting the range of motion of between the connector assembly ( 530 ) and the screw ( 512 ). The screw ( 512 ) has a spherical connecting head ( 514 ). The spherical head includes recessed areas ( 562 ) for receipt of the retainer ring ( 542 ) for limiting the range of motion in a monoaxial direction and with a limit as to displacement by surfaces ( 547 ). Biasing springs ( 502 ) place a constant pressure upon the retainer ring ( 542 ) which frictionally engages the spherical head ( 514 ) of the screw ( 512 ). It is also possible to size and configure the recessed areas ( 562 ) and retainer surfaces ( 547 ) to achieve a fixed relationship between the anchoring screw 512 and the connector assembly ( 530 ). The lower connector member 533 includes a spherical bearing seat surface and one, two, or three gripping and locking grooves as illustrated and described in FIGS. 44 through 47 .
[0131] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0132] 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 any drawings/figures included herein.
[0133] 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. | A pedicle screw fastening that can be made polyaxial, monoaxial, fixed, or provide a predefined monoaxial placement. The fastening system consists of an anchoring bone screw having threads on one end for use in anchoring to the screw to the spine and a spherical connector on the other end operating as a pivot point about which a U-shaped or side loading connecting assembly is used to secure to a connecting rod for use in stabilization of a spine. The connecting assembly, for receipt of a spinal connecting rod, includes a biased retainer ring for maintaining a positive tension between the connecting assembly and the anchored screw. The system allows for an improved manufacturing step wherein the threaded shank of a bone screws can be passed through a lower portion of the connecting assembly allowing a variety of bone screw sizes to be used with a common sized connector. | 0 |
RELATED APPLICATIONS
This is a continuation of application Ser. No. 502,073, filed Aug. 30, 1974, now abandoned, which is a continuation-in-part of our copending parent application, Ser. No. 401,663, filed Sept. 28, 1973, entitled ARCHITECTURAL GLAZING SYSTEM, and now abandoned.
THE INVENTIVE IMPROVEMENT
Glazing devices have been suggested for holding glass panels in place in buildings and for holding windshields in place in automobiles and trucks, and such devices have to meet many specifications relative to the force of wind and weather, variations in temperature, ease and security of installation, retention of glass in a crash, etc. Glazing devices thus present difficult problems in achieving optimum solutions.
The invention involves recognition of the problems encountered by glazing devices, and proposes a simpler and better solution using a spring material enclosed in an elastomeric casing and arranged to press tightly against the glass to seal the glass and hold it securely in place. The invention aims at security, ease of installation, and reliable functioning in all weather and operating conditions.
SUMMARY OF THE INVENTION
The inventive glazing device includes a longitudinally extending strip for engaging and holding the periphery of a glass panel. The strip includes a length of spring material and an elastomeric material extruded over and encasing the spring material. The spring material is formed of a high-tensile-strength, resilient wire element formed in a transverse pattern of zig-zag loops with the pattern extending along the length of the strip, and longitudinally extending rows of knitted strands link the loops together in the zig-zag pattern. The strip is anchored in place adjacent the glass panel so a cantilevered portion of the strip extends from the anchorage to engage the glass panel. The spring material extends from the anchorage into the cantilevered portion to the region of the engagement of the strip with the glass panel, and the glass is held in a position displacing the cantilevered portion to flex the spring material in the region between the anchorage and the engagement with the glass to produce a predetermined pressure of the strip against the glass panel for sealing and holding the glass securely in place.
DRAWINGS
FIGS. 1-8 are partially schematic, cross-sectional views of four preferred embodiments of the inventive glazing device holding a glass panel in place on a structural edge;
FIG. 9 is a partially schematic, plan view of a preferred embodiment of a carrier material for use in the inventive glazing device;
FIGS. 10 and 11 are partially schematic, cross-sectional views of preferred embodiments of the inventive glazing device applied to an architectural glazing;
FIG. 12 is a partially schematic, cross-sectional view of a preferred embodiment of a three-part glazing device for architectural purposes;
FIGS. 13-15 are partially schematic, cross-sectional views of additional preferred embodiments of the inventive glazing device for architectural purposes; and
FIGS. 16-18 are partially schematic, cross-sectional views of preferred embodiments of the inventive glazing device for holding and sealing automotive windshields.
DETAILED DESCRIPTION
The inventive architectural glazing device includes a resilient carrier providing springiness and resilient strength for securely supporting and sealing glazing strips in place. Suitable carriers can be formed of several materials such as resilient plastic, resilient plastic wire, and metal in the form of sheets, slotted sheets, perforated sheets, and expanded metal. However, a preferred form of carrier 10 is shown in FIG. 9 as zig-zag wire loops 11 held together by stitching 12 and extending longitudinally through the metal loops. The result is generally non-stretchable longitudinally but sufficiently flexible laterally to be bent into a coil. Wire loops of carrier 10 can be bent into any desired cross-sectional shape by generally known roll-forming methods, and although carrier 10 is familiar in other environments, it has not been used in architectural glazing strips. The desired strength and resilience of carrier 10 can be adjusted by varying the size and tensile strength of the wire in loops 11 and by varying the position and numbers of rows of stitching 12. Either carrier 10 as illustrated in FIG. 9 or another suitable carrier is used in each of the glazing devices shown in FIGS. 1-8 and illustrated therein only schematically.
In addition to forming carrier 10 in different ways of different materials, the elastomeric material covering carriers 10 can be formed of a variety of rubber and synthetic rubber materials. The covering of carriers 10 with elastomeric material is preferably accomplished in a cross-head extruder so that carrier 10 is formed and shaped as desired and then provided with an extruded covering of elastomeric material to complete each strip of the inventive glazing device. The drawings show that many configurations are possible for the inventive device, and those skilled in the art will understand that other configurations can be used for specific circumstances.
The glazing device of FIG. 1 includes a pair of strips 13 and 14 each having a pair of carrier strips 10 as illustrated, and positioned to hold a glass panel 15 on a structural edge 16. Edge 16 is generally in the plane of glass panel 15 and extends toward glass panel 15 around the periphery of glass panel 15. Strip 13 extends through the space between panel 15 and edge 16, and includes a slot 17 having inturned edges 18. Strip 14 extends around slot 17 and has a double-edged hook 19 engaging the edges 18 of slot 17 to hold strips 13 and 14 together. Carriers 10 extend into hook 19 and straddle slot 17 to secure the engagement of strips 13 and 14 together. Carriers 10 also extend into the regions where strips 13 and 14 engage the surfaces of glass panel 15 and structural edge 16 to press strips 13 and 14 securely and tightly in place. Either strip 13 or 14 can be an interior strip, and when the other strip is pressed into locking engagement, the two strips firmly seal both the inner and outer surfaces of panel 15 and edge 16.
The glazing device of FIG. 2 is similar to the device of FIG. 1, except that strips 20 and 21 are shaped to place slot 17 and hook 19 between edge 16 and panel 15 in the same plane as edge 16 and panel 15. This leaves the device of FIG. 2 generally plane on both sides of the mounting and otherwise functions in the same way as the device of FIG. 1.
The device of FIG. 3 is similar to the device of FIG. 1, except that strips 22 and 23 each have a single, continuous length of carrier strip 10 extending into both the regions of engagement with edge 16 and panel 15 and respectively around slot 17 and into hook 19. This requires a greater width of carrier material 10 but only two pieces of carrier material 10 -- one for each strip 22 and 23, and it also makes a somewhat stronger construction than shown in FIG. 1.
The glazing device of FIG. 4 is similar to the device of FIG. 2, except that strips 24 and 25 have single-piece carriers 10 as shown in the device of FIG. 3. This also requires a wider carrier 10, but can be made stronger than the device of FIG. 2.
The devices of FIGS. 5 and 6 are similar in having a strip 26 shaped to engage both the inner and outer surfaces of edge 16 or panel 15 and one of the surfaces of the opposite member, and strip 27 engages the other surface of the opposite member and has a hook 28 locking into a slot 29 in strip 26. Strip 26 is secured in place preferably to straddle the inner and outer surfaces of a structural edge, a glass panel is placed against the inwardly extending portion of strip 26, and strip 27 is locked to strip 26 to seal the other surface of the glass panel 15 for securely holding it in place. The differences between the embodiments of FIGS. 5 and 6 are in the shaping and joining of two carriers 10 in strip 26, the FIG. 5 variation having a double thickness of carrier 10 on one side of slot 29 and the FIG. 6 variation having a double thickness of carrier 10 on both sides of slot 29.
The embodiments of FIGS. 7 and 8 are similar in having strips 30 and 31 (FIG. 7) and 32 and 33 (FIG. 8) having respectively a slot 29 and a hook 28 for interlocking together to hold the strips on opposite sides of edge 16 and panel 15. The embodiments of FIGS. 7 and 8 are also similar to the embodiments of FIGS. 2 and 4, except for a different shaping of carrier strips 10, hook 28 and slot 29. The FIGS. 7 and 8 embodiments differ from each other where strip 32 of FIG. 8 extends a small distance around the edges of panel 15 and edge 16, and strip 30 of FIG. 7 merely extends through the space between panel 15 and edge 16.
The inventive glazing device is strong, rugged and securely engages a structural edge and a glass panel and holds the glass firmly and tightly in place to keep a seal against all weather conditions, and it is easy to install and is secure after installation.
Experience with the invention since the parent application was filed has resulted in some improved ways of applying a glazing device in architectural constructions, and expansion of the glazing device into the automotive field. Also, the design and function of the "carriers" has become increasingly important. The advances in knowledge about practicing the invention are explained below.
Carrier 10 as shown in FIG. 5 is highly preferred for use in the inventive glazing device, and is essentially a spring material providing the resilience to give the glazing device the necessary sealing and holding pressure against the glass panel. Spring material 10 is preferably formed of a high-tensile-strength resilient wire element, preferably of a metallic material such as high-carbon steel, although some high-tensile-strength resin materials are being developed that may provide characteristics to form a spring. By selecting a wire element of the proper tensile-strength, diameter, and number of loops per unit of length, the resilience and spring bias of spring material 10 can be adjusted to fit any particular design. Spring material 10 then provides the resilience and gripping force to hold the glazing device securely against the glass and hold the glass in place, and prior art glazing devices lacking an internal spring have a less reliable and less forceful grip.
Glazing devices presently made for architectural and automotive purposes are formed of elastomeric material and provide a gripping force by using a substantial mass of elastomer. These encounter several problems, however, because there is a fairly wide manufacturing tolerance on the ultimate durometer of the elastomeric product, and its firmness or stiffness varies widely with temperature. Also, it loses much of its original grip after a few years, and these characteristics lead to many problems and dangers.
Encasing a spring material within an elastomer relieves the elastomer of gripping requirements which are provided by the spring so that the elastomer can become merely a cover and casing material and provide a sealing surface pressed against the glass. The spring formed of a zig-zag wire element can be designed to provide whatever gripping force is desired, and can do so within a narrower range of tolerance than is possible in relying on the elastomer to do the gripping. Also, the resilient grip provided by the spring material inside the glazing device does not reduce substantially with age and does not vary with changes in temperature so that the resulting grip is predictable, constant, and reliable throughout the life of the seal. This insures that the glass panel is held securely in place and greatly reduces the expense of repair or replacement of glazing devices.
Not only must spring material 10 be properly constructed to give the desired resilience and grip, but it must be properly configured relative to its anchorage and to the glass panel held in place so that the spring material extends from an anchorage region into a cantilevered portion of the glazing device to the region where the elastomer engages the glass. Then in the final assembly, spring material 10 is flexed from a relaxed position to provide the desired pressure against the glass panel. Considering the necessary manufacturing tolerances between the glass size and the frame size, a strong grip by the glazing device as provided by spring material 10 is an important feature of the invention in securely gripping and holding glass panels in place. Also, the powerful grip made possible by spring material 10 is useful in automotive windshield mountings for holding the windshield in place in crashes to help keep the occupants safely within the vehicle. Standards for retention of automotive windshields are increasing, and the powerful grip provided by spring material 10 is one efficient and economical way to meet such standards.
Glazing device 40 of FIG. 10 shows a preferred two-part glazing device for supporting glass panel 41 within a structural edge 42 in an architectural frame 43. Element 44 provides an anchorage, including a channel 45 straddling edge 42 and locked onto edge 42 by holding projections 46. A length of a zig-zag wire element spring material 47 similar to spring material 10 is formed into a U shape as illustrated to give channel 45 a firm grip on edge 42.
Element 44 also includes a spring 10 formed as illustrated to extend into a cantilevered free edge 48 engaging one side of glass panel 41 with spring material 10 providing a firm resilient grip. Element 49 is formed to interlock with an enlarged edge 50 of element 44, and spring material 10 inside of element 49 is bent into a U shape surrounding element 50 and has an enlarged head 51 snapping over and interlocking with head 50 to provide an anchorage for element 49. A cantilevered edge 52 of element 49 extends upward to engage the opposite side of glass panel 41, and cantilevered edges 48 and 52 exert a firm grip against glass panel 41 for holding it securely in place. The spring materials of elements 44 and 49 are encased in an extruded covering of an elastomeric material 53 to enhance the frictional grip of the device and to conform to glass 41 and edge 42 for a secure seal. The interlocking anchorage between elements 44 and 49 braces both elements securely relative to edge 42 so that cantilevered edges 48 and 52 are flexed in the final engagement with glass panel 41 and provide the necessary gripping force. Elastomeric cover 53 is then relieved of gripping responsibility by itself.
Glazing device 55 of FIG. 11 is similar to glazing device 40 of FIG. 10, except for having a different form of interlock between elements 56 and 57. Element 57 has a gripping channel 58 biased by zig-zag wire spring element 59 for gripping edge 42 and also includes a zig-zag spring 10 biasing a cantilevered edge 60 into gripping engagement with glass panel 41. The elastomeric covering 61 over element 57 is thickened to form a head region 62, and spring material 10 of element 56 is formed to wrap around head 62 to interlock elements 56 and 57 together. Element 56 includes a bracing leg 63 pressed against the outside of gripping channel 58 of element 57 and a cantilevered arm 64 biased tightly against glass 41 by the resilience of spring material 10. Element 57 is fitted over edge 42, then element 56 is snap-fit over head 62 so that cantilevered arms 60 and 64 press inward for a firm grip on opposite sides of glass panel 41.
Glazing element 65 of FIG. 12 is a three-piece device including an anchorage 66, and a pair of glazing elements 67 and 68. Anchorage element 66 has a channel 69 biased by a zig-zag spring wire element 70 for gripping edge 42 and also includes a pair of anchorage heads 71 and 72 that are reinforced by spring material 73 bent back on its ends as illustrated. Elements 67 and 68 each have spring material 10 formed to wrap respectively around heads 71 and 72 for an interlock with anchorage 66, and springs 10 bias cantilevered arms 74 and 75 tightly against opposite sides of glass 41 to hold glass 41 securely in place. Anchorage 66 is fitted over edge 42, and then glass 41 is positioned in the opening inside edge 42 by movement into place either from the interior or the exterior, and one of the strips 67 and 68 is preferably positioned on anchorage 66 before this is done. When glass 41 is positioned against one of the strips 67 or 68, the other strip 67 or 68 is snapped in place over anchorage 66 to press against glass 41 and complete the installation. If glass 41 needs to be replaced, either one of the strips 67 or 68 can be removed and replaced along with glass panel 41.
FIG. 13 shows another form of the inventive glazing device using a pair of glazing strips 76 and 77 each having an internal spring material 10 extending from anchorage region 78 into cantilevered edge region 79 engaging glass panel 80 as illustrated. Anchorages 78 are lodged respectively in slots 81 on opposite sides of glass panel 80 which rests on a spacer block 82 between slots 81. One of the strips 76 or 77 is pressed in place in a slot 81, glass 80 is moved into position, and the other strip 76 or 77 is then pressed in place so that springs 10 in each of the strips 76 and 77 are flexed to press cantilevered arms 79 tightly against glass 80 to seal glass 80 and hold it securely in place.
The embodiment of FIG. 14 is similar to the embodiment of FIG. 13, except that glazing strip 77 is replaced by a tape or strip 83 secured to a structural edge 84 around glass 80 and formed of an elastomeric material that is slightly deformable under the pressure of cantilevered edge 79 of strip 76 biased by spring material 10 pressing against glass panel 80. Strip 83 holds glass 80 yieldably against glazing strip 76 whose spring 10 produces the required sealing pressure.
The embodiment of FIG. 15 is similar to the embodiment of FIG. 14, except that glazing strip 85 is extended to have a brace leg 86 lodged in a notch 87 spaced from anchorage slot 81 so that the cantilevered end 88 of glazing strip 85 is also supported by brace leg 86 to increase the pressure applied to glass 80 which is pressed against elastomeric gasket 83 supported on structural edge 84. Spring material 10 extends from the region of anchorage 78 in slot 81 up to cantilevered edge 88 and back down through brace leg 86 to give the desired springy resilience throughout the cross-sectional length of glazing strip 85.
FIGS. 16-18 show three preferred embodiments of the inventive glazing device used to support an automotive windshield 90. Sheet metal strips 91 and 92 are secured together to form a fence 93 around the opening for windshield glass 90, and each of the glazing devices is secured in place around fence 93 and grips windshield glass 90 with sufficient resilient force to provide a good seal and a reliable hold on glass 90 even during a crash.
In the embodiment of FIG. 16, element 94 has a channel 95 reinforced by a zig-zag wire spring element 96 for retaining a position on fence 93 by pressing projections 97 tightly against fence 93. Element 94 also includes a block 98 supporting the edge of glass 90 and projections 99 wedging against sheet metal strip 91 to help hold element 94 securely in place. Spring member 96 of element 94 extends under glass 90 and has an upturned cantilevered end 100 supporting cantilevered edge 101 on the opposite side of glass 90 from fence 93.
A retainer element 102 having a zig-zag spring wire element 103 is shaped to fit in a notch 104 formed inside of cantilevered end 101, and projections 105 interfere to hold strip 102 securely in notch 104. Strip 102 also has a free end 106 that is deformed to the solid-line position from the relaxed broken-line position as illustrated to seal tightly against sheet metal 91. Element 94 has a bearing edge 107, and element 102 has a corresponding bearing edge 108 pressing against opposite sides of glass 90 and biased tightly against glass 90 by the interlock between elements 94 and 102, and by the cantilevered bracing of leg 106 of element 102. The pressure between edges 107 and 108 is determined partly by the tensile strength, diameter, and number of loops per unit of length of spring elements 96 and 103, and is preferably sufficient to retain glass 90 in its mounted position even during a crash of the vehicle. Element 94 is mounted on fence 93, then glass 90 is placed on block 98 of element 94, then retainer strip 102 is pressed in place to interlock with element 94 and press against glass 90 with the desired pressure.
The embodiment of FIG. 17 uses an element 110 having a zig-zag wire spring 111 formed into a channel shape as illustrated to straddle glass 90. Element 110 has a cantilevered edge 112 biased from the broken-line position to the solid-line position in the illustrated engagement with sheet metal 91 to seal against sheet metal 91, and projections 113 interlock with sheet metal 91 and projections 114 interlock with fence 93. Element 110 also has an edge 115 for engaging the outer face of windshield 90, and another edge 116 positioned to receive the peripheral edge of windshield 90. Edges 115 and 116 are formed of the elastomeric material encasing spring material 111. Element 110 is placed around the edge of windshield glass 90, and glass 90, along with element 110, is pressed toward fence 93. Then element 117 is fastened over fence 93 and over upstanding leg 118 of spring material 111 to interlock elements 110 and 117 together. Element 117 also has an edge 119 engaging glass 90 opposite the engagement of edge 115. Projections 120 retain element 117 on fence 93 and provide interlocking engagement with upstanding leg 118 of element 110. Element 117 then draws element 110 tightly into engagement with fence 93, and also presses edge 119 against glass 90 so that edges 115 and 119 squeeze glass 90 tightly from opposite sides and hold it securely in place relative to fence 93, even during a crash of the vehicle.
The embodiment of FIG. 18 is similar to FIG. 17, except that elements 121 and 122 are somewhat differently shaped to accommodate a trim strip 123 secured in a notch 144 in element 121. Cantilevered edge 112 and projections 113 and 114 remain the same, and element 121 includes a zig-zag wire spring element 124 that is also U shaped to straddle the edge of glass 90. Locking element 122 is similar to element 117 of FIG. 17 and has projections 120 for interlocking with element 121 and holding the glazing system securely on fence 93. Edges 119 and 115 squeeze against opposite faces of windshield glass 90 under the bias of spring element 124 for a tight and secure seal and mount.
The illustrated embodiments of the invention show some of the many ways that spring material can be shaped for various sorts of mounts that support the spring material to press resiliently against the glass panel. Also, elastomeric coverings for the spring elements can have many shapes to cooperate with the spring element in engaging and sealing the glass panel and the structure within which the panel is mounted. Those skilled in the art will understand the many materials and configurations possible in applying the invention to various glass panel mountings. | A glazing device is formed of a longitudinal strip engaging and holding the periphery of a glass panel, and the strip is formed of a length of spring material with an extruded elastomeric covering. The spring material is formed of a high-tensile-strength, resilient wire element formed in a transverse pattern of zig-zag loops with longitudinally extending rows of knitted strands linking the loops together. The strip is anchored in place against the glass panel so the spring material extends from the anchorage into a cantilevered portion of the strip to engage the glass panel in a displaced position flexing the spring material to produce a predetermined pressure against the glass. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a back clip and particularly to a back clip for connecting an edge of a shelf to a wall.
Devices for attaching shelves to walls are numerous in form and configuration. These devices include some that are similar to the back clip of the present invention insofar as the existing back clips have been of molded plastic having a body with a wall anchor extending from it and with a wire engaging hook formed in it. In some of the existing devices, the wall anchor is of the kind having laterally expandable fingers that are expanded against the back side of a wall when a pin is extended through the wall anchor.
However, in spite of the myriad of devices for attaching shelves to walls, including a wide variety of clips, none incorporate the combination of features of the present invention as will be described.
SUMMARY OF THE INVENTION
This back clip comprises a unitary molded plastic clip body and a steel drive pin. The clip body is formed with a back section having a wall contact surface and a front surface. A wall anchor extends from the wall contact surface. The wall anchor has a body section with rings on it. Laterally expandable fingers are joined to the rear of the body section by thin plastic connectors that act as hinges. The body section is molded with the fingers straight and together. Therefore, it is not necessary to squeeze the fingers together to insert them into a pre-drilled hole in a wall. The laterally expandable fingers include transverse wall portions in the path of a passage through the body section so that when a drive pin is driven through the body section, its lead end will contact the transverse walls and, through a camming action, spread the fingers into laterally extending positions, and hold them there.
The transverse walls are preferably inclined inwardly and toward the head of the socket so that the pin will pivot the fingers as far outwardly as possible toward ninety degree projections relative to the axis of the passage.
A special feature of this invention is the provision of a web slightly spaced from the transverse walls. There is a small opening through the web, such as a slit. Without the web, a stress line would be formed during molding, the end of the core forming the passage where that core intersects the transverse walls. By providing the web, the location of the stress line is moved to the intersection of the core and the web, and the walls joining the web and the transverse walls can be formed rounded with no stress lines. This avoids failure at the pivot lines of the fingers that might result from stress lines.
The web performs another function. As the drive pin is driven through the passage, it first contacts the web and, because the slit is parallel to the pivot lines of the fingers, the pin will split the web and pivot its halves toward the fingers. Thereafter, when the pin cams the fingers outwardly, the web halves lie against the pin and present edges opposing a tendency of the transverse walls to slide back along the pin. The rings on the body section are sawtooth in side view to enable the body section to be pressed into a hole in a wall but the forward-facing edges of the rings are substantially radial to the body so that they resist removal of the wall anchor from the hole in the wall to a maximum degree.
On the clip body, The lower portion of the back section is formed with a hook member that has an open side facing upwardly to receive a wire or rod of a shelf. A stop is joined to the back wall by an integral thin plastic member that acts as a hinge. The stop has a projection on it with lateral flanges. It also has a recess in it. The back section has a specially designed recess for receiving the projection on the stop. Therefore, when the stop is pivoted about its hinge, the recess in the stop will receive the head of the pin. The length of the stop is such that, when locked in place with the projection in the recess, the stop is positioned across the open side of the hook member. In this position, the stop positively blocks release of the shelf wire from the hook member and at the same time covers the head of the drive pin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of the back clip partially installed on a wall;
FIG. 2 is a side elevation view of the back clip as installed on a wall;
FIG. 3 is an enlarged side elevation view of the back clip with parts shown in section;
FIG. 4 is an enlarged front elevation view of the back clip;
FIG. 5 is an enlarged top plan view in section through the recess in the clip body taken along the plane of the line 5--5 of FIG. 2; and
FIG. 6 is an enlarged view in medial section of the central portion of the socket showing the web with the pin driven through it.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and particularly to FIG. 1, this back clip 10 comprises a clip body 12 and a drive pin 14 that cooperate to support a wire or rod 16 of a shelf 18 to a wall 20. The shelf 18 is of the kind that has a plurality of spaced smaller wires 19 to define a horizontal support upon installation of the shelf. The smaller wires 19 are wrapped about the wire or rod 16 and supported by one or more similar wires or rods (not shown) spaced from and parallel to the wire 16.
The clip body 12 is shown in more detail in FIGS. 3-6. It comprises a unitary plastic member that includes a back section 22 having a front face 24 and a rear face 26. Below its center, the front face 24 has a span 28 that is inclined downwardly and rearwardly, terminating in a short vertical wall 30. The wall 30 leads to a radial hook face 32 formed in a hook extension 34 that projects forwardly from the back section 22. Preferably a central reinforcing web 36 is molded to and extends between the underside of the hook member 34 and the lower portion of the back section 22.
A short thin plastic member 38 extends upwardly from the top of the back wall 22 and connects the back wall 22 to a stop 40. The stop 40 has an outer surface 42 and opposite thereto, coplanar inner surfaces 44 and 46 that are spaced from one another by a recessed section 48. The recessed section 48 is slightly larger than the head of the drive pin 14.
It will be noted that the thin plastic member 38 normally holds the stop 40 in the upright position shown in FIGS. 1 and 3. However, the plastic member 38 is bendable and serves as a hinge allowing the stop to be pivoted to the position shown in FIG. 2. It also should be observed that the plastic member 38 may be set back slightly from the faces 24 and 46. This allows these faces to make contact in the locked position of FIG. 2 without bending the plastic member 38 too sharply.
Extending from the face 44, there is a projection 50 having a tapered wall 52 and having laterally extending flanges 54 and 56 (see FIGS. 4 and 6). Preferably, the leading edges 58 of the projection 50 are rounded (see FIG. 5).
In the face 24 of the back section 22, there is a recess 60, with an inclined wall 62, complementary to the projection 50 and its inclined face 52. The recess also has tapered side walls 64 that make entrance to the recess easier (see FIG. 5). To accommodate the lateral flanges 54 and 56, another recess 66 communicates with the recess 60. For ease of molding, as known in the art, the recess 66 extends between and opens through the sides of the back wall 22. The span between the projections 54 and 56 is greater than the narrowest width of the recess 60, so the projections will snap into the transverse recess 66 thus providing interengaging means.
Integrally molded to and extending from the back wall 22 is a wall anchor 70. The wall anchor 70 comprises a socket 72 and a drive pin 74.
The socket 72 includes a body section 76, and a finger section 78. There is a passage 80 through and the body section 76 communicating with the finger section 78. The finger section 78 includes two fingers 82 and 84 having flat outer surfaces 86 and 88, respectively, terminating in tapered nose sections 90 and 92 at the lead end of the socket 72. Inwardly, the fingers 82 and 84 have opposed flat faces 94 and 96. Toward their trailing ends, the fingers 82 and 84 have barbs 100 and 102, respectively, that are sawtooth in side elevation as shown in FIG. 3.
The fingers 82 and 84 are formed with transverse walls 103 and 104 that extend across the passage 80 through the body section 76. Preferably, these walls 103 and 104 are inclined inwardly and toward the entrance to the passage 80 at angles of about 60°, to the axis of the passage 80. Immediately adjacent the walls 103 and 104, there are short hinge sections 105 and 106 molded as integral parts of the plastic socket 72 of generally the same thickness as that of the wall of the body section 76 of the socket. Spaced from the walls 103 and 104, a web 107 is formed integral with the socket 72. A slit across the width of the web 107 parallel to the faces 94 and 96 has opposed edges 108 and 109. The slit separates the web into halves 110 and 111 which are generally parallel to the walls 103 and 104. Although the intersection of the passage 80 and the web 107 can have stress lines, because of the presence of the web 107, the short hinge sections 105 and 106 can be unstressed and even rounded.
Referring to the body section 76, a plurality of longitudinally extending ribs 112 project inwardly on the inner wall of the passage 80. The primary purpose of these ribs 112 is to grip the shank of the drive pin 74 holding the pin 74 in a ready condition. In other words, the circumscribed internal diameter defined by the ribs 112 is slightly less than the diameter of the shank of the drive pin 74.
On the outer surface of the body section 76, there are a plurality of rings 114 that are generally sawtooth in side elevation. The outer diameters of the rings 114 are essentially the same as the span between the barbs 100 and 102 so that both the fingers 82 and 84 and the body section 76 of the socket 72 will fit in the same size hole in a wall 20.
In its preferred form, the drive pin 14 has a shank 120 with a point 122 on its lead end that can be round or pointed as a typical nail point. Generally, the lead section of the shank 120 is cylindrical like a nail, whereas the trailing section is formed with a double helix thread 124. The double helix thread 124 is sawtooth in side elevation so that the drive pin 14 can be driven, such as by a hammer, into a wall and can be rotated to withdraw it. For both of these purposes, there is a head 126 on the trailing end of the drive pin 14 with a screwdriver kerf or phillips head slot 128 in it. The diameter of the cylindrical shank 120 is about equal to the internal diameter of the passage 80, whereas the outer diameter of the helical threads 124 is greater than the diameter of the passage 80. Therefore, when the drive pin 14 is started into the passage 80 and pressed within the longitudinal ribs 112, the ribs 112 will grip the pin 14 and hold it in place. Because the socket 72 is plastic, it will yield, and the pin can be inserted manually.
Operation and Use
The drive pin 14 is pressed into the passage 80 until the leading portion of the shank 120 is pressed within the area of the ribs 62. These ribs 62 will hold the drive pin 14 in place. A hole should be drilled in the wall 20 of a diameter slightly greater than the diameter of the body of the socket 72, and less than the diameter of the rings 76. The socket 72 can then be pushed into the hole in the wall (the fingers not having to be squeezed together), and the rings 114 will hold it in place temporarily (see FIG. 1). Now, a hammer can drive against the head 126 of the drive pin 14. As the drive pin 14 extends into the socket 80, it engages the transverse walls 103 and 104 of the fingers 82 and 84 and pivots the fingers toward the ninety degree orientations shown in FIG. 2. As illustrated in FIG. 6, the web halves 110 and 111 are not stretched along the shank 120 of the pin 74, placing their edges 108 and 109 in positions to help hold the fingers 82 and 84 in their spread positions. The barbs 100 and 102 grip the wall surface as shown in FIG. 2.
After the wall clip is installed on a wall, the shelf until 18 can be set in place with the wire 16 resting on the hook surface 32. Since the normal position of the stop 40 is upwardly projecting, it stands out of the way of interference with the introduction of the wire 16 into the hook 32. Thereafter, using manual pressure, such as by a thumb, the stop 40 can be pivoted toward the position shown in FIG. 2. As the stop 40 approaches that position, the projection 50 will enter the recess 60. Because of the tapered side walls 64, the flanges 54 and 56 enter the recess 60 readily. As the side walls 64 narrow, the resistance increases, but the plastic yields and allows the flanges 54 and 56 to snap into the recess 66. This positively locks the stop 40 in the position shown in FIG. 2. In this position, the stop overlies the opening of the hook 32 and blocks escape of the wire 16. In addition, the head 126 of the drive pin 14 is received within the recess 48 and is covered from view by the stop 40.
Should it be desired to remove the shelf and wall clip, the stop 40 can be pried to free the projection 50 and its lateral flanges 54 and 56 from the recesses 66 and 60. Then the shelf rod 16 can be lifted from the hook 32. Thereafter, the drive pin 14 can be rotated by a screwdriver in a direction that will cause the threads 124 to withdraw the drive pin from the socket 72. Once the drive pin has cleared the faces or walls 103 and 104 of the fingers 82 and 84, they can pivot back to the straight positions shown in FIG. 1, and the socket 72 can be withdrawn from the hole in the wall.
There are various changes and modifications which may be made to this invention as would be apparent to those skilled in the art. However, any of these changes or modifications are included in the teaching of this disclosure and this invention is limited only by the scope of the claims appended hereto. | A back clip comprising a clip body and a drive pin. A wall anchor is integral with the clip body and has fingers laterally expandable when the drive pin is driven through the anchor. The fingers have transverse wall portions engageable by the drive pin to swing the fingers to substantially ninety degree angles to the axis of the drive pin and anchor. A web is in front of the transverse wall portions in the path of the drive pin. A hook member on the body receives a shelf wire. A stop is hinged to the body by an integral short plastic strap and is pivotable to block the open side of the hook member and to hide the head of the drive pin. | 8 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to improvements in means for mounting cables and the like.
(2) Description of the Prior Art
It is known to provide cable ladders for attachment to a wall or other part of a building and having side runners interconnected by transverse members or rungs for the attachment of electric cables or the like carried through the unit.
However, in conventional cable mounting ladders it was necessary to make custom made angled or shaped members which interconnected adjacent sections of cable mounting ladder so as to avoid obstructions and also to make custom made riser members or dropper members which were bolted to adjacent cable mounting ladder sections which were located in different horizontal levels or planes. Such procedures were time consuming and expensive, and increased installation time. In installation of conventional mounting ladders it was also necessary to drill holes in the cable mounting ladder at precisely measured locations which were dependent on the particular installation job involved.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the invention in one aspect provides a method of installation of a cable mounting ladder to a building or other suitable structure, said cable mounting ladder including a plurality of transverse rungs which interconnect a pair of opposed side flanges or side runners, said method including the steps of:
(1) cutting a continuous length of cable mounting ladder into predetermined lengths or sections;
(2) attaching each section to an adjacent supporting structure;
(3) attaching a curved section of cable mounting ladder to one or more adjacent straight sections of cable mounting ladder to avoid obstructions in a horizontal plane or to extend vertically or downwardly from one horizontal plane to another.
The invention in another aspect provides a cable mounting ladder for use in the above described method, including a plurality of transverse rungs which interconnect a pair of opposed side flanges.
Preferably at least one of the side flanges is provided with divisions or cuts such that the ladder may be deformed or shaped to form a curve in a lateral direction to avoid an obstruction in a horizontal plane. Means may be provided such as a deformable strip to interconnect the divided sections of side flange. Alternatively both runners may be provided with divisions or cuts such that the ladder may be deformed or shaped to a curve which may extend upwardly or downwardly and means being provided for retaining both flanges in their curved form such as rigid link plates being interposed between adjacent sections of side flanges thus forming a plurality of hinged portions.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that a preferred embodiment of the invention may be readily understood and carried into practical effect, reference is now made to the accompanying drawings, wherein:
FIG. 1 is a perspective view of part of a cable mounting ladder according to the invention;
FIG. 2 is a longitudinal sectional view along line 2--2 in FIG. 1;
FIG. 3 is a perspective view of part of a cable mounting ladder according to the invention mounted with its rungs in a horizontal plane and shaped to a double lateral curve to pass around an obstacle;
FIG. 4 is a perspective view of a ladder according to the invention shaped to rise from one level to another; and
FIG. 5 is a partly sectioned nut and bolt assembly used in securing parts of a ladder according to the invention in a curved condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The cable mounting ladder shown in the drawings is formed integrally of a single piece of sheet metal cut and shaped to form two parallel side runners or flanges 10 interconnected by a series of similar equally spaced transverse rungs 11.
Each of the side runners has two right-angle bends along one longitudinal edge portion, which is uppermost in the drawings, to form a reinforcing web 12 and flange 13, and along the two longitudinal edge portions it has a right angle bend to form a base flange 14.
Each of the rungs 11 is formed integrally with the base flanges 14 of the two side runners 10, and is in the form of two spaced parallel transverse inverted channels 15 interconnected by a series of spaced parallel or longitudinal ribs 16 perpendicular to the channels 15 and parallel to the side runners 10. As shown particularly in FIG. 2, the outer flanges of the two channels 15 of each rung 11 are of considerably greater depth than the inner flanges of these channels, which are connected by the spaced ribs 16, so that the ribs 16 are spaced well above the base flanges 14 of the side runners 10, the top surfaces of the channels 15 of the rung being still further above the base flanges 14. There are also provided transverse slots 11A and curved webs 14A as shown in FIG. 1.
A series of equally spaced holes 19 for attachment of the ladder to a wall or other support structure are formed through both side runners 10. When it is required to join two similar cable mounting ladders side by side, this may be done by inserting attachment bolts through co-aligned holes 19 of adjacent runners 10 of each respective cable mounting ladder. If one ladder has to be shortened by cutting, simple fish plates may be used where required to join two ladder sections end to end.
The cable mounting ladder, as described, may be mounted in any suitable way, for example on cantilever support brackets as indicated at 19A in FIG. 3 and will be found very effective for straight runs of cables, which may be easily secured within the ladder by cable clips or clamps of multiple design engaged with the rungs, or may be easily tied to the rungs in desired arrangement, the spaced strips 16 facilitating this. The formation of the rungs is such that they will be very strong, and also will permit free circulation of air to prevent overheating of the cables. Sections of the ladder may be connected together end to end by fish plates bolted to the side runners of succeeding ladder sections.
It is frequently found that the route to be followed by the cables requires obstructions to be negotiated. FIG. 3 shows such an obstruction at 20, the side runners 10 being formed with divisions to enable the ladder to be deformed to a double lateral curve to clear the obstruction. The divisions consist of cuts or slots 21 through one or other of the side runners, between succeeding rungs 11, and correspondingly located cuts or slots 22 through the reinforcing web 12, flange 13 and base flange 14 of the opposite side runner 10, which is bent, as indicated at 23, between the top and bottom cuts 22, in shaping the ladder to the required configuration. Alternatively in some applications cuts 22 may be omitted and the side runner 10 simply bent in the required configuration. To secure together the side runner sections separated by the cuts 21, fairly readily deformable strips 24, each with a series of apertures 25, are provided, each of these strips being bent over at top and bottom to form narrow stiffening flanges 26. The deformable strips 24 are shaped to fit to the side runners 10 which are on the outside of the curves of the ladder, and are secured by bolts 27 passed through apertures 18 of the side runners and through appropriate registering apertures 25 of the strips 24, the bolts then being engaged by nuts 28. As shown in FIG. 5, each bolt 27 has a large head 29 and a shank 30 which, near to the head, is slightly coned and formed with opposite flats 31, the shank beyond this part being of reduced diameter and threaded. The apertures 18 of the side runners have flat sides with which the bolt flats 31 engage, to facilitate the tightening of the nut 28, which is of flanged type.
The ladder shown in FIG. 4 is deformed to rise from one level to another, and for this purpose both of the side runners 10 are formed with channel shaped slots 32 having an upwardly located vertex, each through the main or outside part of the runner and also through the base flange 14; and also, for a curve in opposite direction, with channel shaped slots 33 having a downwardly located vertex, each through the main or outside part of the runner and also through the reinforcing web 12 and flange 13. To hold the side runners to the curves to which they have been shaped, fish plates or other rigid connection members 34 are used being bolted to the inside faces of the side runners. The bolt holes 35 of the fish plates may be slotted to permit variations to the curvature of the ladder. Also shown are cuts 32A, 33A between webs 12 and flange 13 and base flange 14, respectively, providing for completely severed cable mounting ladder sections.
The various cuts or slots in the side runners may be made to suit the particular requirements a ladder is to meet; or alternatively the runners may be formed with weakened lines, between succeeding rungs 11, capable of being easily severed, to the extent required, at the site of installation. | This invention relates to a cable mounting ladder including a plurality of transverse rungs which interconnect a pair of opposed side flanges or side runners, with the side flanges being severed, or partially severed, so that the ladder can be formed into an arcuate or curved shape. | 7 |
FIELD OF INVENTION
[0001] This invention relates generally to bookmarkers and in particular relates to a bookmarker, which may be attached to the spine of a book by means of an adhesive.
BACKGROUND ART
[0002] A plurality of bookmarkers have heretofore been manufactured and used including bookmarkers that are clipped or in some way removably attached to the pages of a book or which are removably attached to the spine of a book.
[0003] For example U.S. Pat. No. 5,992,887 relates to a book clasping and page marking device is formed as a generally U-shaped clip for passing around and around the clamping the edges of a set of pages or the cover of a book.
[0004] Moreover U.S. Pat. No. 5,911,442 teaches a publication reference aid system apparatus therefore including a plurality of tabs.
[0005] Furthermore U.S. Pat. No. 5,305,706 illustrates a page numbering indicating bookmarker capable of being selectively attached to a planar surface in a book which enables the reader to record a desired page number.
[0006] Furthermore U.S. Pat. No. 6,056,492 shows a book having a removable bookmark and the method of making a book having a removable bookmark.
[0007] Finally U.S. Pat. No. 5,439,254 teaches a method of making a bookmarker which includes selecting a sheet of material, coating a portion of the sheet of material with an adhesive and cutting a plurality of bookmarkers from the sheet of material with each bookmark having an enlarged area having adhesive on one side and an elongated bookmarking portion extending from the enlarged portion. The enlarged portion may have a microencapsulated adhesive coating over one side thereof so that the bookmark can be rapidly attached to a book spine. The bookmark may also be made from a transparent polymer material so as to appear invisible except upon close examination.
[0008] These and other bookmarks present relatively complicated structures.
[0009] It is an object of this invention to provide an improved bookmark which may be easily manufactured and attached to a book.
[0010] It is a further object of this invention to provide a bookmarker which may be easily removably attached to the spine of a book.
[0011] It is an aspect of this invention to provide a bookmarker adapted to be removably secured to a book comprising first and second tab portions separated by a fold line, bookmarking portion adapted to overlie said tab portion in the region adjacent said fold line, said tab portions including a releasable adhesive for securing said tab portions together, securing said bookmarking portions between said tab portions and releasably securing said bookmarker to said book.
[0012] It is a further aspect of this invention to provide a bookmarker adapted to be removably secured to the spine of a book comprising first and second tabs separated by a fold line, said second tab is smaller than said first tab, bookmarking ribbon adapted to overlie said tab portions in the region adjacent said fold line, said first tab including an adhesive to secure said tabs together, secure said ribbon between said tabs and permit said first tab to be releasably secured to said spine of said book.
[0013] It is yet another aspect of this invention to provide a method of applying a bookmarker to a book wherein said bookmarker includes a first and second tab having a fold line therebetween, said method comprising applying a pressure sensitive adhesive to at least said first tab, positioning a ribbon over said fold line and moving said tabs together so as to secure said ribbon therebetween in the region adjacent said fold line, placing said first tab with said adhesive against the spine of said book so as to releasably secure said bookmarker to said book.
[0014] These and others objects and features of the invention shall now be described in relation to the following drawings
BRIEF DESCRIPTION OF DRAWINGS
[0015] [0015]FIG. 1 illustrates a typical application of the bookmark.
[0016] [0016]FIG. 2 illustrates a transparent tab version of the bookmark.
[0017] [0017]FIG. 3 illustrates the insertion of the bookmark in the hardcover book with a crevice in the spine.
[0018] [0018]FIG. 4 illustrates a hardcover book with a crevice in the spine with the book closed.
[0019] [0019]FIG. 5 illustrates the bookmarker with ribbons.
[0020] [0020]FIG. 6 illustrates the bookmark where the tab is larger than the spine of a book.
[0021] [0021]FIGS. 7 and 8 illustrates the production detail of the bookmark.
[0022] [0022]FIGS. 9 and 10 illustrates two bookmarks removed from the book having a tremble class indicia on the tab or a maple leaf indicia on the tab.
DESCRIPTION OF THE INVENTION
[0023] In the description which follows, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are not necessarily to scale and in some instances proportions may have been exaggerated in order to more clearly depict certain features of the invention.
[0024] The production detail drawing illustrates the main body of the first tab 2 , a fold line 4 and a second tab or fold panel 6 which is smaller in extent than the main body of the first tab 2 . One side of the first tab 2 includes an adhesive 8 . A ribbon 10 is placed adjacent the adhesive side along the fold line 4 and the fold panel or second tab 6 is disposed so that the sticky side of the adhesive in the fold panel 6 meets the sticky side of the adhesive on main tab 2 so as to secure the two pieces together. It is possible that only the first tab 2 includes the pressure sensitive adhesive. Alternatively the same side of the first and second tab may include the adhesive. In this manner the ribbon 10 is clasped between the tab 2 and the fold panel 6 so that the tab 2 securely retains the ribbon 10 in place. The ribbon 10 therefore includes two bookmarking portions 12 , 14 where the ends may include tassels portions 16 , 18 . One side of the tab 2 may include some indicia such as treble clef or maple leaf or other advertising means. Furthermore the tab 2 may be transparent as illustrated in Figure B. Since the first tab 2 is larger than the second tab 6 the adhesive 8 on the surface of the first tab 2 that extends beyond second tab 6 is available for releasable securement to the spine of a book.
[0025] In use the bookmark may be applied to the spine 20 of a book as illustrated in FIG. 1 and the bookmark portions or ribbons 12 , 14 mark the appropriate pages as shown. Any number of ribbons or cords may be used as shown in FIG. 3 or other number as required.
[0026] Furthermore the bookmark may be inserted into the crevice as shown in FIG. 4 with the sticky side or adhesive side towards the pages. Thereafter the book may be closed and a user firmly presses against the spine with one's finger to firmly secure the tab of the bookmark as shown.
[0027] For thinner books as shown in Figure E the tab may be folded around the corners.
[0028] Furthermore it would be apparent that one may utilize ribbons or cords with or without tassels.
[0029] Furthermore the adhesive may be any variety of adhesive including microencapsulated varieties such as used in post it notes in which case the marker can be reusable.
[0030] The bookmarker as shown includes a number of advantages including:
[0031] (a) attractive bookmarker remains secured to a reading material to mark a page;
[0032] (b) the marker does not fall out of the book;
[0033] (c) the bookmarker secures a page or numerous pages;
[0034] (d) the bookmarker is simple to use;
[0035] (e) the bookmarker saves user time, energy and aggravation while locating a desired page;
[0036] (f) the bookmarker as shown eliminates folded page corners or lost bookmarkers;
[0037] (g) the bookmarker may be used with a wide array of reading materials including magazines, hardback or paperback books.
[0038] The bookmarker can be produced from paper or fabric reinforced vinyl and may be coloured or transparent and measured approximately ⅜ of an inch to one inch in diameter.
[0039] Moreover positioned under the underside of the bookmarker is an adhesive material protected by a protective layer such as a section of wax coated paper until needed as shown extending from the top of the bookmarker are one, two or more woven ribbons or chords used to mark locations within a book.
[0040] In order to utilize the bookmarker the wax coating from the adhesive material is removed and the tab may be applied to the book spine so that the ribbons extend upward and over through the pages. Furthermore the ribbons or chords may be produced in a variety of eye-catching colours and designs.
[0041] Furthermore the tab may be of a variety of colours and may feature a variety of designs including indicia, pictures or symbols. A variety of lengths of bookmark ribbons or chords may be produced to accommodate books of any size. Furthermore the product may be scented to further enhance the users affinity.
[0042] The bookmarker shown herein is superior to the bookmarker shown in U.S. Pat. No. 5,439,254 in the following respects:
[0043] 1. the bookmark shown in U.S. Pat. No. 5,439,254 is relatively stiff and hard to use whereas the invention described herein is relatively flexible with the ribbons shown herein.
[0044] 2. Furthermore the bookmark illustrated herein more firmly secures the ribbons with the fold panel and tab firmly clasping the ribbons therebetween.
[0045] 3. Furthermore the adhesive side of the tab illustrated herein includes adhesive only on a portion of the underside of the tab to assist in the easy removal of the bookmarker, if desired. In other words the fold panel 6 of the bookmarker covers of a portion of the adhesive on the back of the tab 2 so as to assist in the easy removal of the bookmarker.
[0046] 4. More than one page may be marked with the invention described herein.
[0047] Although the preferred embodiment as well as the operation and use have been specifically described in relation to the drawings, it should be understood that variations in the preferred embodiment could be achieved by a person skilled in the trade without departing from the spirit of the invention as claimed herein | A bookmarker adapted to be removably secured to a book comprising first and second tab portions separated by a fold line, bookmarking portion adapted to overlie said tab portion in the region adjacent said fold line, said tab portions including a releasable adhesive for securing said tab portions together, securing said bookmarking portions between said tab portions and releasably securing said bookmarker to said book | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a Divisional of U.S. patent application Ser. No. 13/317,963 entitled, “Composite Electrodes for Lithium Ion Battery and Method of Making” filed on Nov. 1, 2011 by the present inventors, and is also related to U.S. patent application Ser. No. 13/317,973 entitled, “Composite Electrodes for Lithium Ion Battery and Method of Making” filed on Nov. 1, 2011 by the present inventors. The entire disclosures of each of the foregoing applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention pertains to methods of making composite electrodes for lithium ion batteries, and more particularly, to methods of fabricating composite cathodes suitable for both liquid cell and all-solid-state cell applications, and batteries containing the same.
Description of Related Art
Electrodes, especially the cathodes, for traditional lithium ion batteries are typically multi-component structures. They include: nanoparticles of the active cathode material for lithium storage; an electron conductor that is either carbon black, carbon nanotube, carbon fiber, or graphene; a binding agent that is an insulating polymer that binds all the nanoparticles to each other and to a substrate; and an ionic conductor that is usually provided by forming the film of the composite of other components deposited on a metallic current collector foil and then soaking in a liquid electrolyte.
The active material nanoparticles as well as the nanoparticles of conductive carbonaceous materials are performed. To improve the cell performance, researchers over the years have worked on size distribution of the nanoparticles, doping of the active material nanoparticles with other elements, and coating the active material nanoparticles with an electronic conductor film or an ionic conductor film. Several of these methods as previously disclosed include:
U.S. Pat. No. 7,608,362 describes a method of producing a composite cathode active material powder comprising at least one large diameter active material selected from the group consisting of metal composite oxides and at least one small diameter active material selected from the group consisting of carbon-based materials and metal oxide compounds. Mixing the large and small diameter active materials in a proper weight ratio improves packing density; and including highly stable materials and highly conductive materials in the composite cathode active materials improves volume density, discharge capacity and high rate discharge capacity. The large diameter active material is selected from the group consisting of compounds Li x Co 1−y M y O 2−α X α and Li x Co 1−y−z Ni y M z O 2−α X α , and at least one small diameter active material is selected from the group consisting of compounds represented by Li x Co 1−y−z Ni y M z O 2−α X α , Li x Mn 2−y M y O 4−α X α , and Li x Co 2−y M y O 4−α X α , Where M is selected from the group consisting of Al, Ni, Mn, Cr, Fe, Mg, Sr, V, rare earth elements and mixtures thereof, and X is selected from the group consisting of O, F, S, P, and combinations thereof, and carbon-based material. The carbon-based material may be selected from the group consisting of graphite, hard carbon, carbon black, carbon fiber, carbon nanotubes (CNT) and mixtures thereof.
U.S. Pat. No. 7,842,420 describes a method of fabricating powder of cathode material from a starting mixture which includes a metal, a phosphate ion, and an additive which enhances the transport of lithium ions in the resultant material. The cathode material comprises Li x MPO 4 wherein M is metal such as iron, and x ranges from 0 upwards to approximately 1, and the additive is selected from the group consisting of: V, Nb, Mo, C, and combinations thereof. The additive may function as a nucleating agent which promotes the growth of at least one component of the material. In still other instances, the additive may promote the reduction of a carbon-containing species in the starting mixture so as to generate free carbon, and this free carbon may be at least partially sp 2 bonded. In yet other instances, the additive is operative to modify the lattice structure of the material so that the transport of lithium ions through the modified lattice is enhanced in relation to the transport of lithium ions through a corresponding unmodified lattice. The mixture is heated in a reducing environment to produce the material then ball milled to produce the powder. Heating may be carried out in a temperature range of 300-750° C.
U.S. Pat. No. 7,396,614 describes a method of fabricating a composite positive electrode material comprising a non agglomerating lithium vanadium oxide particles, of the form Li 1+x V 3 O 8 in which 0.1≦x≦0.25, as active material, a carbon black material which confers electron conduction properties to the electrode, and a mixture of lithium salt and organic binder which confers ionic conduction properties and mechanical properties to the electrode. The composite positive electrode can be prepared by mixing the active material and the carbon black in a solution of the binder and lithium salt in an appropriate solvent and then by evaporating the solvent under hot conditions under a nitrogen atmosphere. The process for the preparation of the active compound consists in reacting at least one Li precursor with at least one vanadium precursor. The lithium precursor can be chosen from lithium oxides such as Li 2 CO 3 , LiNO 3 , LiOH, LiOH.H 2 O and Li 2 O and organic lithium salts, such as lithium acetylacetonate, lithium acetate, lithium stearate, lithium formate, lithium oxalate, lithium citrate, lithium lactate, lithium tartrate or lithium pyruvate. The vanadium precursor can be chosen from vanadium salts and vanadium oxides such as α-V 2 O 5 , NH 4 VO 3 , V 2 O 4 and V 2 O 3 .
U.S. Pat. No. 7,923,154 describes a method of synthesis of carbon-coated powders having the olivine or NASICON structure. Carbon-coating of the powder particles is necessary to achieve good performances because of the rather poor electronic conductivity of NASICON structures. For the preparation of coated LiFePO 4 , sources of Li, Fe and phosphate are dissolved in an aqueous solution together with a polycarboxylic acid and a polyhydric alcohol. Upon water evaporation, polyesterification occurs while a mixed precipitate is formed containing Li, Fe and phosphate. The resin-encapsulated mixture is then heat treated at 700° C. in a reducing atmosphere to produce a fine powder consisting of an olivine LiFePO 4 phase, coated with conductive carbon. This powder is used as active material in a lithium insertion-type electrode.
U.S. Pat. No. 7,892,676 describes a method of producing a cathode material comprising a composite compound having a formula of A 3x M1 2y (PO 4 ) 3 , and a conductive metal oxide having a formula of M2 a O b , wherein A represents a metal element selected from the group consisting of Groups IA, IIA and IIIA; each of M1 and M2 independently represents a metal element selected from the group consisting of Groups IIA and IIIA, and transition elements. The cathode material is prepared by the following steps: preparing a solution including A ion, M1 ion, and PO 4 3− ; adding M2 salt into the solution; adjusting the pH of the solution so as to form M2 hydroxide and to convert M2 hydroxide into M2 oxide; and heating the solution containing M2 oxide so as to form the cathode material with fine particles of M2 oxide dispersed in an aggregation of particles of A 3x M1 2y (PO 4 ) 3 .
U.S. Pat. No. 7,939,198 describes a method to produce a composite cathode comprising an electroactive sulfur-containing cathode material that comprises a polysulfide moiety of the formula —S m —, wherein m is an integer equal to or greater than 3; and an electroactive transition metal chalcogenide having the formula M j Y k (OR) l wherein: M is a transition metal; Y is the same or different at each occurrence and is oxygen, sulfur, or selenium; R is an organic group and is the same or different at each occurrence; j is an integer ranging from 1 to 12; k is a number ranging from 0 to 72; and l is a number ranging from 0 to 72; with the proviso that k and l cannot both be 0. The chalcogenide encapsulates the electroactive sulfur-containing cathode material and retards the transport of anionic reduction products of the electroactive sulfur-containing cathode material. The method relates to the fabrication of a composite cathode by a sol-gel method wherein the electroactive sulfur-containing cathode material, and optionally binders and conductive fillers, are suspended or dispersed in a medium containing a sol (solution) of the desired electroactive transition metal chalcogenide composition; the resulting composition is first converted into a sol-gel (e.g., a gel-like material having a sol-gel structure or a continuous network-like structure) by the addition of a gelling agent, and the resulting sol-gel is further fabricated into a composite cathode.
All the approaches above still require an organic binder to bind the various nanoparticles together among themselves and to the substrate or current collector. The liquid electrolyte that permeates the cathode made up of lithium storage particles, electron conducting particles, the film of insulative organic binder surrounding the particles, and the voids provides lithium ion conduction. Thus the transport of lithium ion from the liquid and the energy storage particles is limited by the surrounding insulative binder film; this leads to local solid electrolyte interface (SEI) layer formation around the particles because of the side reaction taking place between the liquid electrolyte and organic binder film. The continuous adverse change in the properties of this SEI layers limit the performance and the lifetime of the traditional lithium ion cells.
J. S. Wang et al. [Journal of Power Sources 196:8714-18 (2011)], tried to increase the specific energy density of traditional cells. The cell has a cathode consisting of 1.2 mm thick Al foam filled with a slurry composed of 84 wt. % Li(NiCoMn) 1/3 O 2 (L333, NCM-01ST-5, Toda Kogyo)+9 wt. % poly(vinylidene fluoride-cohexafluoropropylene) binder (Kynar Flex 2801, Elf Atochem)+3.5 wt. % carbon black (Super P, MMM)+3.5 wt. % synthetic graphite (KS6, Timcal); an anode, made using 1.2 mm thick Cu foam filled with the slurry of 93 wt % active carbon material (SG, Superior Graphite, SLC 1520), 3 wt. % carbon black (Super P), and 4 wt. % SBR binder (an aqueous styrene-butadiene rubber binder, LHB-108P). The best performance of 10 mAh/cm 2 was obtained only at low C rate C/50. A rapid fade was observed at C rate as low as C/20. The energy density of the cell is low because of thick electrodes, also the fundamental low cycle life affecting the traditional cell due to SEI layer has not been addressed by this approach.
In recent years, attempts have been made in making binder free and liquid electrolyte free cathodes in cells as reported by the following:
Hayashi, et al. [Journal of Power Sources 183:422-26 (2008)] constructed a laboratory-scale solid-state cell consisting of the composite cathode powder obtained by mixing Li 2 S—Cu materials, the lithium ion conductor 80Li 2 S.20P 2 S 5 glass-ceramic, and electronic conductor acetylene-black with the weight ratio of 38:57:5. The composite powder (10 mg) as a cathode, and the 80Li 2 S.20P 2 S 5 glass-ceramic powder (80 mg) as a solid electrolyte were placed in a polycarbonate tube (with a diameter of 10 mm) and pressed together under 3700 kg/cm 2 , and then an Indium foil as a negative electrode was pressed under 1200 kg/cm 2 on the pellet. After releasing the pressure, the obtained pellet was sandwiched by two stainless-steel rods as current collectors. The cells were charged and discharged at room temperature in an Ar atmosphere using a charge-discharge measuring device (BTS-2004, Nagano). The constant current density of 64 μA/cm 2 was used for charging and discharging with the maximum discharge capacity of 490 mA-h/g.
Sakuda et al. [Chem. Mater., Vol. 22, No. 3, 2010] constructed all-solid-state cells as follows. Mixing Li 2 SiO 3 coated LiCoO 2 and the 80Li 2 S 3 -20P 2 S 5 glass-ceramic electrolyte with a weight ratio of 70:30 using an agate mortar to prepare composite positive electrodes. A bilayer pellet consisting of the composite positive electrode (10 mg) and glass-ceramic solid electrolytes (80 mg) was obtained by pressing under 360 MPa in a 10 mm diameter tube; indium foil was then attached to the bilayer pellet by pressing under 240 MPa. The pellet was pressed using two stainless steel rods; the stainless steel rods were used as current collectors for both positive and negative electrodes. All the processes for preparation of solid electrolytes and fabrication of all-solid-state batteries were performed in a dry Ar-filled glovebox ([H 2 O]<1 ppm). A discharge capacity of 60 mAh/g was obtained at a discharge current density of 64 μA/cm 2 at 30° C.
Also, Sakuda et al. [Journal of Power Sources 196:6735-41 (2011)]; using the same cell construct described above, used LiCoO 2 composite cathode, where LiCoO 2 was coated with LiNbO 3 then 80Li 2 S 3 -20P 2 S 5 films; these particles where then mixed with 80Li 2 S 3 -20P 2 S 5 particles to form the composite cathode. The resulting best cell was charged/discharged at the current density of 0.13 mA/cm 2 and gave a discharge capacity of 95 mA-h/g.
Importantly, the LiCoO 2 particle coating was done with Pulse Laser Deposition (PLD), a process that is relatively unsuitable for routine manufacturing. And all the solid state cells were made by pressing the stack of powder of various components into small area cylindrical disk, a cell fabrication technique that is not readily scalable. The mechanical contact between the particles that dependent on pressing pressure provides less than ideal electrical contact between various particles. The latter combined with too thick solid state electrolyte layer in the cell leads to undesirable overall cell impedance that limits the extractable capacity.
What is needed, therefore, is a scalable, efficient process for making composite cathodes for lithium ion batteries that is suitable for use in both liquid cell and all-solid-state cell applications.
Objects and Advantages
Objects of the present invention include the following: providing an improved composite electrode for lithium ion batteries; providing a composite cathode for alkali ion batteries; providing a composite cathode suitable for both liquid cell and all solid state metal ion batteries; providing an improved alkali ion battery; providing methods for fabricating composite electrodes for metal ion batteries; and providing a scalable, manufacturable process for making composite electrodes and batteries containing them. These and other objects and advantages of the invention will become apparent from consideration of the following specification, read in conjunction with the drawings.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a method for making a composite electrode for a lithium ion battery comprises the steps of:
preparing a slurry containing particles of a selected inorganic electrode material suspended in a selected solvent;
preheating a porous metallic substrate;
loading the preheated metallic substrate with the slurry;
baking the loaded substrate at a first selected temperature;
curing the baked substrate at a second selected temperature sufficient to form a desired nanocrystalline material within the pores of the substrate;
calendaring the cured composite to reduce internal porosity; and,
annealing the calendared composite at a third temperature greater than the second temperature to produce a self-supporting multiphase electrode.
According to another aspect of the invention, a cathode for a lithium ion battery comprises:
a first phase comprising an inorganic energy storage material;
a second phase comprising a solid state lithium ion conductor; and,
a third phase comprising a reticulated metal structure, interspersed throughout the first and second phases, the reticulated metal forming a structural reinforcement and a current collector,
wherein the metal structure comprises from 5 to 25% of the volume of material, the first and second phases together comprise from 75 to 95% of the volume of the material, and the cathode contains no more than 30 vol. % porosity.
According to another aspect of the invention, an anode for a lithium ion battery comprises:
a first phase comprising a lithium ion storage material;
a second phase comprising a solid state lithium ion conductor; and,
a third phase comprising a reticulated metal structure, interspersed throughout the first and second phases, the reticulated metal forming a structural reinforcement and a current collector,
wherein the metal structure comprises from 5 to 25% of the volume of material, the first and second phases together comprise from 75 to 95% of the volume of the material, and the anode contains no more than 30 vol. % porosity.
According to another aspect of the invention lithium ion battery comprises:
a cathode comprising:
a first phase comprising an inorganic energy storage material; a second phase comprising a solid state lithium ion conductor; and, a third phase comprising a reticulated metal structure, interspersed throughout the first and second phases, the reticulated metal forming a structural reinforcement and a current collector, wherein the metal structure comprises from 5 to 25% of the volume of material, the first and second phases together comprise from 75 to 95% of the volume of the material, and the cathode contains no more than 30 vol. % porosity;
an anode comprising a lithium storage material; and,
a lithium-conducting electrolyte separating the cathode from the anode.
According to another aspect of the invention, a lithium ion battery comprises:
an anode comprising:
a first phase comprising a lithium ion storage material; a second phase comprising a solid state lithium ion conductor; and, a third phase comprising a reticulated metal structure, interspersed throughout the first and second phases, the reticulated metal forming a structural reinforcement and a current collector, wherein the metal structure comprises from 5 to 25% of the volume of material, the first and second phases together comprise from 75 to 95% of the volume of the material, and the anode contains no more than 30 vol. % porosity;
a cathode comprising an energy storage material; and,
a lithium-conducting electrolyte separating the cathode from the anode.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings accompanying and forming part of this specification are included to depict certain aspects of the invention. A clearer conception of the invention, and of the components and operation of systems provided with the invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting embodiments illustrated in the drawing figures, wherein like numerals (if they occur in more than one view) designate the same elements. The features in the drawings are not necessarily drawn to scale.
FIG. 1 illustrates schematically a vertical section of a GELSPEED deposition chamber in accordance with one aspect of the present invention.
FIG. 2A illustrates the steps for fabricating a composite electrode in accordance with one aspect of the invention.
FIG. 2B illustrates a cross-sectional SEM image of a self supporting composite LiCoO 2 :Al cathode in accordance with one aspect of the invention.
FIG. 3 illustrates the steps for fabricating a solid state Li ion cell using a self supporting composite electrode in accordance with another aspect of the invention.
FIG. 4 illustrates the steps for fabricating a solid state Li ion cell using self supporting composite anode and cathode in accordance with another aspect of the invention.
FIG. 5 illustrates the steps for fabricating a solid state Li ion cell using a self supporting composite cathode with a buffer layer in accordance with another aspect of the invention.
FIG. 6 illustrates the steps for fabricating a solid state Li ion cell using self supporting composite anode and cathode with a buffer layer in accordance with another aspect of the invention.
FIG. 7A illustrates the steps for fabricating a hybrid cell using a self supporting composite cathode in accordance with one aspect of the invention.
FIG. 7B illustrates the discharge capacity of the cell of FIG. 7A having self supporting LiCoO 2 :Al composite as the cathode and Li foil as the anode.
FIG. 8 illustrates the steps for fabricating a hybrid cell using self supporting composite anode and cathode with a buffer layer in accordance with another aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention includes an industrially scalable method of fabricating a composite cathode suitable for both liquid cell and all-solid-state cell applications. The cathode consists of inorganic nanoparticles for energy storage, lithium ion conduction, and electron conduction in a metallic foam framework, which acts as a current collector and a supplementary electron conducting path, and bound together by a lithium ion conducting inorganic film.
The fabrication of multiphase electrodes may be generally summarized as follows:
Preparing the precursor sol that consists of energy storage material nuclei (first phase), the gelling agent that also act as nano-particles capping material, binder, and lithium ion conductor (second phase-A).
Adding to this slurry preformed nanoparticles of complementary lithium ion conductor (second phase-B); then adding preformed nano-particles of complementary electron conductor (third phase-B). The final precursor slurry is then formed by sonicating the mixed materials for complete homogenization.
Heated metallic foam is then populated with the final precursor slurry using any of various gel coating techniques, preferably “gel phase spray process for electroless electrochemical deposition” (GELSPEED). After baking, curing, calendaring, and final temperature anneal, the metallic foam acts as a three-dimensional support for the electrode material nanoparticles and other supporting phases, and as a stress suppressor, electron conductor, and current collector (third phase-A).
The precursor solvent is preferably deionized water. The energy storage material reagents are preferably water soluble metallic salts of Co, Ni, Mn, Fe, Al, Li, Cu, Mo, etc. as the metal ion source; urea, or thiourea as ligand and oxygen or sulfur source; phosphoric acid as the source of phosphorus; and nitric acid, sulfuric acid, triethanolamine, acetic acid, or citric acid as additional ligand. The lithium metal oxide, sulfide, or phosphate, or the metal oxide, or sulfide may also be used instead of soluble metallic salt. These reagents are dissolved in deionized water and heated at temperature ranging between 80 to 100° C. to form the nuclei of the energy storage material. The nuclei are typically about 10 nm to 5 μm in diameter. Lithium polysilicate solution, (Li 2 O) x (SiO 2 ) y , where x/y is 1 to 10, is then added to the energy storage nuclei sol as a capping phase to arrest further crystal growth and transform the solution into a more gelatinous slurry. The lithium polysilicate phase typically amounts to about 1 to 10% of the electrolyte material. Preformed nanoparticles of a lithium ion conductor such as Li 2 WO 4 , Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 , Li 3 PO 4 , Li 2 MoO 4 , or Li 6 La 3 Zr 2 O 12 are added to the gel. Preformed nanoparticles of an electronic conductor like carbon nanotubes, TiO x , nickel, tungsten, tin, Cu, or CuO, etc., are also added to the gel. These particles are preferably 10 to 100 nm in size and amount to about 1 to 30 wt. % of the electrode material. This mixture is then sonicated at 5 kHz to 1 MHz for about 5 to 20 minutes to form a homogeneous slurry with viscosity ranging from 100 to 10,000 cP. (It will be appreciated that the slurry is non-Newtonian, and further that the slurry will become more gel-like over time as the lithium polysilicate continues to polymerize, so the prepared slurry is preferably used promptly upon completion of the sonication step.) Heated metallic foam such as Ni foam, stainless steel foam, Cu foam, or aluminum foam, etc, is then populated with the slurry (typically dispensed at about 15 to 30° C.) using GELSPEED. The resulting solidified gel in the metallic foam is then baked at a temperature ranging between 100 to 200° C. This is followed by curing at temperature ranging between 250 to 400° C. to transform the energy storage material nuclei into nanoparticles. The new structure is then calendared to form a thick, 3-D electrode consisting of energy storage nanoparticles, lithium ion conducting nanoparticles, electronic conducting nanoparticles, with lithium polysilicate binding the nanoparticles to each other and to the metallic foam. Applicants have discovered, surprisingly, that in the inventive structure the metallic foam serves as an effective structural electrode support, electronic conductor, and current collector. The 3-D electrode is then annealed at temperature ranging between 300 to 800° C. so that the energy storage nanoparticles can form the desired material phase necessary for optimum lithium ion intercalation.
The GELSPEED process of the present invention is a variation of VPSPEED described in Applicant's U.S. Pat. No. 7,972,899, the entire disclosure of which is incorporated herein by reference. For the GELSPEED process, the nebulizer of the shower is replaced with a slot die. The slot die allows the dispensing of viscous fluids and slurries, which yields a much higher growth rate (typically more than 50 μm/minute). FIG. 1 illustrates a vertical section of a GELSPEED chamber 10 that includes a substrate holder assembly 31 ′ to secure substrate (workpiece) 33 and a showerhead 41 ′ for supplying and distributing processing solution over substrate 33 . The substrate holder assembly 31 ′ has two substrate chucking mechanisms: the one provided by the vacuum orifices 54 , and the other provided by the magnetic pellet X 2 . It is contemplated that in many cases the metallic foam substrate is magnetic; at the onset of the deposition the X 2 is used to chuck the substrate as the vacuum cannot be used to secure a porous substrate. Once the foam is loaded and the deposited material is cured, the vacuum chuck is turned on to hold down the substrate and to help pull a fresh gel coating solution into available pores of the coated substrate. The ring structure X 1 is used to impound the fluid and to provide the seal when the vacuum chuck is activated. The showerhead assembly 41 ′ includes a slot die 60 , which is preferably movable to some degree, configured to deliver a viscous reagent gel to substrate 33 . The slot die may be of various designs. One suitable type is that manufactured by Innovative Machine Corporation. The width of the slot size is about the size of the substrate to be coated. The coating uniformity is determined by the fluid delivery pressure (typically 1 to 50 psi) and the slot die opening (0.0005″ to 0.005″). The system comes with a controller that controls the deposition cycles, the temperature of the substrate holder during the deposition (100 to 150° C.), baking (100 to 200° C.), and curing (150 to 250° C.). Bake and cure times are preferably in the range of 1 to 30 minutes and 5 to 30 minutes, respectively. Additional curing at temperatures higher than 250° C. is carried out ex-situ. The chamber may further include a drain line 34 which is part of the return subsystem that directs partially spent processing solution from the chamber 10 to a reservoir (not shown). 45 ′ is the heat cartridge, the source of heat in the substrate holder assembly 31 ′. 52 is the cooling jacket with 53 as the coolant liquid inlet and 53 ′ coolant liquid outlet.
Process steps to fabricate a composite electrode are illustrated generally in FIG. 2 . Beginning with a heated metallic foam preform (top), a portion of the foam is loaded with electrode materials in the form of a gel (center). After heat treatment, calendaring, and annealing, the composite electrode, supported by the metallic foam, is formed (bottom). The calendaring step compresses the composite so the final electrode is thinner and denser, as indicated schematically in the drawing. The Examples that follow will illustrate the use of the invention to make various composite structures and compositions. Those skilled in the art may easily modify the process recipes through routine experimentation in order to create electrodes for particular applications.
EXAMPLE 1
To form a LiCoO 2 :Al composite cathode, 9.0 g cobalt nitrate, 3 g urea, 1.0 g Al(NO 3 ) 3 , and 3.0 g Li(NO 3 ) were dissolved in 50 ml of de-ionized water and heated until the CoAlLi[complex]O nuclei is formed and the hot solution is 20 ml. 5 ml of 1M citric acid was then added. This was followed by 1 ml of 40 wt. % lithium polysilicate in deionized water. The mixture was then sonicated to form a gel. Then, 0.3 g of Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 and 0.3 g of TiO x nanoparticles were added for improved ionic conductivity and electronic conductivity respectively. The gel was then resonicated to homogenize the gel. The GELSPEED process was then used to populate a 3″×3″ Ni foam substrate 1 heated at 150° C. The coated foam 2 was cured at 250° C. for about 5 minutes. Coating and curing were repeated 2 more times. Additional curing was done in a box furnace at 300° C. for 10 minutes. This was followed by calendaring under a 100 ton press to compact and densify the self supporting composite LiCoO 2 :Al cathode 3 . Estimated pressure applied to the composite was 500 to 5000 kg/cm 2 . The formed structure was then annealed in Argon at 500° C. for 10 minutes to complete the process. A cross-sectional SEM image of a self supporting composite LiCoO 2 :Al cathode is shown in FIG. 2B . Note that comparable results can also be obtained by replacing cobalt nitrate in the formulation with 3 g LiCoO 2 nanoparticles, while reducing the LiNO 3 to 0.1 g, and urea to 0.3 g.
EXAMPLE 2
To form a CuS composite cathode, 5 g copper nitrate, 5 g thiourea, and 4 ml hydrazine monohydrate were dissolved in 50 ml de-ionized water and heated until the Cu[complex]S nuclei was formed and the hot solution was 20 ml. 4 ml of 1M acetic acid was then added. This was followed by 1 ml of 40 wt. % lithium polysilicate in deionized water. The mixture was then sonicated to form a gel. Then, 0.3 g Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 and 0.3 g TiOx nanoparticles were added for improved ionic conductivity and electronic conductivity respectively. The gel was then resonicated to homogenize the gel. The GELSPEED process was then used to populate a 3″×3″ Ni foam substrate heated at 150° C. The coated foam was cured at 200° C. for about 5 minutes. Coating and curing were repeated 2 more times. Additional curing was done in the tube furnace at 300° C. for 10 minutes in sulfur ambient. This was followed by calendaring under a 100 ton press to compact and densify the self supporting composite CuS cathode. The formed structure was then annealed in sulfur at 400° C. for 10 minutes to complete the process.
EXAMPLE 3
To prepare a SnO composite anode, 5 g tin ethoxide, 0.4 g urea, 0.5 g Al(NO 3 ) 3 , and 0.3 g Li(NO 3 ) were dissolved in 50 ml of de-ionized water and heated until the SnAlLi[complex]O nuclei was formed and the hot solution is 20 ml. 4 ml of 1M acetic acid was then added. This was followed by 1 ml of 40 wt. % lithium polysilicate in deionized water. The mixture was then sonicated to form a gel. Then, 0.3 g Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 and 0.3 g TiO x nanoparticles were added for improved ionic conductivity and electronic conductivity respectively. The gel was then resonicated to homogenize the gel. The GELSPEED process was then used to populate a 3″×3″ Ni foam substrate heated at 150° C. The coated foam was cured at 250° C. for about 5 minutes. Coating and curing were repeated 2 more times. Additional curing was done in a box furnace at 300° C. for 10 minutes. This was followed by calendaring under a 100 ton press to compact and densify the self supporting composite SnO anode. The formed structure was then annealed in argon at 500° C. for 10 minutes to complete the process.
In addition to the exemplary compositions in the preceding examples, other electrode compositions and reagents may easily be substituted according to the inventive method. The list of other cathodes includes LiMn y O x , where x is 2 or 4 and y is 1 or 2; LiFePO 4 ; LiMnPO 4 ; LiMn (1−x) Fe x PO 4 ; LiNiO 2 ; LiMn (1−x−y−z) Ni x Co y Al z O 2 ; TiS; MoS; FeS, and CuMS, where M is Fe, Zn, Sn, Ti, or Mo. The list of other anodes includes SnO x ; SnS x ; Li 4 Ti 5 O 12 ; LiC x ; MnO x ; and CoO x . The precursors of the constituting elements of these compounds are any water soluble compounds of these elements. The precursors may alternatively be non water soluble nanoparticles of these compounds. Preferred ligands are urea for the oxides, thiourea for the sulfides, and phosphoric acid for the phosphates. Other complimentary ligands include acetic acid, citric acid, oxalic acid, nitric acid, triethanolamine, and hydrazine. The lithium ion and electronic conducting additives include Li 2 WO 4 , Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 , Ohara Glass®, LiAlGaPO 4 , Li 7−x La 3 (Zr 2−x Nb x )O 12 , LiLaTiO, LiLaZrO, Ti 4 O 7 (Ebonex® ceramic), Li 2 WO 4 , Li 2 MoO 4 carbon nanotube, carbon nanowire, carbon nano-particles, semiconductor nanowire, semiconductor nano-particles, metal nanowire, metal nano-particles and ceramic nano-particles.
Some specific electrode materials include the following:
LiMn 2−x M 1 x O 4 where M 1 is selected from the group comprising Al, Sn, Zn, and Fe, and 0≦x≦0.05; LiCo 1−x M 2 x O 2 where M 2 is selected from the group comprising Ni and Al, and 0≦x≦0.05; LiNi 1−x M 3 x O 2 where M 3 is selected from the group comprising Co and Al, and 0≦x≦0.05; LiMn x Ni y Co z Al t O 2 where x+y+z+t=1, and 0≦(x, y, z, and t)≦1; LiM 4 PO 4 , where M 4 is selected from the group comprising Fe, Co, Ni, and Mn; CuS, or CuM 5 S where M 5 is selected from the group comprising Fe, Sn, Mo, and Zn; LiFePO 4 ; Li 4 Ti 5 O 12 ; FeS; and MoS.
It will be understood by those skilled in the art that the atmosphere used in the various heat treatments, particularly the final high-temperature anneal, will be dictated by the type of electrode being formed and therefore may be oxidizing, reducing, or inert. Oxidizing atmospheres may include air or oxygen at a selected pressure, whereas reducing atmospheres may include hydrogen, natural gas, carbon monoxide, methane, etc. Inert atmospheres include nitrogen and argon.
Process steps to fabricate an inorganic solid state lithium ion cell using the self supporting composite cathode are illustrated generally in FIG. 3 . Beginning with a self supporting cathode made according to the process shown in FIG. 2 , a high alkali metal (preferably lithium) ion conducting solid state electrolyte [for example, Li y Al (1−x) Ga x S(PO 4 )] is deposited as a layer by VPSPEED or other suitable process. The Li anode and current collector is then deposited on top of the electrolyte by evaporation or other suitable method, thereby forming a Li cell (bottom).
EXAMPLE 4
To fabricate a LiCoO 2 :Al solid state cell, the self supporting composite LiCoO 2 :Al cathode 3 as prepared in Example 1 was used. About 4 μm thick Li y Al (1−x) Ga x S(PO 4 ) solid state electrolyte 4 was then deposited and processed on the cathode 3 as described in Applicant's U.S. Pat. Appl. Pub. 2011/0168327, the entire disclosure of which is incorporated herein by reference. This was followed by the deposition of 2 μm thick Li 5 by Field-Assisted VPSPEED (FAVPSPEED), described in detail in Applicant's U.S. Pat. Appl. Pub. 2011/0171398, the entire disclosure of which is incorporated herein by reference. (It may alternatively be deposited using a traditional vacuum technique.) 50 μm thick Li foil was then hot laminated onto the 2 μm deposited Li for current collection to complete the cell.
Process steps to fabricate an inorganic solid state lithium ion cell using both a self supporting composite cathode and a self supporting composite anode are illustrated generally in FIG. 4 . Beginning with a self supporting cathode 3 (top) made according to the process shown in FIG. 2 , a solid state electrolyte 4 [for example, Li y Al (1−x) Ga x S(PO 4 )] is deposited as a layer by VPSPEED or other suitable process (center). A self supporting composite anode and current collector 6 is then attached to the electrolyte using lithium ion conducting glue 7 , thereby forming a Li cell (bottom).
EXAMPLE 5
Both composite self supporting LiCoO 2 :Al cathode and Li y Al (1−x) Ga x S(PO 4 ) solid state electrolyte are deposited and processed as described in EXAMPLE 4. A 5 μm thick lithium ion conducting glue consisting of 6 g polyvinylidene fluoride (PVDF) dissolved in 40 g dimethoxyethane (DME) solvent, 15 g 2M 3M™ Fluorad™ (lithium (bis)trifluoromethanesulfonimide) dissolved in Tetrahydrofuran (THF), with 4 g Ohara glass nano-particles is then spray deposited by VPSPEED on the solid state electrolyte. The self supporting SnO anode of EXAMPLE 3 is then hot pressed on the glue at 120° C. to complete the cell fabrication.
Process steps to fabricate an inorganic solid state lithium ion cell using a self supporting composite cathode with a buffer layer are illustrated generally in FIG. 5 . Beginning with a self supporting cathode 3 (top) made according to the process shown in FIG. 2 , a buffer layer 8 (for example, LiNbO 3 ) is deposited by VPSPEED on the cathode. This buffer layer serves to reduce the internal resistance of the cell caused by lattice mismatch and built in field between cathode and electrolyte. Next, a solid state electrolyte 4 [for example, Li y Al (1−x) Ga x S(PO 4 )] is deposited as a layer by VPSPEED or other suitable process. The Li anode and current collector 5 is then deposited on top of the electrolyte by evaporation or other suitable method, thereby forming a Li cell (bottom).
EXAMPLE 6
The LiCoO 2 :Al solid cell with a buffer layer construct is same as that of EXAMPLE 4; except that a 0.05 μm thick LiNbO 3 is deposited on LiCoO 2 :Al as a buffer layer before the deposition of Li y Al (1−x) Ga x S(PO 4 ) solid state electrolyte. The aqueous solution of LiNbO 3 consisting of lithium nitrate 0.1M, niobium nitrate 0.1M, urea 0.2M, nitric acid 0.05M, and 5% volume alcohol is spray deposited by VPSPEED at 250° C., followed by annealing in Ar at 500° C. for about 10 minutes.
Those skilled in the art will appreciate that other materials may be suitable for the buffer layer in particular applications. Some suitable materials include: LiNbO 3 , Li x SiO y , Li-βAl 2 O 3 , Li x AlSiO y , Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 , Li 7−x La 3 (Zr 2−x Nb x )O 12 , Li y Al (1−x) Ga x S(PO 4 ), Li 0.35 La 0.55 TiO 3 , and LiTi 2 (PO 4 ) 3 .
Process steps to fabricate an inorganic solid state lithium ion cell using both a self supporting composite cathode and a self supporting composite anode, and a buffer layer are illustrated generally in FIG. 6 . Beginning with a self supporting cathode (top) made according to the process shown in FIG. 2 , a buffer layer (e.g., LiNbO 3 ) is deposited on the cathode as described in EXAMPLE 6. Again, this buffer layer serves to reduce the internal resistance of the cell caused by lattice mismatch and built in field between cathode and electrolyte. A solid state electrolyte [for example, Li y Al (1−x) Ga x S(PO 4 )] is deposited on top of the buffer layer by VPSPEED or other suitable process. A self supporting composite anode and current collector is then attached to the electrolyte using lithium ion conducting glue, thereby forming a Li cell (bottom).
EXAMPLE 7
The LiCoO 2 :Al solid cell with a buffer layer construct is the same as that of EXAMPLE 6. Next a lithium ion conducting glue layer described in EXAMPLE 5 is deposited on the solid electrolyte. The self supporting SnO anode of EXAMPLE 3 is then hot pressed on the glue at 120° C. to complete the cell fabrication.
Process steps to fabricate a hybrid lithium ion cell using a self supporting composite cathode and a buffer layer are illustrated generally in FIG. 7 . Beginning with a self supporting cathode 3 (top) made according to the process shown in FIG. 2 , a buffer layer 8 (e.g., LiNbO 3 ) described in Example 6 is deposited as previously described on the cathode. A solid state electrolyte 4 [for example, Li y Al (1−x) Ga x S(PO 4 )] is deposited on top of the buffer layer by VPSPEED or other suitable process. A lithium foil anode and current collector 5 is then placed on top of the electrolyte with or without polymer separator. Finally, the assembly is placed in a pouch 12 , which is filled with liquid electrolyte 11 (for example, a LiPF 6 solution) and sealed to form the completed Li cell (bottom). The liquid electrolyte further enhances the lithium ion conduction among all components of the cell.
EXAMPLE 8
The formation of a hybrid LiCoO 2 :Al cell with a buffer layer construct is same as that of EXAMPLE 6, except that the assembly is placed in a pouch filled with liquid electrolyte. The liquid electrolyte is a 1.5M solution of LiPF 6 in 1:1 ethylene carbonate/propylene carbonate solvent. The discharge capacity of the cell, about 15 mAh/cm 2 at C/3, is shown in FIG. 7B . This shows minimum fade after about 40 cycles. The columbic efficiency of the cell is excellent at about 100%.
Process steps to fabricate a hybrid lithium ion cell using a self supporting composite cathode and anode, and a buffer layer, are illustrated generally in FIG. 8 . Beginning with a self supporting cathode 3 (top) made according to the process shown in FIG. 2 , a buffer layer 8 (e.g., LiNbO 3 ) is deposited as previously described on the cathode. A solid state electrolyte 4 [for example, Li y Al (1−x) Ga x S(PO 4 )] is deposited on top of the buffer layer by VPSPEED or other suitable process. A self supporting composite anode 9 is then placed on top of the electrolyte with or without polymer separator. Finally, the assembly is placed in a pouch 12 , which is filled with liquid electrolyte 11 (for example, a LiPF 6 solution) and sealed to form the completed Li cell. Again the liquid electrolyte enhances the lithium ion conduction among all components of the cell.
EXAMPLE 9
The formation of a hybrid LiCoO 2 :Al solid cell with a buffer layer construct is same as that of EXAMPLE 8, except that the lithium foil anode is replaced by the self supporting SnO anode of EXAMPLE 3.
It will be further appreciated that the inventive process yields a novel structure that exhibits many superior characteristics that make it desirable for use in various battery designs. For example, the composite structures described by Wang et al. [Journal of Power Sources 196:8714-18 (2011)] used metal foam but were not calendared because, presumably, it was considered desirable to have a substantially porous electrode structure that could be infiltrated by liquid electrolyte in order to improve the kinetics of charging and discharging. However, the structure ultimately showed a somewhat limited lifetime. The inventive, calendared electrode, despite its relatively high density, surprisingly shows excellent ionic conductivity, which is provided mostly by the inorganic binder and lithium ion conducting nanoparticle additives.
Some exemplary physical characteristics of the inventive electrode include the following: The completed cathode preferably has 5 to 25% of its volume occupied by the metal foam and 75 to 95% by the electrode active materials and other additives. Final density is preferably between 2 and 6 g/cm 3 . Porosity is typically between 5 and 30%. The metal is preferably Ni but may alternatively be any suitable metallic conductor, such as Al, Cu, Fe, stainless steel, etc. Although in many of the examples constructed, the substrate was metal foam having interconnected porosity, it will be appreciated that a woven or other porous fibrous metal such as steel wool may also be suitable for some applications.
Some unique attributes of the inventive structure include the following:
a. A self supporting dense cathode can be interchangeably used to fabricate inorganic solid state cells or liquid cells. b. Ionic conductivity is provided mostly by the inorganic binder, and other inorganic ion conducting additives instead of liquid electrolyte residing in the pores of less dense traditional cathodes that have insulative organic binders. c. Electronic conductivity is provided by a reticulated metallic wire mesh, metal wool, or metal foam and preferably inorganic electron conducting additives. The reticulated metallic phase further serves as a mechanical reinforcement for the structure. d. The cathode thickness is typically in the range of 100 μm to 500 μm. e. The cathode may have an inorganic solid state electrolyte or a bilayer of lithium ion conducting buffer and inorganic solid state electrolyte deposited on it. f. The latter structure when used in a liquid cell blocks the formation of any solid-electrolyte-interface layer; this creates a cell with long cycle life and no self discharge. g. The structure, when used in a solid state cell, can deliver energy in the mA/cm 2 range compared to values in the μA/cm 2 range commonly observed in traditional inorganic solid state cells. h. The anodes of the inventive cells may be either an inorganic solid state electrolyte protected Li anode or another composite self supporting anode. i. The inventive composite structure shows no Li dendrite formation and all materials making up the cell are inorganic with very high melting temperature, hence, the cells are very safe.
It will be appreciated by those skilled in the art that many variations and combinations may be constructed using the methods described in the foregoing Examples, which are provided for illustrative purposes and are not intended to limit the scope of the invention as defined by the claims that follow. | A method for making a composite electrode for a lithium ion battery comprises the steps of: preparing a slurry containing particles of inorganic electrode material(s) suspended in a solvent; preheating a porous metallic substrate; loading the metallic substrate with the slurry; baking the loaded substrate at a first temperature; curing the baked substrate at a second temperature sufficient to form a desired nanocrystalline material within the pores of the substrate; calendaring the cured composite to reduce internal porosity; and, annealing the calendared composite at a third temperature to produce a self-supporting multiphase electrode. Because of the calendaring step, the resulting electrode is self-supporting, has improved current collecting properties, and improved cycling lifetime. Anodes and cathodes made by the process, and batteries using them, are also disclosed. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to a curtain wall system for multi-story buildings and, more particularly, to a wall system that is resistant to damage caused by swaying motions of buildings during an earthquake.
BACKGROUND OF THE INVENTION
[0002] Curtain wall systems are exterior wall systems on multi-story buildings that are made of appropriate cladding materials (e.g., glass, aluminum, stone, concrete, etc.) and which carry no superimposed vertical (gravity) loads. Hence, the term “curtain” implies that a curtain wall system is essentially “hung like a curtain” from the primary structural frame of the building. A curtain wall system does not, by itself, help a building stand erect.
[0003] Although curtain wall systems are normally considered to be “non-structural” parts of a building, such terminology is misleading because curtain walls must have the ability to withstand structural loads imposed by natural phenomena such as earthquakes and severe windstorms. In this context, the term “curtain wall” is a misnomer because non-structural parts of a building can be subjected to structural loads. This invention focuses on a curtain wall system that is highly resistant to the potentially damaging effects of earthquake-induced movements of building frames.
[0004] Many curtain wall systems are constructed with glass window elements glazed within an assemblage of aluminum framing members. Architectural glass, due to its brittle nature, is inherently vulnerable to curtain wall movements during earthquakes. Research studies have been conducted to investigate the seismic performance of various types of architectural glass elements held within various aluminum curtain wall framing systems using various glazing systems. Among the findings of these studies were the following: (1) architectural glass is vulnerable to damage and fallout under simulated earthquake conditions; (2) horizontal, in-plane racking movements of a curtain wall frame constitute the primary cause of glass damage and glass fallout under simulated earthquake conditions; (3) different types of architectural glass exhibit different degrees of resistance to glass fallout under simulated seismic conditions; and (4) flexural stiffness of aluminum framing members has an influence on the susceptibility of architectural glass to seismic damage (i.e., under simulated seismic conditions, stiffer curtain wall frames are associated with more glass damage and glass fallout than are more flexible frames).
[0005] Architectural glass is not the only type of curtain wall element that is vulnerable to fracture and fallout under earthquake conditions. Curtain wall systems comprised of any rigid, brittle elements such as stone panels, cementitious panels, etc. are also potentially vulnerable to the damaging effects of earthquake-induced building motions.
[0006] The primary factors causing earthquake-induced damage of conventional curtain wall systems are: (1) movements of the building's primary structural frame in response to earthquake ground movements; and (2) the fact that vertical framing members (mullions) in conventional curtain wall systems are connected structurally to more than one floor of the primary structural frame.
[0007] The present invention is directed to solving one or more of the problems discussed above in a novel and simple manner.
SUMMARY OF THE INVENTION
[0008] In accordance with the invention there is provided a curtain wall system in which curtain frame panels of each floor are not fixedly connected to curtain wall panels of adjacent floors.
[0009] Broadly, there is disclosed herein an earthquake-immune exterior wall system for use with a multi-story building structure. The wall system includes a plurality of anchor means for connecting the wall system to the building structure, each anchor means adapted to being fixedly connected to the building structure for a single story of the multi-story building structure. Connecting means are provided for connecting each of a plurality of first elongate members directly to only one of the anchor means so that each first elongate member is fixedly connected to a single story of the multi-story building structure. A plurality of second elongate members are connected between adjacent pairs of first elongate members. The first and second elongate members collectively define panel hanging areas. A plurality of exterior cladding panels are secured to the first and second elongate members at the panel hanging areas to define the exterior wall system of the building structure.
[0010] It is a feature of the invention that the anchor means comprises steel anchor frames. Each anchor frame is rectangular in configuration and is constructed of tubular steel. The connecting means comprises anchor brackets connecting each first elongate member to upper and lower horizontal members of the anchor frames.
[0011] It is another feature of the invention that the first elongate members comprise vertical mullions.
[0012] It is an additional feature of the invention that the second elongate members comprise horizontal mullions.
[0013] It is yet another feature of the invention to provide flexible means for connecting the first and second elongate members connected to any one story to first and second elongate members connected to the story immediately above the one story. The flexible means comprises a flexible gasket of polymeric material.
[0014] There is disclosed in accordance with a further aspect of the invention an earthquake-immune curtain wall system for use with a multi-story building structure. The wall system comprises a plurality of anchor means for connecting the wall system to the building structure. Each said anchor means is adapted to being fixedly connected to the building structure for a single story of the multi-story building structure. Connecting means connect each of a plurality of vertical mullions directly to only one of the anchor means so that each vertical mullion is fixedly connected to a single story of the multi-story building structure. A plurality of horizontal mullions are connected between adjacent pairs of vertical mullions. The vertical and horizontal mullions collectively define panel frames for each story. A plurality of exterior cladding panels are secured to the vertical and horizontal mullions at the panel frames to define the exterior curtain wall system of the building structure.
[0015] It is a feature of the invention that each panel frame further includes intermediate horizontal mullions to define plural subframes and an exterior cladding panel is secured at each subframe.
[0016] This invention relates to a curtain wall system for multi-story buildings that is highly resistant to the damage caused by multidirectional swaying motions in building frames during an earthquake. In a conventional curtain wall system, each story is connected structurally to the stories above and/or below it. Interstory relative movements resulting from earthquake-induced swaying motions of the building frame cause significant load transfer from story to story and cause such a conventional curtain wall system to be susceptible to earthquake damage. Not only does this damage necessitate expensive repairs, but serious threats to life safety are imposed when debris falls from a damaged wall system. In contrast, each story of the newly invented earthquake-immune curtain wall system is structurally isolated (i.e., decoupled) from adjacent stores, which produces the beneficial effects of minimizing wall system damage and the attendant risks of falling debris (in the forms of broken glass, stone, concrete, etc.) during an earthquake.
[0017] The earthquake-immune curtain wall system achieves structural isolation of each story by employing a newly developed “seismic decoupler joint” between each story and a newly developed structural support system for vertical mullions in the wall system frame. As a result, relative movements between adjacent stories in the building frame transfer no significant forces between adjacent stores in the curtain wall frame. This invention embodies a curtain wall system that is essentially “immune” from the effects of earthquake-induced building frame motions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1 A- 1 C are a schematic depiction of the displacement response of a typical building frame having a conventional curtain wall system to earthquake-induced ground motions;
[0019] FIGS. 1 D- 1 F are a schematic depiction of the displacement response of a building frame having an earthquake-immune curtain wall system according to the invention to earthquake-induced ground motions;
[0020] [0020]FIG. 2 illustrates a typical framing and anchorage configuration of a conventional curtain wall system;
[0021] [0021]FIG. 3 illustrates a front elevation view, in various stages of assembly, of an earthquake-immune curtain wall system according to the invention;
[0022] [0022]FIG. 4 is a side view of the curtain wall system of FIG. 3;
[0023] [0023]FIG. 5 is a front elevation view of a steel anchor frame for the curtain wall system according to the invention;
[0024] [0024]FIG. 6 is a side elevation view of the steel anchor frame of FIG. 5;
[0025] [0025]FIG. 7 is a front elevation view of a portion of a panel frame of the curtain wall system according to the invention including vision panels and spandrel panels;
[0026] [0026]FIG. 8 is a side view of the panel frame of FIG. 7 also illustrating a seismic decoupler joint;
[0027] [0027]FIG. 9 is a vertical section taken along the line 9 - 9 of FIG. 7 illustrating the seismic decoupler joint according to the invention;
[0028] FIGS. 10 A- 10 C illustrate front views of the seismic decoupler joint during horizontal, in-plane, interstory movements of a building frame under earthquake conditions;
[0029] FIGS. 11 A- 11 C are vertical sections depicting positions of the seismic decoupler joint during horizontal, out-of-plane, interstory movements of a building frame under earthquake conditions;
[0030] FIGS. 12 A- 12 C are vertical sections depicting positions of the seismic decoupler joint during vertical, interstory movements of a building frame under earthquake conditions;
[0031] [0031]FIG. 13 is a front elevation view showing positions of the curtain wall system during in-plane and out-of-plane interstory movements of the building frame during earthquake conditions;
[0032] [0032]FIG. 14 is a vertical section of that shown in FIG. 13; and
[0033] [0033]FIG. 15 is a front elevation view of a steel anchor frame for the curtain wall system according to an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Typical swaying motions of a conventional building frame 27 in response to earthquake-induced ground movements are shown schematically in FIGS. 1A, 1B and 1 C. Particularly, FIG. 1A illustrates the building frame 27 in a normal, vertical position. FIG. 1B illustrates the building frame 27 in a first mode response. FIG. 1C illustrates the building frame 27 in a second mode response. Specific mode shapes of the building frame are affected by the flexural stiffness of the floor system relative to that of the columns. Regardless of the specific mode shape, interstory drift (the difference in horizontal displacement between adjacent stories in the building frame) is a primary cause of earthquake damage in conventional curtain wall systems. Earthquakes of low to moderate magnitude can cause expensive curtain will damage and loss of building envelope weather-resistant seals. More severe earthquakes can, in addition to the aforementioned damage and loss of serviceability, impose hazards to life safety if damaged curtain wall fragments fall from the building frame.
[0035] Interstory drift can cause damage in curtain wall systems because vertical framing members in conventional curtain wall systems are connected structurally to more than one floor of the primary structural frame, as depicted in FIG. 2. For example, vertical mullions 20 are connected at anchors 22 to the building structure for “Story (i)” and at anchors 24 to the building structure for “Story (i+1)”. Horizontal mullions 26 are connected between adjacent pairs of vertical mullions 20 . Rectangular curtain wall panels or rectangular curtain wall frame units 28 , see FIG. 1A, are connected between each pair of adjacent vertical mullions 20 and horizontal mullions 26 .
[0036] As illustrated in FIGS. 1B and 1C, such rectangular curtain wall panels or rectangular curtain wall frame units 28 are forcibly distorted into parallelograms 29 as a result of interstory drift when the curtain wall system at a given floor level is connected structurally to adjacent stories of the building frame. This forcible distortion of rectangular shapes into parallelogram shapes can cause frame-to-cladding panel contact, which can result in fracture of brittle cladding elements (e.g., architectural glass panels, stone cladding panels, precast concrete cladding panels, etc.) secured within the curtain wall system.
[0037] In accordance with the invention, vertical mullions are attached to only one story of the building frame, as depicted in FIGS. 3 and 4. The essence of the invention is to “decouple” (disengage) each story of the curtain wall system from adjacent stories, thereby permitting free movement of each story of the curtain wall system with respect to adjacent stories. By so doing, no significant loads are transferred between adjacent stories of the curtain wall system when the main building frame undergoes swaying motions under earthquake conditions. The result is a curtain wall system that is highly resistant to earthquake conditions.
[0038] Typical swaying motions of a building frame 27 ′ having an earthquake immune curtain wall system in response to earthquake-induced ground movements are shown schematically in FIGS. 1D, 1E and 1 F. Particularly, FIG. 1D illustrates the building frame 27 ′ in a normal, vertical position. FIG. 1E illustrates the building frame 27 ′ in a first mode response. FIG. 1F illustrates the building frame 27 ′ in a second mode response. As illustrated in FIGS. 1E and 1F, rectangular curtain wall panels or rectangular curtain wall frame units 28 ′ remain rectangular even with interstory drift when the curtain wall system at a given floor level is structurally decoupled from adjacent stories of the building frame. This result can be compared to the conventional curtain wall system depicted in corresponding FIGS. 1 A- 1 C.
[0039] [0039]FIGS. 3 and 4 illustrate building structure of a typical multi-story building including vertical columns 30 operatively connected to individual floors 32 and associated spandrel beams 34 . Building structure for three floors or stories identified as “Story(i−1)”, “Story(i)”, and “Story (i+1)”, is illustrated. As is apparent, the building can have any number of floors. A curtain wall system in accordance with the invention is defined by plural curtain wall panel frames, one of which 36 is shown, connected to each story. Plural steel anchor frames 38 are connected to the spandrel beams 34 , as discussed below. The panel frames 36 are connected to the anchor frames 38 . The panel frame includes plural elongate vertical framing members or mullions 40 , three of which are illustrated, connected to the anchor frames 38 . Connected to the vertical mullions 40 are respective lower horizontal mullions 42 , intermediate horizontal mullions 44 , and upper horizontal mullions 46 . The particular sizes of the mullions 40 , 42 , 44 and 46 are dependent on the particular 10 building requirement, as well as sizes of cladding panels to be connected therebetween, as discussed below. Also, depending on panel size, the intermediate horizontal mullions 44 may be omitted. In the illustrated embodiment of the invention the mullions are formed of extruded aluminum. Each panel frame 36 is defined by the upper and lower horizontal mullions 46 and 42 and the outermost of the vertical mullions 40 . Any intermediate vertical mullions 40 or the intermediate horizontal mullions 44 divide the panel frame 36 into smaller panel frames or subframes.
[0040] Referring to FIGS. 5, 6 and 7 , the steel anchor frames 38 are illustrated in greater detail. Each frame 38 is connected to a spandrel beam 34 at each story level in the main building structure using connection bars 48 secured as necessary to the spandrel beam 34 . Each anchor frame 38 is connected to the spandrel beam at two locations to provide stability of the anchor frame 38 against rotation about X, Y, or Z orthogonal axes, as shown in FIG. 5. Each anchor frame is typically constructed of horizontal and vertical tubular steel members 50 and 52 , respectively, in a rectangular configuration with sufficiently large cross sections to provide adequate strength and bending stiffness to resist design wind loads. Because wind loads are site specific, required cross sections of the anchor frames are determined by structural engineering design for wind loads as appropriate for each specific building site and each location on the building envelope. Alternatively, plural anchor frames 38 could be replaced with a single unit 138 consisting of elongate horizontal members 150 connected with plural spaced vertical members 152 , see FIG. 15.
[0041] Referring to FIG. 5, each steel anchor frame 38 has two anchor brackets 54 at locations that provide for pin supports via bolted connections to each vertical mullion 40 . Each anchor bracket 54 is centrally located at the opposite horizontal tubular steel members 50 . Vertical mullions 40 are connected to the steel anchor frames 38 , as shown at 55 in FIG. 4. As a result, each vertical mullion 40 has a simply supported portion 56 between the anchor brackets 54 and a cantilever portion 58 above the uppermost anchor bracket 54 .
[0042] The lower, intermediate, and upper horizontal mullions 42 , 44 and 46 are secured mechanically to vertical mullions 40 supported in the steel anchor frames 38 as shown in FIG. 7. With the aluminum curtain wall framing thus in place, vision panels 60 and spandrel panels 62 of any appropriate construction are secured to the curtain wall frame 36 by an appropriate glazing system or perimeter anchorage technique. For the purposes of illustration in this example, a combination of structural silicone glazing and dry glazing gaskets is employed to secure vision panels 60 and spandrel panels 62 to the curtain wall frame 36 . Again, it should be noted that the selection of cladding material and the selection of glazing system is at the discretion of the designer and is not an intrinsic part of the earthquake-immune curtain wall system.
[0043] Connections between the horizontal mullion 42 , 44 and 46 and the vertical mullions 40 are the same as those in conventional curtain wall systems. Required cross sections of all vertical and horizontal mullions are determined by structural engineering design for site-specific wind loads. Unlike the conventional curtain wall system illustrated in FIG. 2 the vertical mullions 40 according to the invention are not secured by mechanical attachment to adjacent stories (i.e., Story (i+1) and/or Story (i−1)). This structural decoupling is accomplished by means of continuous seismic decoupler joints 64 along the top surface of the upper horizontal mullion 46 and the bottom surface of the lower horizontal mullion 42 as shown in FIG. 8. By means of this configuration, relative movements of adjacent stories in the main building frame (such as those caused by earthquakes) transfer no significant loads from story to story. It should also be noted that, for maximum seismic resistance, the earthquake-immune curtain wall system should not be connected directly to interior ceiling elements, and that the ceiling of Story (i) should be attached to the underside of the floor structure of Story (i+1).
[0044] The interior facing side of the steel anchor frames 38 can also serve as a convenient and stable surface upon which interior architectural coverings 39 can be affixed in the spandrel area of Story (i), as shown in FIG. 8.
[0045] A vertical section of the seismic decoupler joint 64 is shown in FIG. 9. The decoupler joint uses a pair of continuous, flexible gaskets 66 made of polymeric material that accommodates in-plane, out-of-plane, and vertical movements between adjacent stories of the main building frame under earthquake conditions.
[0046] Each gasket 66 is made of an elongate, extruded flexible material that may span the entire width of a floor. In cross section, each gasket includes a central portion 68 connected between locking end portions 70 . The central portion 68 is originally flat. When installed, the central portion is rolled into position and assumes a U-shape, as illustrated in FIG. 9. The locking end portions 70 are force-fit into channels 72 provided in the lower horizontal mullions 42 and upper horizontal mullions 46 , as shown. The channels 72 , in cross section, include teeth 74 for lockably engaging corresponding notches 76 in each locking end portion 70 . As shown, a flexible gasket is placed at both the front and rear of adjacent lower horizontal mullions 42 and upper horizontal mullions 46 . As a result, the central portions 68 extend inwardly between the lower horizontal mullion 42 of Story (i+1) and the adjacent upper horizontal mullion 46 of Story (i).
[0047] The seismic decoupler joint 64 also includes a rotation-accommodating face cap 78 that accommodates movement by means of a face cap hinge 80 and the use of a bead 82 of glazing sealant, e.g., structural silicone or other appropriate material, that has high deformation capability. This bead 82 of glazing sealant is located along the lower edge of the cladding panel, such as the spandrel panel 62 , as shown in FIG. 9. When the face cap hinge 80 rotates counterclockwise, the sealant 82 is compressed, as shown in FIG. 11B. If the face cap hinge 80 were to be rotated clockwise, then the sealant 82 would be stretched. However, as will be described later, the glazing sealant bead 82 adjacent to the rotating face cap hinge 80 will see only compression (and not tension) as a result of horizontal, out-of-plane, relative movements between adjacent stories of the main building frame under earthquake-induced motions.
[0048] The cladding panels 60 and 62 are otherwise sealed in the curtain wall frame 36 using, for example, setting blocks 84 , backer rods 86 , glazing tape 88 , and glazing gasket 90 , as is conventional.
[0049] Detailed depictions of how the seismic decoupler joint accommodates in-plane, out-of-plane, and vertical interstory movements are shown in the drawing figures, as described below. The continuous, flexible gaskets 66 within the seismic decoupler joint 64 also provide thermal insulation and a weather seal between adjacent stories of the building.
[0050] [0050]FIGS. 10A, 10B and 10 C illustrate a front view of operation of a segment of the seismic decoupler joint 64 in the following positions: (1) in its normal position (FIG. 10A); (2) when Story (i) moves horizontally in-plane to the right relative to Story (i+1) (FIG. 10B); and (3) when Story (i) moves horizontally in-plane to the left relative to Story (i+1) (FIG. 10C). Horizontal, in-plane interstory movements are accommodated by the seismic decoupler joint 64 , located between each story, which prevents the transfer of any significant loads between stories of an earthquake-immune curtain wall system.
[0051] [0051]FIGS. 11A, 11B and 11 C illustrate a vertical section of the seismic decoupler joint 64 in the following positions: (1) in its normal position (FIG. 11A); (2) when Story (i) moves horizontally out-of-plane outward (i.e., outward from the building face) relative to Story (i+1) (FIG. 11B); and (3) when Story (i) moves horizontally out-of-plane inward relative to Story (i+1) (FIG. 11C). Horizontal, out-of-plane, interstory movements are accommodated without stressing the continuous flexible gasket 66 in the seismic decoupler joint 64 —provided that the magnitude of the relative movement is less than approximately the total length of each individual strip of gasket 66 in the seismic decoupler joint 64 , or approximately twice the length “L” in FIG. 11A. Out-of-plane movements in excess of approximately the length 2 L would stretch the flexible gaskets 66 (and possibly tear them), but there would still be no significant amount of interstory load transfer in the curtain wall system. It is also shown in FIGS. 11B and 11C that the sealant bead 82 at the bottom of the Story (i+1) cladding panel is compressed, but is not stretched, as a result of horizontal, out-of-plane, interstory movements.
[0052] [0052]FIGS. 12A, 12B and 12 C illustrate a vertical section of the seismic decoupler joint 64 in the following positions: (1) in its normal position (FIG. 12A); (2) when Story (i) moves vertically upward relative to Story (i+1) (FIG. 12B); and (3) when Story (i) moves vertically downward relative to Story (i+ 1 ) (FIG. 12C). Vertical interstory relative movements are accommodated without vertical interstory load transfer, provided that the relative vertical movement does not exceed the vertical gap built into the seismic decoupler joint 64 , or the distance “H” in FIG. 12A.
[0053] [0053]FIG. 13 contains a front view and FIG. 14 a vertical section of the earthquake-immune curtain wall system during simultaneous in-plane and out-of-plane interstory movements. (The movements are drawn to an exaggerated scale for clarity and emphasis.) It can be observed that, within the geometric limits designed into a specific version of the earthquake-immune curtain wall system, simultaneous in-plane, out-of-plane, and vertical interstory movements can be accommodated by the system without significant interstory load transfer.
[0054] In summary, the seismic decoupler joint 64 : (1) accommodates interstory movements in all directions; (2) transfers no significant loads between adjacent stories; and (3) provides an effective thermal insulation and weather seal between adjacent stories in an earthquake-immune curtain wall system. | Described herein is a curtain wall system for multi-story buildings that is highly resistant to the damage caused by multidirectional swaying motions in building frames during an earthquake. In a conventional curtain wall system, each story is connected structurally to the stories above and/or below it. Earthquake-induced swaying motions of the building frame cause significant load transfers from story to story and cause such a conventional curtain wall system to be susceptible to earthquake damage. Not only does this damage necessitate expensive repairs, but serious threats to life safety are imposed when debris falls from a damaged wall system. In contrast, each story of the earthquake-immune curtain wall system is structurally isolated (i.e., decoupled) from adjacent stories, which produces the beneficial effects of minimizing wall system damage and the attendant risks of falling debris (in the forms of broken glass, stone, concrete, etc.) during an earthquake. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to transparent, electrically conductive semiconductor windows and more particularly such windows which are made of treated semiconductor materials, which are transparent in the infrared spectrum, and which have good electrical conductivity.
Transparent conductive windows through which optical energy must pass and which have good electrical conductivity have utility in a number of applications. These include resistance heated windows, electro magnetic interference (EMI) shielded windows, anti-static windows and transparent electrodes for use in windows. In co-pending application Ser. No. 883,897 filed July 9, 1986, entitled TRANSPARENT CONDUCTIVE WINDOWS, COATINGS, AND METHOD OF MANUFACTURE and assigned to Northrop Corporation, the assignee of the present application, transparent conductive windows, coatings and their method of manufacture are described which employ thin conductive metal layers which are sandwiched between dielectric matching layers. The devices of this prior application afford both good electrical conductivity and transmissivity in the infrared and ultra violet ranges.
The device of the present invention affords a number of advantages over that of the aforementioned prior application. These include the capability of providing transmissivity over a greater band width; higher transmissivity for optical waves having angles of incidence away from the normal; greater mechanical durability; and greater ease and economy of fabrication.
Other known applicable prior art devices are discussed by J. L. Vossen in an article on transparent conducting films which appeared in Physics of Thin Films, Volume 9, published in 1977 by Academic Press. In this article, the use of semiconductor oxides forming transparent conductive films is discussed. It has been found, however, that semiconductor oxide substrates exhibit the shortcomings of low carrier life time, resistivity which is higher than to be desired and relatively low optical transmissivity particularly in the infrared range, as compared with the devices of the present invention.
OBJECTS AND SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a transparent, conductive window made of semiconductor material.
It is an object of this invention to provide a semi-conductor window having high optical transmittance in the infrared range and low sheet resistance.
It is a further object of this invention to provide a semi-conductor window in the infrared range having low sheet resistance and a wider optical band width.
It is still another object of this invention to provide an improved semiconductor window for the infrared range having low sheet resistance which has higher mechanical durability.
It is another object of this invention to provide a semi-conductor window of good transmissivity in the infrared range and of low electrical sheet resistance which is easier and more economical to fabricate.
It is still a further object of this invention to provide a semiconductor window having low sheet resistance which has higher transmissivity to optical waves which depart from a normal angle of incidence.
The device of the invention comprises a semiconductor substrate which in one embodiment is silicon, in another embodiment germanium, and in a third embodiment, gallium arsenide. In the embodiments employing germanium and silicon substrates, the substrates are doped with an N type dopant element which diffuses into the substrate surface, leaving its optical constants essentially unchanged. The dopant is diffused to greater depths than are commonly employed in other technologies and its concentration, distribution, and depth of diffusion are closely controlled to effect optimum optical transmittance and low electrical resistivity. The dopant may be applied to the substrate surface by a variety of means, depending upon the chemistries of the substrate and dopant and their responses to various ambient environmental conditions. The dopant may be deposited on the substrate surface from an inert gas carrier in a controlled atmosphere in a furnace, for example. It may be deposited on the substrate surface from a liquid solution, suspension, or slurry, by spinning or spraying, and preconditioned by thermal treatment in a controlled atmosphere. It may be deposited in vacuum by various means, including evaporation from an electron beam or thermal source, sputtering in dc, rf, or magnetron-supported discharge, or combinations thereof, ion beam sputtering, molecular beam epitaxy, or variants thereof, and ion implantation. It may also be deposited on the substrate surface by reactants in the vapor phase (i.e., chemical vapor deposition) at, above, or below atmospheric pressure. However applied, dopant may be diffused into the surface of the substrate at elevated temperatures (600°-1200° C.). A series of dielectric antireflection stacks are then deposited on both of the opposite surfaces of the substrate to minimize the reflectivity of such surfaces.
In the case of the embodiment employing a gallium arsenide substrate, a gallium arsenide film is epitaxially deposited on the substrate along with a dopant such as silicon to produce a thin film window having an exceptionally wide band pass in the infrared range (1-16 microns). A similar, doped semiconductor film may be deposited on a silicon or germanium substrate, by homoepitaxy or heteroepitaxy. Examples of homoepitaxy include, but are not limited to, doped silicon on silicon and doped germanium on germanium; i.e., the deposited layer is, in essence, chemically identical to the substrate host, with the addition of a trace amount of a dopant species. Examples of heteroepitaxy include, but are not limited to, gallium arsenide on germanium and aluminum nitride on silicon; i.e., the deposited layer is chemically different, but structurally similar to the substrate host, on an atomic scale. In addition, similarities in chemical bond type and coefficient of thermal expansion are required between substrate host and deposited layer for the occurrence of heteroepitaxy. A series or "stack" of dielectric antireflection coatings is then deposited on the doped and undoped surfaces of any of the substrates employed.
As used herein, the term "doped" means establishing an impurity concentration in a semiconductor by diffusion, epitaxial deposition, or other means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing illustrating the structure of the first and second embodiments of the invention;
FIG. 2 is a graph illustrating the transmission characteristics of the first embodiment;
FIG. 3 is a graph illustrating the transmission characteristics of the second embodiment;
FIG. 4 is a schematic drawing illustrating the fabrication of the first embodiment;
FIG. 5 is a schematic drawing illustrating the fabrication of a second and third embodiment of the invention; and
FIG. 6 is a schematic drawing illustrating the third embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the first and second embodiments of the invention are schematically illustrated. The first embodiment employs a semiconductor substrate 11 of silicon while in the second embodiment the substrate is of germanium. The thickness of the substrate is not critical but should be sufficient to make for a structurally self supporting unit and may typically be of the order of 0.015-0.050 inches. Thicker substrates, e.g. 0.5 to 1.0 inches, could also be employed. Such a self supporting unit is called for in view of the fact that adherents presently available which could be used to attach the substrate to a supporting optical window do not have good optical transmittance in the infrared spectrum. With the discovery of adherents with the proper optical characteristics, a supporting window might be employed. A doped semiconductor layer 14 which may be of phosphorous, arsenic or antimony for either substrate is vacuum deposited or carried to the surface of the substrate in an inert gaseous or liquid medium, and diffused into the substrate to a considerably greater depth than in the prior art. The doped layer is diffused to depths between 15 and 50 microns and in the preferred embodiments is of the order of 25 microns thick. The dopant is preferably of the N type and leaves the optical constants of the substrate substantially unaltered when compared with undoped material. N type dopant is preferred over P type dopant in view of the fact that at the same level of electrical conductivity N type dopant results in less optical absorption than P type, thus enhancing optical transmission.
Layered over doped layer 14 are a plurality of dielectric layers 15-18 which are typically thermally evaporated on by techniques well known in the art to form an anti-reflection stack. These layers are typically of a material such as germanium or zinc sulfide and have thicknesses of the order of 0.3 microns. Similar dielectric anti-reflection layers 19-22 are deposited on the bottom surface of substrate 11. The materials employed for these anti-reflection layers and the thicknesses of the deposition thereof are chosen for optimum anti-reflection characteristics for each particular embodiment.
The characteristics of the embodiment of the invention having a germanium substrate are shown in FIG. 2. This embodiment has a sheet resistivity of 5 ohms/square. As can be seen from the graph, between 85% and 95% transmittance is provided in the infrared spectrum between three and twelve microns for light with a normal angle of incidence. With a 70 degree angle of incidence over this same range transmittance varies between about 55% and 78%.
SILICON SUBSTRATE
Referring now to FIG. 3, the characteristics of an embodiment of the invention with a silicon substrate, as described further on in the specification, is shown. For this embodiment, sheet resistance is 5 ohms/square and as can be seen from the figure, transmittance is 90% for light waves between 3 and 5 microns having a normal angle of incidence. As further shown, for an angle of incidence of 70 degrees over the same wave length band, transmittance is about 75%.
Referring now to FIG. 4, equipment utilized to fabricate an embodiment of the invention with a silicon substrate is shown, and the method for fabricating this embodiment utilizing this equipment will now be described in connection with this Figure.
EXAMPLE I
(Silicon Substrate)
A silicon wafer 20 having a thickness of 0.015 inches has its bottom surface coated with a silicon dioxide coating 21 to a thickness of 1 micron. The silicon dioxide coating is used to provide a barrier layer impervious to the dopant species thus protecting the bottom surface from contact therewith. This silicon dioxide layer can be deposited by any conventional techniques such as sputtering, evaporation or spin coating by conventional techniques well known in the art and is done prior to the placement of the substrate in the furnace 26. Also, in order to remove any residual native oxide from the silicon surface to be doped, after the silicon dioxide layer has been deposited, the substrate is dipped in cold dilute hydrofluoric acid, 10% by volume, for about thirty seconds and then rinsed in deionized water and blown dry with nitrogen immediately prior to insertion in the furnace. This last mentioned step is necessary to prevent any residual oxide on the silicon surface from acting as a barrier to the diffusion of the phosphorous to be used as a dopant. This light etching will not remove an appreciable amount of the silicon dioxide deposited on the lower surface of the substrate. Prior to the insertion of the substrate in the furnace, the furnace temperature is set at 950° C. with valve 27 open and the remaining valves closed to permit the flow of nitrogen gas into the furnace at a rate of 2000 cc/min. The substrate 20 is then placed on quartz boat 24 which is mounted in the flat zone of the quartz lined furnace 26. The flow of nitrogen at 2000 cc/min through valve 27 into the furnace is continued for a period of five minutes to permit thermal equilibration of the substrate 20 while purging the substrate surface.
When the temperature of the substrate 20 has equilibrated at 950° C., valve 28 is opened (valve 27 is left open) and nitrogen is flowed at a rate of 40 cc/min through liquid phosphorous oxychloride 30 contained within bubbler flask 31 for a period of 5 minutes to effectively purge the bubbler system. After the bubbler system has been purged by the nitrogen, valve 34 is opened and oxygen flowed into furnace 26 at a rate of 60 cc/min. Valve 28 is left open to effect the feeding of evaporated phosphorous oxychloride into furnace 26 on a nitrogen carrier. The oxygen reacts with the phosphorous oxychloride vapor fed into the furnace from flask 31 to form a phosphate glass on the surface of substrate 20. This deposition process is continued for a period of twenty minutes. At the end of this period, valves 28 and 34 are closed and valve 27 is opened to permit the flow of nitrogen into the furnace for five minutes to purge the furnace.
At the end of this five minute period, valve 27 is closed and the doped substrate removed from the furnace and its surface resistance measured using a four point probe or other convenient device. Typically the resistance so measured is about four times the surface resistance of the doped silicon substrate after the diffusion step. Thus, a silicon surface with phosphate glass measuring 20 ohms/square will yield a silicon surface measuring 5 ohms/square after diffusion has been completed in a following step. If the resistance is too high the silicon substrate is returned to the furnace and the phosphorous oxychloride deposition continued for a period to lower the resistance to the desired point. It is to be noted in this regard that resistance decreases as the concentration of the dopant layer increases.
The furnace is then heated to a temperature of 1150° C. and the doped substrate placed back in the furnace on the quartz boat and valve 27 opened to permit a flow of nitrogen into the furnace at a rate of 1500 cc/min. After sufficient time (five minutes) has elapsed to permit thermal equilibration of the doped substrate, valve 37 is opened to permit a flow of oxygen into the furnace at a rate of 1600 cc/min, with nitrogen continuing to be supplied to the furnace through valve 27 but with the rate of flow reduced to 50 cc/min. Valve 38 is also opened to permit a flow of hydrogen into the furnace at a rate of 2600 cc/min. The flow of oxygen at 1600 cc/min through valve 37, hydrogen at 2600 cc/min through valve 38 and nitrogen at 50 cc/min through valve 27 is continued for thirty minutes to produce a native oxide coating on the dopant surface having a thickness of 5000 angstroms. At the end of this thirty minute period, valves 37 and 38 are closed to shut off the oxygen and hydrogen supplied to the furnace and valve 27 is adjusted to provide a nitrogen flow to the furnace at the rate of 1500 cc/min, such supply of nitrogen being continued to purge the atmosphere in the furnace, the furnace being kept at its heated temperature for 600 hours to complete the diffusion of the dopant into the substrate. Diffusion time can be varied between 400 and 1000 hours to provide optimum optical transmission and sheet resistance. The substrate can be removed from the oven to check these parameters and diffusion either terminated or continued, as may be called for. After etching in dilute (10% by volume) hydrofluoric acid to remove all residual SiO 2 and phosphate glass from either side of the substrate, the anti-reflectant coatings (15-22) are then deposited by conventional vacuum evaporation from an electron beam source, using monitoring instruments to measure the rate of deposition and the thickness of deposition. In a typical antireflectant coating for this example, layers 15 and 19 consist of germanium and are 0.073 microns thick; layers 16 and 20 consist of aluminum oxide (Al203) and are 0.188 microns thick; layers 17 and 20 are germanium, 0.088 microns thick, and layers 18 and 22 are aluminum oxide (Al203), 0.750 microns thick.
GERMANIUM SUBSTRATE
In fabricating a window having a germanium substrate, an N-type dopant such as antimony, arsenic, or phosphorous is deposited upon the surface of a substrate by vacuum evaporation or sputtering. The desired dopant in elemental or non-oxide compound form (e.g. antimony) is first vacuum deposited on the germanium surface to a thickness of five angstroms. The dopant layer is then covered by a protective coating of a material such as silicon or silicon monoxide to a thickness of 500 to 1000 angstroms in a vacuum environment. The doped substrate is then placed in a standard electrically heated diffusion furnace employing a flowing reducing gas mixture of nitrogen or argon and hydrogen (3.5% hydrogen by volume), the furnace being sealed at both ends to exclude the ambient atmosphere as is commonly done in chemical vapor deposition processes. The gas mix passes through a bubbler filled with a low vapor pressure oil at the tube exit to prevent back streaming of the ambient atmosphere. The doped substrate is then diffused for twenty hours in the furnace at a temperature of 750° C. in an atmosphere of a mixture of nitrogen or argon and 3.5% hydrogen by volume.
The electrical and optical characteristics of the finished product are determined by the details of processing, e.g., the amount of dopant deposited, the diffusion temperature, and the diffusion time. For example, with antimony dopant deposited on a germanium wafer to a thickness of five angstroms which is covered by a protective coating of elemental silicon 500 angstroms thick and with the antimony being diffused for twenty hours at 750° C. in an atmosphere of argon having 3.5% hydrogen by volume, an end product is produced having a surface resistance of four ohms/square and a transmissivity of 40% in the 8-12 micron band and 42% in the 3-5 micron band. On the other hand with antimony deposited on a germanium wafer to a thickness of 200 angstroms with identical processing as for the first example, an end product having a surface resistance of 1.5 ohms/square and transmissivity of 30% in the 8-12 micron band is provided.
An example of a method for fabricating an embodiment of the invention utilizing a germanium substrate will now be described in connection with FIG. 5.
EXAMPLE II
(Germanium Substrate)
A germanium wafer is used having a thickness of 0.015 inches. A germanium binder layer is deposited by sputtering on one surface of the germanium substrate to a thickness of 500 angstroms. Over this germanium binder layer, an antimony dopant layer of 5 angstroms thickness is then deposited by sputtering. Over the antimony dopant layer a silicon monoxide or elemental silicon protective encapsulant layer is deposited by sputtering to a thickness of 500 to 1000 angstroms. Referring now to FIG. 5, the substrate 51 is then placed in quartz lined furnace 52 which has electrical resistance or inductive heating elements 54. The substrate is supported on a fused quartz boat 56 with the furnace being heated to 400° C. The atmosphere inside the furnace is then purged by feeding nitrogen into the furnace through inlet 52a at 3 liters/minute for a period of thirty minutes. The gas is exited into bubbler 57 wherein to prevent back streaming of the ambient air it is passed to the ambient atmosphere through a low vapor pressure oil, such as diffusion pump fluid. The temperature of the furnace is then raised from 400° C. to 750° C. over a period of thirty minutes, and during this time a gas mixture of nitrogen and 3.5% hydrogen is fed into the furnace at a rate of 1.5 liters/minute. The temperature of the oven is maintained at 750° C. while continuing to feed the nitrogen/hydrogen mixture into the furnace to achieve drive in diffusion of the antimony dopant layer into the germanium substrate. This step is carried on for a period of 16 hours. The furnace is then cooled down from 750° C. to 400° C. over a period of four hours while continuing to feed the nitrogen/hydrogen mixture thereto. With the oven at 400° C., the atmosphere in the furnace is purged by feeding nitrogen at a rate of 1.5 liters/minute for a period of thirty minutes. It is to be noted that in both this and the preceding gas purge steps, that argon can be used in place of nitrogen.
The doped germanium substrate is then removed from the furnace and residual dopant and protective encapsulant material removed from its surface by wet chemical etching, this end result being achieved with a solution composed of ten to fifty percent concentrated hydrofluoric acid, by volume, balance deionized water. The substrate is dipped in this mixture at room temperature and gently agitated until all coating residue is removed from the surface as indicated by visual observation. Following this acid dip, the substrate is rinsed in deionized water and blown dry with dry nitrogen gas. Its electrical sheet resistance is then measured using the four-point probe technique, which is well known in the industry, and its infrared optical transmission is verified with an infrared spectrophotometer covering the appropriate wavelength region.
Both the doped and undoped surfaces of the substrate are then coated with a plurality of anti-reflection coatings 15-22 (See FIG. 1). These anti-reflection coatings are deposited by vacuum evaporation from an electron beam gun source with appropriate optical and accoustical thickness and deposition rate monitoring instrumentation which is well known in the art. Only three layers per surface are employed in this embodiment. Layers 15 and 19 consist of thorium tetrafluoride (ThF4) and are 0.621 microns thick; layers 16 and 20 consist of germanium and are 0.098 microns thick; layers 17 and 21 are thorium tetrafluoride (ThF4), 0.621 microns thick.
Referring now to FIG. 6 an embodiment of the invention employing a gallium arsenide semi-insulating substrate 40 is shown. Substrate 40 is typically 0.012 to 0.025 inches thick. In this embodiment a gallium arsenide film 41 is grown on the substrate utilizing metal organic chemical vapor deposition (MOCVD). The epitaxial thickness may be 15 to 50 microns, but is typically 25 microns. Epitaxial deposition by this technique is well known in the art and is described for example on page 324 of Semiconductor Devices by S. M. Sze, Published by John Wiley & Sons in 1985. This process in its essence uses sources of trimethylgallium vapor and arsine with hydrogen as a carrier gas. The vapor carried on hydrogen is passed over the gallium arsenide substrate heated in a furnace to 650°-900° C. at which temperatures the vapor and gas decompose. The gallium and arsenic thus produced have high affinity for the gallium arsenide substrate and condense on this substrate, forming a crystal surface structure thereon. The thickness of the deposited layer 41 is determined by the amount of gas flowed over the substrate. Since gallium arsenide in its pure state is not electrically conductive at room temperature, an electrically active dopant, silicon in the form of silane is added to the gas stream during the epitaxial growth of layer 41. The silane is added to the gas stream at a very low flow rate such that the resultant silicon is incorporated into the gallium arsenide on the order of 1 silicon atom for 10 6 gallium arsenide molecules. In this example, the antireflectant coating consists of only three layers per surface. Referring to FIG. 6, layer 41 is epitaxially grown gallium arsenide, layers 43 and 47 consist of zinc selenide and are 0.177 microns thick, layers 44 and 48 consist of silicon monoxide and are 0.224 microns thick, layers 45 and 49 consist of magnesium fluoride and are 0.315 microns thick, and layers 46 and 50 are absent in this design.
An example of the fabrication of the embodiment of the invention employing a gallium arsenide substrate as described is as follows in connection with FIG. 5.
EXAMPLE III
(Gallium Arsenide)
A gallium arsenide wafer 51 having a thickness of 0.017 inches was placed on a silicon carbide coated susceptor 56 in a quartz reaction chamber such as shown in FIG. 5. This chamber is sealed off from the ambient atmosphere and purged by flowing hydrogen at the rate of 6.5 liters per minute for fifteen minutes. The susceptor 56 for the gallium arsenide substrate is then raised to 800° C. by inductively heating the susceptor (using rf power applied through the coil 54) for a period of fifteen minutes with the addition of arsine being flowed through the chamber at the rate of 0.60 liters/min. The vapors of trimethyl gallium at -12.8° C. on a hydrogen carrier flowing at a rate of 0.080 liters/min and silane gas diluted with hydrogen at 40 parts silane to one billion parts hydrogen are flowed through the chamber for a period of one hundred minutes to achieve a 24 micron thick epitaxial layer of gallium arsenide. At the end of this period, the flow of trimethyl gallium vapor and silane on the hydrogen carrier is terminated, the flow of arsine being continued. The furnace is then permitted to cool to room temperature, the flow of arsine being shut off when the temperature reaches 550° C.
The anti-reflectant layers are then applied as for the previous embodiment by conventional vacuum evaporation. In this example, the antireflectant coating consists of only three layers per surface. Referring to FIG. 6, layer 41 is epitaxially grown gallium arsenide, layers 43 and 47 consist of zinc selenide and are 0.177 microns thick, layers 45 and 49 consist of magnesium fluoride and are 0.315 microns thick, and layers 46 and 50 are not employed in this design.
While the invention has been described and illustrated in detail, it is to be clearly understood that this is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the invention being limited only by the terms of the following claims. | A semiconductor window which is transparent to light in the infrared range and which has good electrical conductivity is formed with a substrate of semi-conductor material which has a conduction modifying dopant diffused, grown or deposited on one surface thereof to a substantial depth so that a layer thereof exhibits reduced resistance to a value below 10 ohms/square. Anti-reflection dielectric layers are stacked on both outer surfaces thereof. The dielectric substrate may be of silicon, germanium or gallium arsenide depending on the transparency bandwidth of interest. The thickness of the substrate and the doping of the surface thereof is closely controlled to obtain both low electrical resistivity and high optical transmissivity. | 6 |
BACKGROUND OF THE INVENTION
1. Related Applications
This application is related to copending U.S. patent application Ser. Nos. 08/461,715 filed Jun. 5, 1995, and 08/784,985 filed Jan. 17, 1997.
2. Field of the Invention
The present invention relates to a control system/method for controlling the shifting of vehicular fully or partially automated mechanical transmission systems of the type including an engine equipped with an engine retarding device or devices, such as a compression brake, and in particular, relates to a control system/method of the above-described type which is effective to adaptively determine the optimal time to deactivate the retarding device or devices to achieve rapid and smooth upshifting.
3. Description of the Prior Art
Vehicular fully and partially automated mechanical transmission systems are known in the prior art as may be seen by reference to U.S. Pat. Nos. 4,361,060; 4,595,986; 4,648,290; 4722,248; 5,050,427; 5,136,897; 5,335,566 and 5,582,558, the disclosures of which are incorporated herein by reference.
Such fully or partially automated mechanical transmission systems typically include a microprocessor-based controller for issuing command output signals to various controllers to implement or assist selected transmission shifts, including manipulation of the engine fueling and/or of engine or input shaft brakes to cause the transmission input shaft to rotate at a substantially synchronous speed for a given output shaft speed and target gear ratio.
Engine brakes, usually called "engine compression brakes" or "exhaust brakes" are well known in the prior art and such devices, such as the well known "Jake brake," are commonly provided on heavy duty vehicles. These devices are typically manually operated, may provide variable retardation by manual selection of one, two or three banks of cylinders operation, and are utilized to retard the vehicle and, in recent developments, to quickly retard engine/input shaft speed for more rapid synchronization during an upshift. Examples of vehicular automated mechanical transmission systems utilizing automatically actuated engine brakes may be seen by reference to U.S. Pat. Nos. 4,933,850; 5,042,327; 5,409,432 and 5,425,689, the disclosures of which are incorporated herein by reference.
Generally, as is well known in the prior art, engine compression brakes are effective to alter, usually hydraulically, the engine valve timing/porting so that a relatively large compressive force and resistance is provided to rotation of the engine and the vehicle drive wheels acting through to drive axles, drive shaft, transmission and master clutch.
Other devices and techniques to selectively retard engine rotation are also known. By way of example, by increasing the load on engine-driven accessories, such as air-conditioning, the deceleration of the engine may be increased. As used herein, the term "engine braking" or like terms is intended to include such devices and/or techniques, as well as techniques involving more common engine brakes.
The prior art automated mechanical transmission systems of the type having manually and/or automatically operated engine brakes were not totally satisfactory as engine brake assisted upshifts tended to be somewhat harsh and abrupt and/or were not as rapid as desired.
In accordance with aforementioned U.S. Pat. No. 5,409,432, some of the drawbacks of the prior art were overcome by the provision of control system/method for an engine brake-equipped automated mechanical transmission system which was effective to provide relatively smooth, high-quality, rapid upshifts. By allowing automatic actuation of the engine brake, during certain upshifts, the engine brake was operated by the system controller during an upshift to exert a minimum retarding torque at initiation of the shift and to then exert a smoothly increasing retarding torque, until a maximum retarding torque value is achieved, and to exert a smoothly decreasing retarding torque upon sensing that engine rotational speed (ES) and input shaft rotational speed (IS) were within a predetermined value (about 80 to 100 RPM) of synchronous speed, which is equal to the product of output shaft speed times the numerical value of the target gear ratio (OS*GR T ). The controller preferably initiated these events in advance in view of actuator response times, current values of engine speed and output shaft shaft, and/or the rates of change thereof.
A problem with the above-described and other systems utilizing automatically controlled engine braking to assist some or all upshifts was that a fixed offset or shut-off point was used to determine when to shut off the engine braking device. If the shut-off occurred too early in the shift, the upshift took too long because the transmission input shaft and associated gearing did not declerate as rapidly as desired. If the shut-off occurred too late in the shift, the input shaft and associated gearing may have decelerated too rapidly for a smooth engagement and/or may have decelerated to a speed making target ratio engagement difficult or impossible.
A problem associated with using engine retarding devices to assist upshifting is that these devices tend to have a relatively long response time (often 100-500 milliseconds) so that a command to shut off the devices must anticipate the actual optimal time to shut off the devices by several hundred milliseconds. Also, vehicle configuration (2 or 3 banks of cylinders available for compressor braking) and/or operating conditions will cause large fluctuations in vehicle retarding device performance.
SUMMARY OF THE INVENTION
In accordance with the present invention, the drawbacks of the prior art are minimized or overcome by the provision of an adaptive control system/method that monitors the performance of selected samples, or of all, engine retarding device assisting upshifts and adjusts the shut-off point offset accordingly based upon real time measurements. In a preferred embodiment, the foregoing is accomplished by sensing the engine or input shaft acceleration at the time of or just prior to completing an assisted upshift. If the acceleration is greater than a reference value (i.e., if deceleration is too low), then the retarding device was turned off too early and the offset time is decreased, if the acceleration is less than a reference value (i.e., if deceleration is too high), then the retarding device was turned off too late and the offset is increased. The decrements and increments to the offset value are preferably in relatively small values to prevent overshifting of an optimal offset value.
Accordingly, it is an object of the present invention to provide a new and improved control for an automated mechanical transmission system equipped with an engine brake or other engine retarding device which will automatically control the engine brake during upshifts to provide smooth, high quality and rapid upshifts.
This and other objects and advantages of the present invention will become apparent from a reading of the following description of the preferred embodiment taken in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic illustration of an automated mechanical transmission system of the type particularly well suited to be controlled by the method/apparatus of the present invention.
FIG. 1B is a schematic top view illustration of a typical six-cylinder diesel engine having three banks of two cylinders each.
FIG. 2 is a schematic illustration of an engine brake-assisted upshift.
FIGS. 3A and 3B schematic illustrations of the control system/method of the present invention in flow chart format.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 schematically illustrates a vehicular automated mechanical transmission system 10 including an automated multiple-speed, change-gear transmission 12 driven by a fuel control engine 14, such as a well-known diesel engine, through a non-positive coupling such as a master friction clutch 16. The output of the automated transmission 12 is output shaft 18 which is adapted for driving connection to an appropriate vehicle component such as the differential of a drive axle, a transfer case or the like, as is well known in the prior art.
The crankshaft 20 of engine 14 will drive the driving plates 22 of the master friction clutch 16 which are frictionally engageable to driven plates 24 for driving the input shaft 26 of transmission 12.
The above-mentioned power train components are acted upon, monitored by and/or controlled by several devices, each of which will be discussed briefly below. These devices include a throttle pedal position or throttle opening monitor assembly 28 which senses the operator set position of operator control throttle device 30, a brake applied monitor assembly 32 which senses operator operation of a brake pedal 34 and a shift control monitor assembly 36 by which the operator may select a reverse (R), neutral (N) or forward drive (D) mode of operation of the vehicle. The devices may also include a fuel controlled device 38 for controlling the amount of fuel to be supplied to engine 14, and engine speed sensor 40 which senses the rotational speed of the engine, a clutch operator 42 which engages and disengages master clutch 16 and which may also provide information as to the status of the clutch, and input shaft speed sensor 44 for sensing the rotational speed of transmission input shaft 26, a transmission operator 46 which is effective to shift the transmission 12 into a selected gear ratio and to provide a signal indicative of a gear neutral position and/or the currently engaged gear ratio of the transmission, and an output shaft speed sensor 48 for sensing the rotational speed of the output shaft 18. An engine brake 50 is provided for selectively retarding the rotational speed of engine 14 and a manually operated engine brake operator 52 is provided, usually in the vehicle cab, allowing the operator (as well as the system controller) to selectively apply the engine brake. Preferably, engine 14 is electronically controlled and is equipped to provide information on and to accept command signals from a data base conforming with a known protocol such as SAE J1939.
Drive components and controls therefor of the type described above are known in the prior art and may be appreciated in greater detail by reference to U.S. Pat. Nos. 4,959,986; 4,576,065 and 4,445,393, the disclosures of which are hereby incorporated by reference. The sensors may be of any known type of construction for generating analog and/or digital signal proportional to the parameter monitored thereby. Similarly, the operators may be of any known electric, hydraulic, pneumatic or combination type for executing operations in response to command output signals.
The above-mentioned devices supply information to and/or accept command outputs from a central processing unit or control 54. The central processing unit 54 may include analog and/or digital electronic calculation and logic circuitry as is well known in the prior art. An electrical power source (not shown) and/or a source of pressurized fluid (not shown) provides an electrical and/or fluid power to the various sensing and/or operating and/or processing units.
In addition to direct inputs, the central processing unit 54 may be provided with circuits for differentiating input signals from various of the sensors to provide a calculated signal indicative of the rates of change thereof.
As is known, and as disclosed in aforementioned U.S. Pat. No. 4,595,986, central processing unit 54 is adapted to receive various input signals 54A from the sensors and to process same according to predetermined logic rules to issue command output signals 54B to the appropriate system actuators.
In automated, mechanical transmission systems of the type illustrated in FIG. 1, synchronization of the jaw clutch members associated with engagement of a target gear ratio is normally accomplished by selectively increasing or decreasing engine speed, with a master clutch engaged, to cause the input shaft to rotate at a rotational speed generally equal to the product of the output shaft speed multiplied by the numerical ratio of the target gear ratio. For downshifts, where input shaft speed must generally be increased, increased fueling of the engine will provide the desired increase in engine speed while for upshifts, where input shaft speed must normally be decreased, reduced fueling of the engine will allow the engine speed to decay down to an acceptable value. However, where more rapid upshifting is required, the deceleration rate of the engine may be increased by the use of braking devices such as the engine compression brake 50 described above and/or an input shaft brake which is normally manually operated by a ride through detent switch associated with a master clutch control and thus is normally only seen with transmissions having a manual clutch pedal. Engine compression brakes have the added benefit of being manually operable to function as a retarder to supplement the vehicle brake system for operation such as descending a long grade which might seriously overheat the vehicle service brakes.
Engine brake 50, also known as an "engine compression brake" or an "exhaust brake" such as a well known "Jake Brake", are well known in the heavy duty truck industry. Briefly, such devices are usually manually actuated by an operator control such as switch 52, and are effective to apply a retarding torque to rotation of an engine, usually by hydraulically modifying the configuration of the engine exhaust valving. The exhaust brakes are typically used to provide two functions, first they are utilized to supplement the vehicle brake system to retard the vehicle under certain conditions such as traveling downhill and second they are also utilized during an upshift of a transmission, especially a skip upshift, to more rapidly achieve synchronous by retarding the rotational speed of the input shaft more rapidly than would occur under the normal deceleration of the input shaft and/or engine in the absence of exhaust braking. While the manual use of engine compression brakes with both manual and automated mechanical transmissions does provide more rapid upshifting, it has not been totally satisfactory as such engine brake assisted upshifts tend to be somewhat harsh and abrupt.
According to the present invention, as may be seen by reference to FIGS. 2 and 3, in addition to manual operation of engine brake 50, the engine brake is also operable in response to command output signals from system controller 54, which command output signals may be supplied via a data base conforming to the SAE J1939 protocol. In its preferred embodiment, the control method/system of the present invention will override manual control of the engine brake only during upshifts and will be effective to apply the engine brake in a manner designed to provide rapid, high-quality, smooth upshifting of the transmission 12. Referring to FIG. 2, the controller is effective to apply the engine brake in such a manner that the retarding torque of the engine brake will cease when engine speed is within the "synchronous window" (OS×GR T ±about 40 RPM). The transmission actuator 46 then will be commanded to cause engagement of the jaw clutch members of transmission 12 associated with the target gear ratio.
Engine brake devices tend to have relatively slow (long) reaction time and, thus, a signal to turn off the engine braking device must be generated about 200-300 milliseconds before a desired termination of retarding torque. This reaction time (EB TURN OFF REACTION TIME) also tends to vary considerably with various vehicle operating conditions. Referring to FIG. 2, which schematically illustrates an engine brake-assisted upshift, an engine brake reaction time is assumed and, based upon this time value and the sensed or calculated values of engine speed (ES), rate of change of engine speed (dES/dt), output shaft speed (OS), rate of change of output shaft speed (dOS/dt) and the numerical value of the target gear ratio (GR T ), a shut-off point is selected when a command is issued to the engine brake to turn off. The shut-off point is selected so that at the end of the reaction time, the engine brake will be off and ES=(OS*GR T )±about 40 RPM. If the engine brake is turned off too soon (i.e., if the assumed reaction time exceeds the actual reaction time, see line segment 70), the engine speed will revert to the normal decay rate (dES/dt with engine brake inactive)) and it will take an excessive amount of time for ES=(OS*GR T )±40. If the engine brake is turned off too late (i.e., if the actual reaction time exceeds the assumed reaction time, see line segment 72), then the engine speed will continue to rapidly decrease beyond the value of ES=(OS*GR T )±40 and harsh or unachievable shifts may result.
If the assumed reaction time is generally equal to the actual reaction time, at the expiration of the assumed reaction time, the sensed rate of change of engine speed will be greater than the unassisted decay rate but less than the rate with the engine brake active. Accordingly, comparing the sensed deceleration of the engine (dES/dt) to reference values will provide an indication of whether the actual engine brake reaction time is generally equal to, greater than or less than the assumed reaction time. If engine deceleration after the assumed reaction time is greater than or equal to a first reference value (dES/dt>REF 1 ), where the first reference value is generally equal to but somewhat less than the engine brake-assisted engine deceleration rate, then the actual reaction time is greater than the assumed reaction time and the assumed reaction time will be incremented by a predetermined value, usually relatively small to prevent overshooting. If engine deceleration after the assumed reaction time is equal to or less than a second reference value (dES/dt<REF 2 ), where the second reference value (REF 2 ) is a value generally equal to the unassisted decay rate of the engine (dES/dt with engine brake inactive), then the actual reaction time is less than the assumed reaction time and the value of the assumed reaction time will be decremented by a small amount. FIG. 3 schematically illustrates the control system/method of the present invention in flow chart format.
Preferably, the amount by which the assumed reaction time (T REACTION ) is incremented or decremented is relatively small, about 5-20 milliseconds. Alternatively, the reaction time could be corrected by a variable amount determined as a function of dES/dt at the end of the reaction time and/or other system variables. Further, the values of the reference values (REF 1 and/or REF 2 ) can be predetermined or varied as a function of sensed parameters, such as sensed unaided engine decay rate or the like.
Although the present invention has been described with a certain degree of particularity, it is understood that the description of the preferred embodiment is by way of example only and that numerous changes to form and detail are possible without departing from the spirit and scope of the invention as hereinafter claimed. | A control system/method for controlling engine brake (50) assisted upshifts in a vehicular, at least partially automated transmission system (10). A value representing expected engine brake turn-off reaction time (T REACTION ) is adjusted as a function of sensed engine deceleration (dES/dt) at the time just prior to completing the assisted upshift. | 5 |
BACKGROUND OF THE INVENTION
This invention relates in general to mechanical compression packing for controlling leakage about shafts, and in particular to packing which does not undergo undesired deformation when placed under load in normal use.
Because there is a wide variety of applications for mechanical packing and seals, including packing for pumps, valves, hydraulic, and pneumatic equipment, a whole industry has grown up in their design and construction. In the areas with which the present invention is concerned, the packing is generally sold in relatively long coils of braided packing material of square or rectangular cross-section from which many suitable lengths may be cut. Conventionally, several lengths are cut from the coil of material for a given installation, each length being formed into a ring about a shaft with the cut ends abutting each other. Often, as many as a half-dozen such rings are disposed about the shaft with their radial sides in abutting relationship.
A so-called packing or stuffing box formed integrally with, and generally extending outwardly from, the housing surrounds the shaft. The interior of the stuffing box is of a diameter sufficiently greater than that of the shaft to accommodate the packing rings. An annular gland is fitted about the shaft and bolted to the exterior of the stuffing box in such a fashion that an end of the gland compresses the packing rings in the stuffing box. Generally, the gland has a flange through which bolts pass which are threaded into the stuffing box. Tightening of the bolts pulls the gland toward the housing and compresses the packing rings within the stuffing box. Under such compression, the materials tend to expand radially to some extent and substantially fill the stuffing box to prevent or minimize the escape of the contents of the housing at the intersection of the shaft and the housing.
In the original manufacture of the packing material, it is braided in the form of a relatively straight length. Because it is then cut to desired short lengths each of which is formed into a ring about a circular shaft, the outside circumference of each packing ring is longer than the inside circumference. Before compression from the gland is applied, the cross-section of each ring tends to form itself into a trapezoidal shape, the narrow side of the trapezoid being the stretched side adjacent the inner surface of the stuffing box. Conversely, the wide side of the trapezoid abuts the shaft. Because of the trapezoidal cross-section which is assumed by each packing ring, the phenomenon is known as "keystoning".
Several problems arise from this keystoning effect. First and foremost, when a plurality of abutting rings are used in a typical application and the packing is compressed by the gland, force is concentrated on the packing ring corners. Severe wear of the shaft under the packing ring corners and of the packing itself at the inner corners is then encountered.
Moreover, the rapid wear of the packing rings foreshortens the useable life of the packing and shaft and reduces the time before leakage becomes intolerable, necessitating adjustment of gland compression.
Various alternatives have been proposed to combat the unwanted effects of keystoning. One alternative involves the use of packing rings which are interspersed with compensating rings machined or die-formed into wedge shapes having the wider axial dimension at the outer diameter. The packing rings are then installed in proper sequence with the "wedge spreaders" to compensate for keystoning. This expedient is useful and has provided some relief from sealing problems, but it is expensive and requires special forms of packing rings and wedges which must be carefully assembled and installed in the proper order.
It is therefore a primary object of the present invention to alleviate problems caused by keystoning of packing rings.
Another object of the present invention is to avoid the use of packing rings and wedges of preshaped cross-sections which must be assembled in a particular sequence.
Still another object of the invention is to avoid the need to die-form packing rings so that they are pre-shaped to fit the stuffing box.
A further object of the invention is the production of mechanical compression packing which is not subject to keystoning.
SUMMARY OF THE INVENTION
Most mechanical compression packing is formed on plait or so-called lattice-braiding machines by braiding yarns from moving yarn carriers about axial warp yarns, in such a fashion that the warp yarns provide fill which is symmetrical about the core. Stated otherwise, the warp yarns when viewed cross-sectionally are conventionally the same in number and by position when any 90° quadrant of a cross-section of the packing is viewed in mirror image compared to the adjacent two quadrants. The cross-section of the packing has a square or rectangular shape when a length of the material is placed on a flat surface, and the opposite sides of the square or rectangle are generally parallel and equal in width. However, when measured lengths of material are wrapped about a cylindrical body such as a pump sleeve or valve shaft to form rings with outer sides abutting the inner surface of a stuffing box, the outer sides are placed under some circumferential tension. As a result, each ring outer side, i.e., the side adjacent the interior of the stuffing box, tends to contract in the direction parallel to the axis of the ring before the rings are compressed by the gland. When the rings are compressed, more of the load is directed axially to the inner portion of the packing rings adjacent the shaft. The force is concentrated at the abutting inner corners of the rings and this results in unwanted wear.
In the present invention, mechanical compression packing is braided in such a fashion that elimination or reversal of the keystoning effect in the installed rings occur. Such an effect is achieved by the use of additional fill in the outer warps of the braiding machine. Not only may a larger amount of warp fill be placed at what is to become the outer or stuffing box side of the packing material, the amount of corner fill on the inner, or shaft, side of the packing may be reduced. Thus, when a length of packing is measured and cut to form a ring about a shaft, the added material toward the outer surface resists shrinkage in the axial direction of the packing ring to a greater degree than the less dense inner surface. Opposite sides of the rings remain parallel and radial sides abut each other closely and uniformly, distributing the gland load more evenly throughout radial sides of the rings and creating a seal of high integrity as well as lengthening the life of the shaft and the packing.
For a better understanding of the invention, together with other and further features, objects, and advantages, there follows a description of a preferred embodiment which should be read with reference to the attached drawing in which:
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A through 1C illustrate schematically cross-sections of braided compression packing of the prior art;
FIG. 2 is an illustration, partly in section, of a shaft passing through a stuffing box with a seal formed of four packing rings which are compressed by a bolted gland;
FIG. 3 illustrates the keystoning of four packing rings of the prior art in the stuffing box before compression by the gland;
FIG. 4 illustrates the loading effects caused by keystoning of four the packing rings after compression by the gland;
FIG. 5 illustrates four installed packing rings braided in accordance with the present invention before compression by the gland;
FIG. 6 illustrates the loading effects achieved in the present invention after compression by the gland; and, FIG. 7 is a schematic illustration of a cross section of braided compression packing made in accordance of the subject invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1a, there is illustrated in cross-section a conventional plait or "square" pattern composed of a central core 12 and axial warp yarns 13, 14, 15, and 16 used to provide fill in the packing material. In some instances, the central core 12 is not utilized. However, in either case, each of the warp yarns has yarn from moving carriers, typically eight in number, braided about it, the path of the carriers being represented by A, B. As is obvious from the drawing, in any 90° quadrant of the packing cross-section, the axial warp yarns are the same numerically and by position.
In FIG. 1b, a similar cross-section of a packing material is shown. In this instance, however, a 20-carrier interwoven or so-called "lattice" pattern is shown with the maximum number of warp positions. Each of the warp yarns of which yarns 17, 19, 21 and 23 are typically always used, has yarn from carriers following paths in the braider deck C, D, E braided about it. A central core 25 may or may not be used. However, a structure is formed in which in either case axial warp yarns which constitute the fill are the same in number and by position in any 90° quadrant when viewed in mirror image with respect to each of the two adjacent quadrants.
Still another pattern is shown in FIG. 1c. Here, a 36-carrier interwoven or so-called "lattice" pattern is shown with the maximum number of warp positions. Each of the warp yarns, of which yarns 27, 29, 31 and 33 are typically always used and yarns 34, 35, 37, 39 are frequently used, has braided about it and the central core 25a, if used, yarns from carriers following paths F, G, H, J in the braider deck in a symmetrical fashion to form a structure in which the axial warp yarns which constitute the fill are the same in number and by position in any 90° quadrant when viewed in mirror image relative to either adjacent quadrant. The structures illustrated are only three of a variety of patterns which may be used. The technique of lattice braiding is well known in the industry and patterns of three, four, or five tracks have been composed. What all of the patterns as presently braided have in common, however, is symmetry of any one quadrant when viewed in mirror image with each of the two adjacent quadrants.
FIG. 2 is a representation in partial cross section of an ideal packing arrangement. Shown fragmentarily and partly in section is a containment structure 41 which constitutes a stuffing box. Passing through the stuffing box to the interior of the container (not shown) is a cylindrical shaft 43. The shaft, depending upon the application, may run from a source of power and support bearings (not shown) at the right as seen in FIG. 2 to an impeller (not shown) at the left as seen in FIG. 2. Four packing rings 45, 47, 49 and 51 are shown in the positions which they occupy to control leakage of materials. As shown here, the interior of the container would be at the left and leakage to the exterior would be to the right through the intersection of the stuffing box 41 and the shaft 43. A gland 55, conventionally formed as a flanged annulus, is provided. A series of openings are formed in the flange parallel to the gland axis. Bolts such as the bolt 57 are passed through the openings and threaded into the end of the stuffing box 41. The bolts are tightened with the object of causing the bolt heads as at 59 to bring pressure uniformly upon the gland and packing rings.
In practice, however, the idealized situation shown in FIG. 2 is not achieved with packing rings of the prior art. As has been described above, wrapping of the packing rings about the cylindrical shaft causes the keystoning phenomenon to occur. FIG. 3 illustrates that keystoning effect. In FIG. 3, each of four packing rings 45-51 will be seen to have assumed a trapezoidal cross-sectional shape. This occurs prior to any compression being applied to the rings by the gland 55 and, in fact, on individual rings prior to die forming if such a technique is employed.
In FIG. 4, the loading effects caused by keystoning are illustrated. Pressure from the gland 55 is greatest upon the wider inner sides of the four packing rings as represented by the arrows 61 which denote a pressure gradient. The forces upon the packing rings are such that the greatest loading is exerted upon the shaft adjacent the inner lower corners of each of the packing rings, as illustrated by the arrows 63 which represent force. Under such conditions, wear of the packing rings as well as the shaft is rapid at the points of great force.
In FIG. 5, the effect of the non-symmetrical braiding on four packing rings cut from braided mechanical packing made in accordance with the present invention is shown. Neither before nor after compression does keystoning exist. The packing rings 45-51 maintain a cross-section in which opposite sides remain parallel despite the wrapping of the rings about the shaft 43. Sides of the rings parallel to the axis abut each other uniformly and closely.
In FIG. 6, the loading effects on the non-symmetrical braided packing rings are illustrated. Because of the parallel close abutment of the packing rings with one another and with the end of the gland 55, forces exerted by the gland parallel to the axes of the shaft and packing rings are equal as represented by the arrows 71. These forces are translated into equal loading effects of each of the packing rings 45-51 upon the shaft 43, as indicated by the arrows 73 which represent a pressure gradient. As has been noted, the non-symmetrically braided mechanical packing creates a packing ring in which the opposite cross-sectional sides are essentially parallel when the packing ring is installed.
Although there is a vast number of applications for mechanical packing, there has been some effort made toward standardization of dimension in the industry. Mechanical packing of any given cross-sectional dimension is commonly associated for use with a range of shaft diameters in which the variation in diameter is approximately 40% for pump shafts. The placement of warp fill in mechanical packing made in accordance with the present invention is preferably such that essential parallelism of the opposite sides of the installed packing ring occurs at or near the minimum shaft diameter for which the cross section is intended. As a result, keystoning will be eliminated or, in the extreme, slightly reversed in the installed rings. Elimination of the keystoning results in a more uniform normal load being applied between the packing rings and the shaft. In addition to superior leakage control, the useable life of the packing rings and the shaft is considerably extended.
Referring now to FIG. 7 a schematic diagram illustrates in cross section one embodiment of a braided compression packing in which corners 80 and 82 have greater amounts of warp fill 83 than do the lower corners 84 and 86 as illustrated at 87. This differential in the amount of corner fill between the inner and outer edges of the packing may be provided by differing numbers of braided axial warp yarns or in any other fashion so as to vary the amount of corner fill to eliminate keystoning. Thus in one embodiment, the reversal of the keystone effect is provided by the use of additional fill in the outer warps. Center core warps 88 or other internal warps, if used, in one embodiment can differ in number, and thus amount of material, from that associated with the corners. As before, additional yarns are braided about the axial yarns along a path generally indicated by 90.
The present invention should not be limited to the details of the embodiments illustrated. Variations in numbers of rings, in materials, and in structural details will suggest themselves to those skilled in the art. Basic to the invention is the concept of building into mechanical packing the capacity to resist undesired deformation and avoid harmful loading effects. The invention should be limited only by the spirit and scope of the appended claims. | A non-symmetrical construction of braided mechanical compression packing which does not undergo undesired deformation when placed in use. This non-symmetry of construction results in longer packing life and reduced shaft wear when used to prevent leakage about rotating shafts. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application Ser. No. 11/918,251, filed on Oct. 16, 2007, which is the U.S. national stage of International Application no. PCT/EP2006/002328, filed Mar. 14, 2006, the entire disclosures of both of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention relates to an improved method for the selective elevation and separation of tissues comprised of multiple layers using a tissue selective insertion method. In one embodiment, liquid is introduced without requiring a solid mechanical device insertion or transection through the mucosal layer and a surgical instrument for performing this method. In particular, the method and surgical instrument may be used for the tissue-selective separation and/or resection of selected portions of benign or malignant tissues (e.g., defining tissue planes, polyp elevation and removal, submucosal tissue tunneling, endoscopic mucosa resection, etc).
BACKGROUND OF THE INVENTION
[0003] During mucosa resection or removal of lesions on or in the wall of certain human and animal anatomy (e.g., gastrointestinal tract, bladder or peritoneal wall) by means of instruments (such as loops, or cutters with or without a cap), lasers, ultrasonic dissectors, etc., bleeding and perforation, for example, of the intestinal or gastric wall can occur. In order to manage these problems, liquid is typically injected under the mucosa into the submucosal layer, resulting in the creation of a “fluid pocket” before removal of lesions (e.g., polyps, adenomas, malignant or benign tumours, endometriosis implants). The primary purpose of this procedural step is to lift off or elevate the mucosal layer or another layer, and hence the lesion, from the muscularis or another layer of the wall. Penetration of the liquid under the mucosa layer causes the mucosa to be “loosened” from the deeper layers by forming a liquid cushion beneath the mucosa. This produces a safety separation or protective surgical margin from the deeper layers as well as providing a protective heat barrier from thermal energy sources.
[0004] Traditionally, the liquid injection procedure is done with a needle. These, conventional “needle injection” techniques for delivery of fluidic agents (in order to allow the subsequent removal of selected tissues) have several problems associated with them. One problem associated with these methods is that the user must rely on “tactile feel” and a constant delivery of fluid in order to precisely place the needle within the submucosal layer before additional liquid is injected under the mucosa via the needle. This process is relatively “unselective” and often results in complete perforation of the target tissue and whereas the fluid accumulates under the mucosal layer without integrating with the submucosal tissue matrix, the fluid escapes rapidly (e.g., in less than a few minutes). Additional problems associated with using conventional methods include difficulty in obtaining access to the delivery site (e.g., relative position of the device with respect to the tissue), necessity of repositioning the distal tip of the device in multiple locations, delivering the fluidic agent to the delivery site, accurately injecting the fluidic agent into the appropriate tissue layer or depth within the tissue, and problems maintaining fluid retention within the tissue, etc. In addition, injection of the fluidic agent becomes extremely difficult when the target tissues are moving or are pliable.
[0005] Conventionally, once the liquid cushion is formed beneath the mucosa, the mucosal resection is then performed using a snare or cap technique to achieve the operative goals. In the case of larger area tumors, however, a “piecemeal” technique is often employed. Alternatively and potentially more clinically desirable, the mucosa resection can be performed using an “enbloc technique” which is carried out with a flexible needle knife type of electrode. This technique for resection is extremely difficult. In particular, the difficulty of this type of intervention is that the injected liquid leaks out of the “fluid pocket” during the operation, causing the deeper layers to become thermally damaged by the needle knife. This thermal damage can in turn lead to perforation of hollow organs (e.g., intestine) or undesired thermal damage to other tissue layers or structures. In order to avoid perforation for instance, the instrument must be removed several times during the resection procedure and liquid must again be injected under the mucosa.
[0006] Accordingly, it is desirable to improve the targeted delivery of therapeutic, diagnostic, or fluidic agents via a tissue selective needle-less fluid introduction process that will facilitate the resection of undesired tissue with increased efficiency.
[0007] U.S. Pat. No. 6,752,799 (DE 19 607 922 C2) discloses a medical device and method for the endoscopic injection of a liquid underneath the mucosa. The device disclosed in this patent is spaced a distance away from the target tissue which allows for a thin fluid stream to substantially travel in “free flight” prior to contacting the tissue while the user holds the device at a specific angle. The fluid is introduced in such a thin stream that the hole created in the mucosa closes after itself without allowing an appreciable amount of fluid to escape. The device creates a “fluid pocket” under the mucosal layer. The initial fluid retention issue is addressed using a self sealing micro-hole, however, after the first incision is made, the fluid escapes rapidly. Therefore, continual re-introduction is still required as this device has not improved fluid retention within the tissue.
[0008] U.S. Pat. No. 6,126,633 discloses a medical device which is capable of approaching the target region in a safer and easier manner by bending and is used for submucosal needle injection. This addresses the relative position of the device with respect to the target tissue, but however neglects the other major obstacles associated with conventional needle designs.
[0009] U.S. Pat. No. 6,666,847 is directed toward providing an improved needle injection system that offers a surgeon easier needle extension and retraction.
[0010] Alternative solutions to the problems of bleeding and intestinal perforation are also being tested wherein liquids of different viscosities are used; however, these liquids still leak out of the mucosa. These attempts still do not offer a satisfactory solution because the escape of the liquid out of the submucosa is only slowed, but is not prevented.
[0011] Each of these patents discloses devices for submucosal needle injection, however, they fail to address all or the majority of the problems associated with this technically challenging and high risk procedure. For example, these patents do not address the difficulties of “manually” finding the appropriate tissue plane without the risk of complete colonic transection or perforation with a needle device (layer thicknesses range from 0.5 mm to 1.5 mm), the limitations on the device approach to the target tissue, and problems with maintaining fluid retention within the tissue.
[0012] It is therefore desired to have a surgical instrument that facilitates the selective introduction of a fluid into tissue layers to allow for elevation and separation of tissue layers. In particular, it is desired to have a surgical instrument that allows the elevation and separation without the requirement for a solid mechanical device insertion or transection through the mucosal layer. In addition, improvements in fluid retention within the target tissue, a device which can approach the tissue at any angle, and/or resection of selected tissues, which will thereby help prevent and avoid damage to surrounding tissues during subsequent procedures are also desired.
SUMMARY OF THE INVENTION
[0013] Embodiments of the invention provide a surgical instrument that includes a device for feeding in at least one liquid, in particular for introduction of a liquid resulting in selective tissue elevation or separation, and/or dissection. The device may also include a device for high frequency surgery, wherein the device for high frequency surgery may be combined with the device for feeding in the at least one liquid, in order to achieve uniform handling. A multifunction device may thereby be achieved, which combines the advantages of water jet surgery (including introduction of liquid for selective tissue elevation or separation and/or dissection by means of liquid) with the advantages of high frequency surgery. The surgical instrument according to the disclosed embodiments makes it possible to selectively introduce a liquid under the mucosal layer into the submucosa to thereby selectively lift and/or separate selected tissue layers.
[0014] Liquid may be introduced under the mucosal layer in a needleless fashion, without the need for manually finding the appropriate tissue plane and without requiring a solid mechanical device insertion or transection through the mucosal layer. Additionally, the mucosal layer may also be coagulated, cut or removed by the water jet when operated at a suitable pressure, so that three functions can be fulfilled by the surgical instrument in accordance with the invention: selective introduction of the liquid into the submucosa layer, coagulation and resection (cutting) of the mucosal layer.
[0015] In another embodiment, resection of the mucosal layer is performed using a device for high frequency surgery without the aid of the liquid. For uniform handling purposes, the various arrangements of the device for feeding in the at least one liquid and/or a high frequency electrode are provided in a single probe to offer a solution for combining the device for feeding in the at least one liquid (e.g., nozzle) and the device for high frequency surgery (e.g., high frequency electrode).
[0016] The high frequency electrode may take several forms. For example, the high frequency electrode may be any type known in the art, such as a needle, hook, needle with an insulated tip, disk, snare or a snare with an insulated tip, by which means the field of application of the device is widened. Any type of snare (i.e., symmetrical or asymmetric snares, snares with or without insulated tips, snares with different shapes or diameters) can be used. The design of a high frequency needle electrode (preferably a retractable micro needle) can be used as a delivery mechanism of a suitable fluid pressure stream in order to deliver at least one fluid into the submucosal layer and alter the tissue properties of said layer, as is described in more detail herein.
[0017] In any of the embodiments, the surgical instrument may further comprise a handle which also has a switch, in particular a sliding switch, for switching on the device for high frequency surgery and is connectable to a separate switch, in particular a foot switch, for activating the device for high frequency surgery. Two spatially separate switches must thereby be actuated, so that the device for high frequency surgery is switched on by the sliding switch and then activated by actuating the separate foot switch. It is thereby ensured that the device for high frequency surgery is not accidentally activated during a procedure. A separate foot switch can be adapted both for activating the device for high frequency surgery and for activating the feeding-in of the at least one liquid, so that by means of the separate foot switch, both the feeding-in of the liquid and the activation of the high frequency electrode can be actuated.
[0018] The probe may be comprised of a plastic hose, which results in a particularly simple and economical solution for designing a flexible probe. Alternatively, the probe may be comprised of a flexible metal tube, which is insulated on the outer periphery. By means of the metal inner core, the probe diameter can be significantly reduced without a severe loss of flexibility. Those skilled in the art can substitute a variety of suitable materials and activation devices, which can be used without deviating from the true scope and spirit of the disclosed invention.
[0019] The surgical instrument according to the disclosed embodiments allow for the selective elevation of the mucosa by introduction of a liquid under the mucosa at any angle, separation of the mucosal layer from an underlying tissue layer and fluid diffusion/penetration into the submucosal tissue matrix (which allows for improved fluid retention within the selected layer). With the aid of a single surgical device, changing instruments during the operation in order to re-inject liquid during resection is no longer required. Rather, when using the surgical instrument according to the invention, if the liquid begins to slowly diffuse or leak out of the submucosal tissue matrix, the device is simply switched over from cutting mode to liquid introduction mode and additional liquid is introduced into the submucosal tissue matrix.
[0020] By selectively targeting the submucosal tissue layer (comprised primarily of collagen) with a liquid delivered at a suitable pressure, the normal tissue properties of the submucosal tissue matrix can be altered, thereby addressing one of the major problems associated with the conventional “needle injection” technique, fluid retention within the tissue. Operating times can therefore be significantly reduced because the instruments do not have to be removed and the fluid retention of the tissue has been significantly improved. Another advantage of the surgical instrument according to the disclosed embodiments is that the function of introducing liquid under the mucosal layer for separation and selective tissue elevation of the tissue layers may be implemented without insertion of a needle or other mechanical instrument into the tissue. This is made possible by the tissue selective properties of the method and device. Advantages of this “needleless” tissue elevation method (as compared to other mechanically invasive methods) include automatically defining the appropriate tissue plane, improved fluid retention within the tissue, reliability, ease of use, faster and higher elevation and more predictability with respect to the introduction of the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] These and other features and advantages of the disclosed embodiments will be better understood by referencing the following detailed description and when considered in conjunction with the following figures.
[0022] FIG. 1 a is a longitudinal cross-sectional view of the distal end of a probe for liquid introduction in accordance with an exemplary embodiment.
[0023] FIG. 1 b is a transverse cross-sectional view of the probe of FIG. 1 a.
[0024] FIG. 2 a is a longitudinal cross-sectional view of the distal end of a probe with a combined high frequency needle and channel for liquid introduction, according to an exemplary embodiment.
[0025] FIG. 2 b is a transverse cross-sectional view of the probe of FIG. 2 a.
[0026] FIG. 3 a is a longitudinal cross-sectional view of the distal end of a probe with a high frequency needle, according to another exemplary embodiment.
[0027] FIG. 3 b is a transverse cross-sectional view of the probe of FIG. 3 a.
[0028] FIG. 4 a is a longitudinal cross-sectional view of the distal end of a probe with a high frequency hook, according to another exemplary embodiment.
[0029] FIG. 4 b is a transverse cross-sectional view of the probe of FIG. 4 a.
[0030] FIG. 5 is a longitudinal cross-sectional view of the distal end of a probe with a high frequency needle with an insulated tip, according to another exemplary embodiment.
[0031] FIG. 6 is a side view of a handle including a liquid connection and a high frequency connection.
[0032] FIG. 7 is a diagram showing the sequence of an endoscopic intervention using a surgical instrument according to the disclosed embodiments.
[0033] FIG. 8 is a perspective view of an exemplary embodiment wherein the device is operated in a fluid introduction mode.
[0034] FIG. 9 is a perspective view of an exemplary embodiment wherein the device is operated in a high frequency mode.
[0035] FIG. 10 is a perspective view of an exemplary embodiment wherein the probe includes a high frequency snare with an insulated tip.
[0036] FIG. 11 is a longitudinal cross-sectional view of a probe with a high frequency snare without an insulated tip, according to an exemplary embodiment.
[0037] FIG. 12 a is a cross-sectional histological photograph of the gastrointestinal tract showing the basic tissue layers.
[0038] FIG. 12 b is a cross-sectional illustration of the gastrointestinal tract depicting the basic tissue layers.
[0039] FIG. 13 a is a macroscopic view of the needleless elevation technique of the disclosed embodiments used in an in-vivo environment.
[0040] FIG. 13 b is a cross-sectional histological photograph of the gastrointestinal tract depicting the fluid diffusion into the submucosal tissue matrix.
[0041] FIG. 14 is a cross-sectional illustration of the gastrointestinal tract depicting the “fluid pocket” produced by a standard needle injection device.
[0042] FIG. 15 a is a cross-sectional histological photograph of the gastrointestinal tract depicting the fluid diffusion throughout the submucosal tissue matrix, when using disclosed embodiments.
[0043] FIG. 15 b is a cross-sectional histological photograph of the gastrointestinal tract depicting a lack of fluid diffusion throughout the submucosal tissue matrix, when not using disclosed embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0044] In one embodiment of the invention, a catheter device is provided and used for the delivery of a fluidic, therapeutic or diagnostic agent under a suitable pressure (selected on the basis of targeting a selected tissue layer) in order to selectively elevate, separate, and/or resect selected portions of tissues. As shown in FIGS. 1 a and 1 b , the distal end 6 of probe 3 comprises a channel 4 for feeding through at least one liquid through nozzle 7 at a suitable pressure. The suitable pressure can be changed according to the desired task. For selectively elevating and separating tissues, a certain target pressure is desired; for coagulating small vessels, a different target pressure may be desired; and for resecting or cutting selected tissues, a different target pressure may be desired. Probe 3 is preferably flexible in nature and can be comprised of a variety of different suitable materials. For example, the flexible probe 3 may be constructed from, nylon, PEEK, polyimide, stainless steel, PTFE, etc.
[0045] FIGS. 2 a and 2 b show the distal end 6 of a probe 3 a according to another exemplary embodiment. The probe 3 a includes a single channel 5 a through which a device 2 for high frequency surgery (e.g., high frequency electrode 8 ) can be fed. The device 2 can also take the form of a retractable micro needle that may be used to penetrate or transect tissue prior to fluid introduction in accordance with the invention. A rarefied gas 15 , for example argon gas (AR), may also be introduced into channel 5 a through conventional means, for example, a handle or port (not shown). The introduction of this gas supports a standard electrosurgical function, argon plasma coagulation, commonly used in clinical practice. At least one liquid, e.g. NaCl solution, can be fed through a channel 4 a within the device 2 for high frequency surgery. Channel 4 a is therefore part of the device 1 for feeding in at least one liquid. A supply container for the liquid and a pump arrangement (discussed below) by which the liquid is forced through channel 4 a under suitable pressure are also provided and connectable to the device 1 .
[0046] FIGS. 3 a and 3 b show the distal end 6 of a probe 3 b according to another exemplary embodiment. The probe 3 b has two channels 4 b , 5 b . Channel 5 b can also accept the introduction of a rarefied gas 15 (e.g., AR) through conventional means. Nozzle 7 is firmly arranged in one of the channels 4 b . At least one liquid, in particular a NaCl solution, can be fed through channel 4 b . Channel 4 b is therefore part of the device 1 for feeding in at least one liquid. A supply container for the liquid and a pump arrangement by which the liquid is forced through the channel 4 b under a suitable pressure are also provided.
[0047] Probe 3 b also includes a device 2 for high frequency surgery. This device 2 for high frequency surgery, for example, for cutting, coagulation, and/or dissection, comprises a high frequency electrode 8 , which is provided in the other channel 5 b of the probe 3 b . The two channels 4 b , 5 b are arranged substantially parallel to one another. It should be noted that this embodiment of the invention is not restricted to two channels and can comprise additional channels, in particular three or four channels, wherein different functions can be assigned to each of the channels. For example, two separate channels could be provided for the fluid introduction mode and the dissection mode, in addition to the channel provided for the high frequency electrode 8 .
[0048] Depending on the field of application, the high frequency electrode 8 may comprise a high frequency needle 2 a ( FIG. 3 a ), a high frequency hook 2 b or spatula ( FIG. 4 a ) arranged in a twist-proof manner, a high frequency needle with insulated tip 2 c , in particular a ceramic tip ( FIG. 5 ) or a disk (not shown). The device 1 shown in FIG. 3 a may also comprise a handle 9 , shown in FIG. 6 . The handle 9 has a connection for the device 2 for high frequency surgery, which can be connected to a high frequency unit (not shown). The handle 9 also has at least one liquid connection of the device 1 for feeding in the at least one liquid, which can be linked to a water jet surgery unit (not shown) or to any other type of pump system which may provide the desired amount of pressure. The two connection lines are fed through the handle 9 and, for example, inserted into endoscope 11 shown in FIG. 7 . The handle 9 also may have a switch 10 , in particular a sliding switch, the actuation of which allows the high frequency electrode 8 to be positioned and switched on. For positioning, the high frequency electrode 8 is moved out of the probe 3 a , 3 b , as indicated by the double arrow and the dotted representation of the electrode 8 in FIGS. 2 a , 3 a , 4 a and 5 . Devices for optical monitoring of the intervention, such as light guides (not shown), may also be provided in the endoscope 11 ( FIG. 7 ).
[0049] The device 1 for feeding in the at least one liquid (i.e., the device for water jet surgery), can be switched from the fluid introduction mode to the dissection mode, and vice versa, by a suitable control system. Activation of the high frequency electrode 8 may be carried out with a foot switch (not shown), by which means unintentional actuation of the electrode 8 is reliably avoided. Activation of the water jet can be carried out with the same foot switch. Conventional switching mechanisms may be use in whole or in part by those skilled in the art.
[0050] The pump arrangement by which the liquid is forced through channel 4 a shown in FIGS. 1 a , 1 b , 2 a and 2 b , for high frequency and water jet surgery or channel 4 b shown in FIGS. 3 a , 3 b , 4 a , 4 b and 5 can be any device which is suitable for creating the required pressures. For example, the ErbeJet and ErbeJet2 manufactured and sold by ERBE Elektromedizin GmbH or a disposable syringe connected via a detachable or permanent pressure-tight connection (e.g., luer lock or other) to a flexible endocapillary which is connected to a pump unit or force amplifier may be used. The force amplifier (e.g., large lever, balloon dilatation syringe or pump unit) creates the required pressures for selective tissue separation and elevation and resultant tissue altering characteristics.
[0051] The surgical instrument and the endoscope 11 shown in FIG. 7 may be used in accordance with certain aspects of the invention. As shown in FIG. 7 , the water jet surgery function of the surgical instrument is activated and a fluid introduction jet is created using either channel 4 a ( FIGS. 1 a , 1 b , 2 a and 2 b ) or a combination of the channel 4 b and the nozzle 7 of the probe 3 b ( FIGS. 3 a , 3 b , 4 a , 4 b and 5 ) so that a liquid, particularly a NaCl solution, is introduced through the mucosa into the submucosal tissue matrix. This forms a long lasting liquid cushion under the mucosa so that the mucosa is lifted off the Muscularis propria. In the next step, the surgical instrument is switched from fluid introduction mode to dissection mode, wherein the pressure of the water jet is increased so that the mucosa can be resected. Additionally, the pressure of the water jet can be further modified to coagulate small vessels.
[0052] In comparison and when the instrument is then switched from the water jet function to the high frequency surgical function and the electrode 8 is positioned, the submucosa is separated, during which time the coagulating effect of the electrode 8 comes into play.
[0053] In a needleless hydrodissection, separation or elevation mode, a fluid is transported selectively under suitable pressure into the submucosa or another desired layer of the selected tissue. The pressure is chosen so that the fluid selectively penetrates and integrates only with the desired tissue layer. Referring to FIGS. 1 a and 1 b , the distal end of the device 1 for feeding in at least one liquid is placed firmly on the desired hydrodissection site or target tissue without the requirement of the endocapillary piercing the mucosa. Alternatively, in the case of previous mucosal insult (i.e., thermal or mechanical breach), the distal end firmly touches the mucosa or mucosal defect (thermal or mechanical), without the need for re-positioning the device. The fluid is transferred via a suitable pressure and selectively diffuses, integrates or penetrates into the submucosal tissue layer matrix.
[0054] By applying a suitable pressure while touching the tissue with the end of the probe, the fluid accumulates precisely in the desired layer. The collagen rich submucosal tissue matrix layer is thereby altered while the fibrin-rich muscularis layer is automatically preserved via the principles of our tissue-selective hydrodissection technique whereby fibrin-rich structures have the ability to deflect a given fluid delivered at a suitable pressure. Therefore, the fluid accumulates and evenly diffuses precisely within the targeted submucosal layer and is not transferred into an underlying fibrin-rich muscularis layer. Further, the needleless hydrodissection may be used either alone or in combination with other instruments (e.g., snare wire, biopsy forceps, cutting loop, laser fibre, etc).
[0055] Needleless, tissue-selective transport of fluid into the submucosa tissue matrix by means of a flexible endocapillary requires, in most cases, a pressure of 5 to 70 bar, by way of example. This allows for a faster, potentially safer, more reproducible, predictable, reliable, durable and often a larger degree of tissue plane separation, elevation, or hydrodissection.
[0056] Accordingly, by using the disclosed embodiments it is possible to lift the mucosa sufficiently off the Muscularis propria and excise it without the gastric or intestinal wall being damaged, while using only a single instrument. Specifically, it is possible to re-introduce liquid into the submucosa if the submucosa begins to lose too much liquid during the course of an extended operation, without changing devices, in order to keep the mucosa adequately spaced from the gastric or intestinal wall.
[0057] Further exemplary embodiments of the invention are shown in FIGS. 8 to 11 . These embodiments are similar to the embodiments discussed with reference to FIGS. 3 a , 3 b , 4 a , 4 b and 5 . The embodiments of FIGS. 8 to 10 are particularly suited toward polypectomy procedures and comprise a probe 3 b with two channels 4 b , 5 b , of which one channel 4 b serves for the introduction of a liquid jet and the other channel 5 b serves to accommodate a high frequency snare 2 d (without an insulated tip ( FIGS. 9 , 11 )) or 2 e (with an insulated tip ( FIG. 10 )). The two channels are integrated into a single probe 3 b for uniform operation. The uniform operation of the fluid introduction device and the high frequency electrode 8 (e.g., high frequency snare 2 d or 2 e ) can be achieved with the embodiment according to FIGS. 8 to 11 in a similar manner as that described with reference to the other embodiments.
[0058] The design of the probe according to FIGS. 8 to 11 substantially corresponds to the above described design of the probe according to the previously described exemplary embodiments. A nozzle 7 , through which the liquid jet for fluid introduction or dissection emerges, is arranged in one of the two channels, e.g., channel 4 b . A high frequency snare is arranged in the other of the two channels, e.g., channel 5 b and can be drawn into or pushed out of the channel 5 b . All types of snares in different forms and diameters and snares 2 e with an insulated tip ( FIG. 10 ) and snares 2 d without an insulated tip ( FIGS. 9 , 11 ) are suitable. Furthermore, symmetrical or asymmetric and/or rotatable or non-rotatable snares can be used.
[0059] The design of a high frequency electrode as a snare with or without an insulated tip is particularly suitable, for e.g., a polypectomy. It has previously been problematic, that under certain circumstances, a polyp was not sufficiently spaced from the muscularis layer and could not be lifted off. The cutting height, therefore, was a matter of judgment for the surgeon. The surgeon was required to balance between removing a sufficient amount of the polyp such that no “risky” material (which later could regenerate) is left in the body while maintaining a sufficient distance away from the muscularis layer so as not to endanger the tissue of the intestinal wall (i.e., risk of perforation). The combination of a high frequency snare and a device for feeding in at least one liquid, as in several disclosed embodiments of the invention, enables the selective introduction of a liquid under the polyp, so that it is sufficiently spaced from the muscularis layer. The polyp can then be excised or resected with less risk and the tissue of the intestinal wall or underlying tissue layer will not be damaged or incur less damage.
[0060] The functioning of the probes 3 b according to the exemplary embodiments as per FIGS. 8 to 11 substantially corresponds to the functioning of the exemplary embodiments described above, wherein, in the fluid introduction mode, a liquid jet, preferably 0.9% NaCl solution, is introduced into the submucosa under the polyps, so that it is sufficiently spaced from the submucosa. The polyp is then resected or excised by means of the snare 2 d , 2 e.
[0061] While FIGS. 3 a - 11 illustrate various alternative embodiments of the device 2 for high frequency surgery implemented in a device having two channels, each of these types of devices 2 for high frequency surgery may also be implemented in an instrument having a single channel, in a similar manner as that illustrated in FIGS. 1 a , 1 b , 2 a and 2 b.
[0062] A histological cross-sectional photograph of the gastrointestinal (GI) tract, clearly showing the basic layers, is provided as FIG. 12 a . The glandular mucosa 101 (to the right) is quite dark because of all the epithelial and connective tissue nuclei it contains. A thin strip of pink marks the muscularis mucosae 102 . Next comes a very dark pink submucosa 103 , which is mainly dense collagen fibers. Further left are two, paler pink layers of the muscularis externa: a wide band of inner circular smooth muscle 104 and a narrower band of outer longitudinal smooth muscle 105 . Furthest left is the serosa 106 , which can be recognized due to its “finished” edge of mesothelium. This particular photograph is likely near the mesenteric attachment because there is so much adipose tissue and some fairly large blood vessels within the serosa 106 . FIG. 12 b is a cross-sectional illustration of the gastrointestinal tract depicting the basic tissue layers. FIGS. 12 a and 12 b are provided to allow for a clear understanding of the tissue anatomy as well as help further understand the altered tissue characteristics of the targeted tissue layer after the tissue selective needleless fluid introduction device and method have been applied (see FIG. 13 b ).
[0063] FIG. 13 a is a macroscopic view of the needleless elevation technique used in an in-vivo environment. The mucosal defect (hole) 110 caused by the selective needleless elevation technique can clearly be seen, having an overall length 111 (centimeter measurement device 112 provides a frame of reference). The overall length 111 of the mucosal defect shown in FIG. 13 a is in excess of 1 centimeter, however, in accordance with the disclosed embodiments, the saline does not leak out of the tissue in a rapid fashion after the fluid integration into the submucosal tissue matrix. FIG. 13 b is a cross-sectional histological view of the gastrointestinal tract depicting the fluid diffusion (edema or swelling, fluid integration, 103 a ) into (penetration) the submucosal tissue matrix 103 . The inventor's extensive tissue research has supported this “tissue altering” needleless elevation technique, which has not previously been seen or reported in clinical reports. By altering the submucosal tissue matrix, fluid retention is greatly improved without worrying about the size of the mucosal breach.
[0064] By comparison, FIG. 14 is a cross-sectional illustration of the gastrointestinal tract depicting the “fluid pocket” produced by a standard needle injection device. The mucosal layer 121 , submucosal layer 122 and muscularis layer 123 can be seen in FIG. 14 . The “fluid pocket” 124 created by the needle injection method and the needle tract 125 associated with the initial insertion can also be seen. When the fluid is “unselectively” delivered to the target tissue by this conventional technique, fluid escapes around the injection site 125 and continues to do so very rapidly. The “fluid pocket” 124 is mostly devoid of any collagen and primarily consists of the fluid delivered.
[0065] Referring to FIGS. 15 a and 15 b a further comparison of the disclosed embodiments with known methods of liquid introduction can be seen. FIG. 15 a is a cross-sectional histological view of the gastrointestinal tract depicting fluid diffusion throughout the submucosal tissue matrix, in accordance with disclosed embodiments. FIG. 15 b is a cross-sectional histological photograph of the gastrointestinal tract depicting a submucosa without the fluid diffusion created by using the disclosed embodiments. When viewed in comparison with FIG. 15 b , it can clearly be seen in FIG. 15 a that the disclosed embodiments provide liquid diffusion throughout the submucosa, thereby allowing for the improved liquid retention in the submucosa.
[0066] It should be noted that while various exemplary embodiments have been described with respect to their use in endoscopic mucosal resection of the gastrointestinal tract, the invention also has applicability in any implementation in which tissue-selective needleless separation, elevation and/or resection of tissue layers is desired such as, for example, polypectomy; endoscopic submucosal dissection (ESD) of large superficial tumours of the esophagus, stomach and colon; removal of tumours of the bladder wall; endometriosis implants on the peritoneal wall; or separation of organs (hydrodissection) using a non-mechanical means (e.g., separation of the gall bladder from the liver capsule using the principle of needleless hydrodissection of fibrin-rich structures).
[0067] The disclosed embodiments have been described herein in considerable detail in order to provide those skilled in the art with a thorough understanding of the novel principles of the invention, method of application, and the various uses thereof without limitation. It is understood by those skilled in the art that the invention can be carried out by various modifications without undue experimentation and deviating from the true scope and spirit of the invention. | A method for the selective elevation and separation of tissues comprised of multiple layers and a surgical instrument for performing the method. The method may be performed without the requirement of a solid mechanical device insertion or transection through the mucosal layer. In particular, the method and surgical instrument may be used for the selected separation and/or resection of selected portions of benign or malignant tissues (e.g. defining tissue planes, polyp elevation and removal, submucosal tissue tunneling, endoscopic mucosa resection, etc). | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a process and an apparatus for continuous production of nonwovens, particularly mineral wool nonwovens.
In the production of mineral wool nonwovens, e.g. from rock wool or glass wool, not only is the fiberisation process of importance, but also the formation of the nonwoven fabric as such constitutes an important process step. It is customary in this respect for a fibre/gas/air mixture produced by a fiberisation unit to be introduced into a box-like so-called chute to separate the fibres, which chute usually features at the bottom an accumulating conveyor acting as a type of filter screen which is constructed in the form of a gas-permeable, rotating, plane conveyor belt. Under the conveyor belt is located an extraction device which generates a certain partial vacuum. In addition, drum-shaped accumulating conveyors with curved suction surfaces are also known from, for example, German patent specification DE-PS 39 21 399.
If the fibre/gas/air mixture--which can also contain a binder--impinges on the accumulating conveyor, the gas/air mixture is sucked through to below the accumulating conveyor acting as a filter, and the fibres are retained on the conveyor in the form of a nonwoven fabric.
In the known process for nonwoven fabric production, there are generally a plurality of adjacently arranged fiberisation units which produce fibre flows in a manner familiar to a person knowledgeable in the art. For the sake of simplicity, the term "fibre flow" or "fibre stream" used in the following shall refer to the flow bundle comprising fibres, process air, and binder where appropriate, with the term "process air" also covering the propellant gas required in order to draw out the fibres, the secondary air entrained during fiberisation, and any false air which may be sucked into the process for the purpose of cooling following fibre drawing.
Into the space bounded by the accumulating conveyor and the side walls of the chute, are thus introduced from the top fibre flows arranged in the form of adjacent core streams which carry fibres which are in the process of production or which have just been produced. In order to facilitate a directed flow and orderly deposition of the fibres as a nonwoven fabric on the accumulating conveyor, it is therefore necessary to extract the introduced process air from below the accumulating conveyor. By this means, one obtains in the chute a vertical stream of the fibre flows, from which the fibre content is trapped at the accumulating conveyor, as if at a filter, to form a nonwoven fabric which is then conveyed away while the process air continues to flow to extraction devices.
The extraction process under and in the accumulating conveyor presents certain difficulties as extraction has to be performed through the forming wool nonwoven, so that at the beginning of nonwoven formation there is, of necessity, less flow resistance while after partially completed nonwoven formation, a greater level of flow resistance has to be overcome. Directly above the nonwoven formation zone, therefore, a non-uniform flow pattern prevails owing to the spatially differing thicknesses of the nonwoven fabric lying below.
At the entry end of the chute, i.e. above the nonwoven formation zone, the fibre flow pattern is made up of a plurality of core streams, with each core stream initially being readily assignable to an individual fiberisation unit. The core streams which occur immediately below the fiberisation units, which core streams exhibit the energy of the propellant gas flows injected for fibre production and as a result of their elevated velocity represent regions of reduced static pressure, are located in relatively close mutual vicinity and exert a mutual suction effect which can lead to unstable oscillating flows in the individual core streams or in the fibre flow as a whole. The overall result is that, above the accumulating conveyor, there is a heterogeneous, spatially and temporally unstable flow pattern which, although in snapshot terms can be regarded as a downward flow, nevertheless exhibits locally a plurality of different flow components acting in the most varied of directions. The minutest changes in a boundary condition lead in this chaotic flow system to changes in the flow pattern which are difficult to control from the outside, which changes, in turn, adversely affect the degree of uniformity with which the nonwoven is formed and which are therefore undesirable.
In the boundary zone in particular around the fibre flows, fibres exhibiting rapid upward movements can also be observed. These upward streams in the boundary zone of the fibre flows are attributable to the fact that, as a rule, only a certain portion of the process air flowing in from above is completely extracted, while another portion at the side of the actual fibre flows is pushed upward again, or is sucked upward by partial vacuum zones in the region of the injected drawing gas flows. These air streams exhibit high flow velocities in an upward direction and entrain fibres in an upward direction to the area of fiberisation. In the case of fibre production by the blast drawing process, for example, suction of already solidified fibres into the nozzle slot together with the secondary air can lead to massive disruptions to production. In addition, the transport of already solidified fibres into the region of binder injection which, in the blast drawing process, is usually located at the entry zone of the chute, can lead to these fibre elements once again coming into contact with binder and then adhering to the chute wall or falling onto the nonwoven fabric as fibres with an excessive accumulation of binder, for example in the form of highly undesirable lumps.
In order to achieve orderly fibre deposition under these conditions, it is necessary to perform a plurality of fine adjustments for a given production process, so as to optimise, by trial and error, the fibre deposition conditions. Any change in the production conditions leads to the requirement that new fine adjustment be performed.
SUMMARY OF THE INVENTION
The object of the invention is to provide a process and an apparatus for performing said process, in which a stable flow is produced in the chute, thus enabling properly defined, homogeneous fibre deposition.
In the first instance, the invention is based on the knowledge that the backflow regions of high velocity, which are formed as a result of the chaotic flow conditions and which, at first sight, appear to be highly undesirable, cannot be forced into a certain flow pattern by additional constructional measures such as, for example, baffles. Rather, in contrast to such an approach and in keeping with the invention, the backflow regions are rendered even larger in volume terms; initially this has the effect that the mean velocity of the backflows is reduced, thus substantially diminishing the extent to which fibres can be transported upward. Surprisingly, moreover, it has been revealed that, rather than a reduction in the backflow regions which are characteristic of the chaotic flow system leading to a stabilisation in the flow pattern, as might have been expected, it is, in contrast, the increase in the space available for the generation of backflow regions which leads to a stabilisation of the flow system. According to the invention, therefore, the backflow regions occurring on the outside of the fibre flows are not constricted but rather increased in volume terms.
Through this measure, the backflow regions have, on the one hand, room at the side to enable them to circulate slowly so that the upward velocities generated are reduced, thus already diminishing the tendency for fibres to be entrained upward; on the other hand, disadvantageous encrustations of binder-containing wool accumulations are avoided in that area of wall in which the stagnation point of the branching flow is located Above the stagnation point, there is a backflow of process air, while below the stagnation point, the process air is extracted through the accumulating conveyor. If the volumes available for the backflow are too small, wool constituents in the region of the said stagnation point impinge onto the wall with a high velocity component perpendicular to the wall. This leads to undesirable encrustations. According to the invention, this stagnation point is therefore relocated a sufficient distance away from the external enveloping surfaces of the fibre flows so that the disruptive velocity component of the flow in the vicinity of the stagnation point is drastically reduced.
A further and essential aspect of the present invention lies in the fact that the extended backflow zone is dimensioned such that, over and beyond the advantages described so far, the wool to be deposited can no longer follow the backflow in the lower flow deflection area, i.e. it is effectively centrifuged out as in a cyclonic flow. In this process, the wool to be deposited is already separated within the actual chute from an appreciable portion of its associated process air. Consequently, this portion no longer needs to be sucked through the nonwoven fabric. This leads to advantages in respect of the necessary suction energy input, this being reduced owing to the substantially lower pressure loss a) of this partial flow, and b) of the remaining process air passing through the nonwoven fabric and/or the accumulating conveyor. Moreover, the differential pressure necessary for extracting the process air from the nonwoven fabric is also therefore reduced, so that the nonwoven fabric is deposited as a more voluminous material, thus facilitating the manufacture of products of low bulk density.
The overall result is a defined limitation of the fibre deposition area and thus of the nonwoven fabric formation zone, provided not by the walls of the chute but by a boundary area formed between the outsides of the fibre flows and those of the backflow regions.
If extraction of a portion of the process air is performed not through the nonwoven fabric but outside the nonwoven formation zone, the limitation of this zone is assisted by the process air flow, and the extraction of large volumes of air is facilitated.
The fact that the walls of the chute are positioned further out in a deliberately created dead flow zone means, however, that binder-containing wool material which has become deposited in the course of a certain time on the wall, can cure onto the wall more readily. If, in contrast, the chute walls mechanically limit the actual main flow, then they are also exposed to the stream forces acting here which, being mainly parallel to the wall surface, are more appropriate so that fibre encrustations become less probable. With the walls being positioned away from the main streams, the cooling of the walls therefore becomes even more important as a means of preventing, in accordance with the doctrine of published German patent application DE-OS 35 09 425, the curing of binder-containing fibre material onto the circumferential walls of the chute. With respect to further details, features and advantages of the cooling system for the walls of the chute, express reference is made to DE-OS 35 09 425, the full contents thereof being hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details, aspects and advantages of the present invention are revealed in the following description of an embodiment by reference to the drawing in which
FIG. 1 shows a schematic representation by way of illustration of the process according to the invention and the apparatus according to the invention, with an accumulating conveyor in the form a flat conveyor belt, and
FIG. 2 shows a further embodiment of the apparatus according to the invention with a drum-shaped accumulating conveyor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As is apparent from FIG. 1, free jet bundles 5, 6, 7 and 8, which are roughly wedge-shaped in their geometry, are produced by, in this illustrative example, four fiberisation units 1, 2, 3 and 4 operating in accordance with the blast drawing process, said free jet bundles 5, 6, 7 and 8 consisting of a fibre/gas/air/binder mixture, being surrounded by a box-shaped chute 9, the upper terminations 9a to 9e of which are formed by covers 9a to 9e which limit the entry of ambient air. The chute covers 9a to 9e are of moveable design in respect of their cover area, and are also water-cooled in order to minimise the occurrence on them of encrustations of binder-containing wool constituents. Through their limiting effect on the sucked-in false air, signified by 48 to 51, backflows are generated, the extent of which is determined by the position and size of the remaining upper inlet cross sections of the chute. The bottom termination of the chute is formed by an accumulating conveyor 10 featuring a gas-permeable conveyor belt 12 which rotates in accordance with the direction indicated by arrow 11. If the fibre/gas/air mixture, which may also contain a binder, impinges on the accumulating conveyor 10, the gas/air mixture is extracted from below the accumulating conveyor 10 acting as a filter by, in this illustrative example, two extraction devices 13, 14, and the wool is deposited with the formation of a nonwoven fabric onto the accumulating conveyor 10 as a wool nonwoven 15.
The free jet bundles 5 to 8, which are initially still wedge-shaped in their geometry, produced by the fiberisation units 1 to 4, form at the entry zone of the chute 9 fibre flows 16, 17, 18, 19 with interposed eddy zones 20, 21, 22 of entrained process air. After a fall of a certain distance in the chute 9, the individual fibre flows 16 to 19 come into contact with one another and eventually join to form a main flow 23 which likewise features, on its outside, eddy zones 24, 25 with backflow regions 26, 27. According to the invention, the lateral limiting walls 28, 29 of the chute 9 are positioned at a sufficiently large distance from the outside edge 30, 31 of the fibre flows, i.e. the main flow 23, so that there is at least sufficient room for the eddy zones 24, 25 to ensure that the backflow regions 26, 27 which occur exhibit small mean velocities. In this way the problem is avoided whereby fibres from the main flow 23 are transported back up into the entry zone of the chute via the eddy zones 24, 25, in which entry zone they may be sprayed anew with binder.
The shape of the eddy zones 24, 25 leads, in the edge zone of the main flow 23, to a division in the downwardly directed air stream into a portion 32 which is returned upward in the backflow region 26, and a portion 33 which is extracted in the vicinity of, but outside, the nonwoven formation zone 35, namely in a zone 36 with a width a in the illustrative example, by the extraction device 13. The remaining portion 34 is sucked through the nonwoven fabric 15 in the nonwoven formation zone 35 with a width b by extraction device 14. Depending on requirements, instead of extraction device 14, several such extraction chambers can, of course, be provided, duly designed and arranged in accordance with the layer growth of the nonwoven fabric. Moreover, extraction chamber 13 in particular can be dispensed with or take the form of a--if necessary throttlable--part of extraction device 14.
As shown in the right-hand part of the illustration, a largevolume flow is also generated in the region of maximum nonwoven layer thickness, in accordance with the invention, so that appreciable upward wool transport is avoided. To this, a zone c where there is no nonwoven formation can be connected in a similar manner, from which zone c a further partial flow of process air 33b can be extracted by an extraction device 13b which is not shown in any further detail and which is located outside the nonwoven formation and conveying region.
The distance of the lateral limiting walls 28, 29 of the chute from the outside edge 30, 31 of the main flow 23, and also the width a of zone 36, and the width b of the nonwoven formation zone 35 are dimensioned in this respect such that disruptive velocity components perpendicular to the limiting wall 28, 29 in the vicinity of the stagnation point signified by 37 are drastically reduced in magnitude. It is known from earlier measurements that these velocities can easily lie in a range from approx. 10 to 20 m/s. According to the invention they are reduced to below 10 to 20% of these values.
The following data are provided to serve as an indication of the volumes involved in the case of the claimed backflow regions:
Given a process gas volume flow of, for example 9,000 m 3 /h (STP) per fiberisation unit, the volume of circulating backflow generated between the end walls 28, 29 and the enveloping surfaces 30, 31 near to the wall is approx. 2,500 m 3 /h (STP). According to the previously customary design in respect of the distance between fiberisation units 1 and 4 on the one hand, and the end walls 28 and 29 respectively on the other, maximum velocities of the upward flows near to the wall of approx. 4 m/s are known to have occurred These velocities are higher than the drop velocity of wool flocks, so that a substantial proportion of wool is taken upward again into the chute entry zone.
With the creation in accordance with the invention of sufficiently sized backflow regions, the circulating backflow volumes of 2,500 m 3 /h (STP), although only having undergone an insignificant change, feature substantially reduced upward velocity with values falling to below 2 m/s and preferentially below 1 m/s.
As a result of the likewise advantageous introduction of a nonwoven-free extraction region a and/or c, approx. 20 to 80%, and preferentially 40 to 60%, of the process air volume from the fiberisation units 1 and 4 near the wall is, in addition, extracted outside the nonwoven formation zone b, without the need to overcome a pressure loss as a result of flow resistance at the nonwoven. In the case of the four fiberisation units in the illustrative example, a portion of 10 to 40% of the process air is extracted without any appreciable pressure loss, and thus with extreme cost-efficiency.
As a further advantage, reference is made to the fact that, if the edge zone extension according to the invention is not provided, the 9,000 m 3 /h (STP) process air per fiberisation unit mentioned in the example numerical data above can only be adhered to in the case of very coarse wool (such as is required, for example, for automotive exhaust mufflers) featuring correspondingly higher drop velocities and a lower level of permeation resistance. In the case of finer wool, the proportion of false air sucked into the chute per fiberisation unit has to be increased by approx. 3,000 to 6,000 m 3 /h (STP) in order to avoid upward wool transport By this means, the position of the backflow regions which are formed is shifted so far down that wool egress out of the chute cover area no longer takes place. Compared with these practical operating data, the invention results in an advantageous reduction of the requisite total volume of exhaust air per fiberisation unit of approx. 20 to 60%, and on average approx. 30%.
FIG. 2 shows a further embodiment of the apparatus according to the invention, in which the accumulating conveyor 10 is designed in the form of drums 38, 39. The drums 38 and 39 each feature a rotating, perforated (gas-permeable) rotor 40 and 41, each of which is powered by a motor (not depicted in any further detail in FIG. 2) in the direction of the arrows 42, i.e. the conveying direction. Furthermore, arranged inside the drums 38 and 39 is an extraction device, not depicted in any further detail, the suction pressure generated by which is active only in suction chambers 45 and 46 located below the curved suction areas 43 and 44. The distance between the two drums 38 and 39 creates a so-called discharge gap 47, the width of which is essentially to be matched to the thickness of the nonwoven 15 being produced. In order to adjust the width of the discharge gap 47, one of the two drums 38, 39 may be of swivellable design. In order to optimise the large-volume flow structure, the extraction devices 45 and 46 may, in particular, be divided such that the suction pressure in the nonwoven-free suction zones a is adjustable.
In this embodiment, the extraction zone a shown in example 1 (see FIG. 1) is arranged to particular advantage as, owing to the two, initially nonwoven-free perforated surfaces entering the chute, there are two extraction zones a formed which, without any great degree of design sophistication, serve the purpose according to the invention of extracting a considerable portion of the process air from outside the nonwoven deposition surface. This eliminates what would be, in itself, a more difficult problem, namely that of providing a further extraction device 13b analog to region c in FIG. 1. By this dual utilisation of the advantages of a nonwoven-free zone a, the formation of zones c in this concept can be avoided to advantageous effect. | A process and apparatus for the continuous production of mineral wool nonwovens in which the objective is to provide a process and an apparatus for the continuous production of mineral wool nonwovens, by means of which a stable flow pattern is created in the chute, thus facilitating a clearly defined, homogeneous layer of deposited mineral wool in which at least one backflow region (24, 25) is generated in the chute (9) outside the fibre flow (23), which backflow region (24, 25) is sufficient for such a large-volume backflow with such a low mean velocity that appreciable upward fibre transport is avoided. In this connection, a portion (32) of the process air entrained with the fibre flow is deflected upward in the backflow, and another portion (34) of the process air is extracted. | 3 |
BACKGROUND OF THE INVENTION
The invention is directed to an organic electroluminescent component, particularly an organic light-emitting diode.
The visualization of data is constantly increasing in significance due to the great increase in the amount of information. The technology of flat picture screens (“flat panel displays”) was developed therefor for employment in mobile and portable electronic devices. The market of flat panel displays is currently largely dominated by the technology of liquid crystal displays (LC displays). In addition to cost-beneficial manufacture, low electrical power consumption, low weight and slight space requirement, however, the technology of LC displays also exhibits serious disadvantages.
LC displays are not self-emitting and can therefore only be easily read or recognized given especially beneficial ambient light conditions. This makes a back-illumination device necessary in most instances, but this multiplies the thickness of the flat panel display. Moreover, the majority part of the electrical power consumption of the display is then needed for the illumination, and a higher voltage is required for the operation of the lamps or fluorescent tubes, which higher voltage is usually generated from batteries or accumulators with the assistance of “voltage-up converters”. Other disadvantages are the highly limited observation angles of LC displays and the long switching times of individual pixels, which switching times typically lie at a few milliseconds and also are highly temperature-dependent. The delayed image build-up is considered extremely disturbing, for example, given utilization in means of conveyance or given video applications.
There are other flat panel display technologies in addition to LC displays, for example the technology of flat display panel cathode ray tubes, of vacuum-fluorescence displays and of inorganic thin-film electroluminescent displays. However, either these technologies have not yet achieved the required degree of technological maturity or—due to high operating voltages or, respectively, high manufacturing costs—they are only conditionally suited for utilization in portable electronic devices.
Displays on the basis of organic light-emitting diodes, which are called OLEDs, do not exhibit these disadvantages. The necessity of a back-illumination is eliminated due to the self-emissivity, as a result whereof the space requirement and the electrical power consumption are considerably reduced. The switching times lie at about one microsecond and are only slightly temperature-dependent, which enables employment for video applications. The reading angle amounts to nearly 180°, and polarization films that are required given LC displays are eliminated, so that a greater brightness of the display elements can be achieved. Further advantages are the employability of flexible and non-planar substrates as well as a simple and cost-beneficial manufacture.
The construction of organic light-emitting diodes typically ensues in the following way.
A transparent substrate, for example glass, is coated with a transparent electrode (bottom electrode, anode), composed, for example, of indium tin oxide (ITO). Dependent on the application, the transparent electrode is then structured with the assistance of a photolithographic process.
One or more organic layers composed of polymers, oligomers, low-molecular compounds or mixtures thereof are applied on the substrate with the structured electrode. Examples of polymers are polyaniline, poly(p-phenylene-vinylene) and poly(2-methoxy-5-(2′-ethyl)-hexyloxy-p-phenylene-vinylene). Examples of low-molecular compounds that preferably transport positive charge carriers are N,N′-bis-(3-methylphenyl)-N,N′-bis-(phenyl)-benzidine (m-TPD), 4,4′,4″-tris-N-3-methylphenyl-N-phenyl-amino)-triphenylamine (m-MTDATA) and 4,4′,4″-tris-(carbazole-9-yl)-triphenylamine (TCTA). Hydroxy-chinoline aluminum-III salt (Alp 3 ) that can be doped with suitable chromophores (chinacridone derivatives, aromatic hydrocarbons, etc.), for example, is employed as an emitter. As warranted, additional substances, that influence the electro-optical and the long-term properties, such as copper phthalocyanine, can be present. The application of polymers usually ensues from the liquid phase with doctor blades or spin-coating; low-molecular and oligomeric compounds are usually deposited from the vapor phase by vapor deposition or “physical vapor deposition” (PVD). The overall layer thickness can amount to between 10 nm and 10 μm and it typically lies in the range between 50 and 200 nm.
A cooperating electrode (top electrode, cathode), which is usually composed of a metal, of a metal alloy or of a thin insulator layer and a thick metal layer, is applied onto the organic layer or layers. The manufacture of the cathode layer usually ensues with vapor phase deposition by means of thermal evaporation, electron beam evaporation or sputtering.
When metals are employed as cathode material, then these must have a low work function (typically <3.7 eV) so that electrons can be efficiently injected into the organic semiconductor. Alkaline metals, alkaline earth metals or rare earth metals are usually employed for this purpose and the layer thickness lies between 0.2 nm and a few hundred nanometers but generally at a few 10 nanometers. Since, however, these non-precious metals tend toward corrosion under atmospheric conditions, it is necessary to additionally apply a layer of a more precious, inert metal such as aluminum (Al), copper (Cu), silver (Ag) or gold (Au) onto the cathode layer that protects the non-precious metal layer against moisture and atmospheric oxygen.
For increasing the stability of the cathodes against a corrosion-caused hole formation, an alloy composed of an efficiently electron-injecting but corrosion-susceptible non-precious metal (work function <3.7 eV) and a corrosion-resistant or precious metal, such as Al, Cu, Ag and Au, is often employed instead of an unalloyed non-precious metal. The proportion of the non-precious metal in the alloy can amount to between a few tenths of a percent and approximately 90%. The alloys are usually generated by simultaneous deposition of the metals from the vapor phase, for example by co-vapor deposition, simultaneous sputtering with a plurality of sources and sputtering upon employment of alloy targets. However, a layer of a precious metal or corrosion-resistant metal, such as Al, Cu, Ag or Au, is usually also additionally applied onto such cathodes as protection against corrosion.
Cathodes composed of precious metals, i.e. metals having a work function >3.7 eV, are very inefficient electron injectors when they are utilized in direct contact with the organic semiconductor. When, however, a thin insulating intermediate layer (layer thickness generally between 0.2 and 5 nm) is arranged between the uppermost, electron-conducting organic layer and the metal electrode, then the efficiency of the light-emitting diodes rises substantially. Oxides such as aluminum oxide, alkaline and alkaline earth oxides and other oxides as well as alkaline and alkaline earth fluorides come into consideration as the insulating material for such an intermediate layer (in this respect, see Appl. Phys. Lett., Vol. 71 (1997), pages 2560 through 2562; U.S. Pat. No. 5,677,572; European Published Application 0 822 603). A metal electrode that is composed of a pure metal or of a metal alloy is then applied onto the thin, insulating intermediate layer. The insulating material can thereby also be applied together with the electrode material by means of co-vapor deposition (Appl. Phys. Lett., Vol. 73 (1998), pages 1185 through 1187).
SUMMARY OF THE INVENTION
An object of the invention is to fashion an organic electroluminescent component, particularly an organic light-emitting diode, such that, on the one hand, a hermetic seal of the top electrode can be foregone and, on the other hand, the selection of materials employable at the cathode side is greater.
This is inventively achieved by a component that is characterized by or comprises
a transparent bottom electrode situated on a substrate;
a top electrode composed of a metal that is inert to oxygen and moisture;
at least one organic function layer arranged between the bottom electrode and the top electrode; and
a charge carrier injection layer containing a complex metal salt of the composition (Me1)(Me2)F m+n , whereby the following applies:
m and n are respectively a whole number corresponding to the valence of the metals Me1 and Me2 (the metal Me1 thereby has the valence m, the metal Me2 the valence n),
Me1 is selected from a group consisting of Li, Na, K, Mg and Ca.
Me2 is selected from a group consisting of Mg, Al, Ca, Zn, Ag, Sb, Ba, Sm and Yb,
with the prescription: Me1≠Me2.
The critical feature of the organic electroluminescent component of the invention is thus in a specific structure at the cathode side, namely in the combination of a top electrode that is indifferent with respect to environmental influences with a charge carrier injection layer composed of a specific complex metal salt having the composition (Me1)(Me2)F m+n , i.e. a double fluoride. As a result of this structure, a hermetic seal or, respectively, sealing of the top electrode can be omitted. As a result of the specific material for the charge carrier injection layer, not only is the offering for the materials employable at the cathode side broadened, this material also achieves an improvement of the emission properties, which are expressed in clearly higher light yield, a reduced operating voltage and a longer service life during operation.
The charge carrier injection layer (composed of a specific complex metal salt) is preferably arranged as a thin insulating layer either between the top electrode and the organic function layer or between the uppermost function layer and the top electrode given the presence of a plurality of function layers. When an electron transport layer is also additionally located on the (uppermost) function layer given the component of the invention, then the charge carrier injection layer is arranged between this transport layer and the top electrode. In all of these instances, the thickness of the charge carrier injection layer preferably amounts to approximately 0.1 through 20 nm.
However, the charge carrier injection layer can also be quasi-integrated into the top electrode, into the (uppermost) organic function layer or into an electron transport layer that is potentially present, i.e. the complex metal salt is then a constituent part of one of these layers. The production of such layers can advantageously ensue by means of co-vapor deposition of the corresponding materials, for example by co-vapor deposition of the top electrode material and of the complex metal salt.
The complex metal salt exhibits the composition (Me1)(Me2)F m+n , whereby m and n correspond to the valence of the respective metal. m=1 (Li, Na, K) or m=2 (Mg, Ca) is valid for Me1; n=1 (Ag) or n=2 (Mg, Ca, Zn, Ba) or n=3 (Al, Sb, Sm, Yb) is valid for Me2. The metal Me1 is preferably lithium (Li); the metal Me2 is preferably magnesium (Mg), aluminum (Al), calcium (Ca), silver (Ag) or Bariumn (Ba).
Advantageously, one of the double fluorides LiAgF 2 , LiBaF 3 and LiAlF 4 is employed as the complex metal salt. More such double fluorides are, for example, NaAgF 2 , KAgF 2 , LiMgF 3 , LiCaF 3 , CaAgF 3 and MgBaF 4 . Complex salts of this type as well as methods for manufacturing them are known in and of themselves (in this respect, see the exemplary embodiments as well as, for example, “Gmelins Handbuch der Anorganischen Chemie”, 8 th Edition (1926), System Number 5 (fluorine), pages 58 through 72).
The top electrode, which generally comprises a thickness>100 nm, is preferably composed of one of the following metals: aluminum (Al), silver (Ag), platinum (Pt) and gold (Au). The electrode material, however, can also be an alloy of two of these metals. Magnesium (Mg), calcium (Ca), zinc (Zn), antimony (Sb) and barium (Ba) come into consideration as other metals for the top electrode.
The bottom electrode is generally composed of indium tin oxide (ITO). Other possible materials for the bottom electrode are tin oxide and bismuth oxide. Glass generally serves as the substrate for the bottom electrode.
The component of the invention preferably comprises two organic function layers, namely an apertured conducting layer arranged at the bottom electrode that transports positive charge carriers and an emission layer situated thereon that is also referred to as the luminescence layer. Two or more apertured conducting layers can also be advantageously utilized instead of one apertured conducting layer.
The materials for these layers are known in and of themselves. In the present case, N,N′-bis3-methylphenyl)-N,N′-bis(phenyl)-benzidine (m-TPD), 4,4′,4″-tris-(N-1-naphthyl-N-phenylamino)-triphenylamine (naphdata) or N,N′-bis-phenyl-N,N′-bis-α-naphthyl-benzidine (α-NPD) is preferably employed for the apertured conducting layer or layers. The material for the emission layer is preferably hydroxychinoline aluminum-III salt (Alq 3 ). Simultaneously, this material can also serve for the electron transport. For example, chinacridone can also be utilized for the emission layer, and one of the oxadiazole derivatives known for this purpose for a potentially present electron transport layer.
The invention offers the following, additional advantages, particularly in view of organic light-emitting diodes:
Facilitated Handling
Due to the stability of the material of the top electrode, work need not be carried out under an inert gas atmosphere in the manufacture and further-processing of OLEDs.
Performance
Compared to top electrodes of non-precious metals, the operating voltage is clearly lowered and the light yield and efficiency are considerably enhanced.
Improved Properties
Compared, for example, to LiF as the material for the intermediate layer, compounds such as LiAlF 4 have the advantage that they are less hygroscopic, which facilitates the handling and storage. The double fluorides are also easier to evaporate and are less basic than LiF, as a result whereof the compatibility with the organic function layers is increased.
The invention shall be explained in still greater detail on the basis of exemplary embodiments and Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a traditional OLED display;
FIG. 2 is a diagrammatic view of an OLED display of the invention;
FIG. 3 is a graph showing luminance/voltage characteristics;
FIG. 4 is a graph showing efficiency/luminance characteristics;
FIG. 5 is a graph showing a comparison of the luminance of various materials.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
Production of Lithium Aluminum Fluoride LiAlF 4
Lithium aluminum hydride LiAlH 4 is carefully hydrolyzed with distilled water and conversion is subsequently undertaken with hydrofluoric acid (HF) being in excess. The complex metal salt LiAlF 4 that thereby precipitates out is extracted, repeatedly washed with water and ethanol and then dried.
EXAMPLE 2
Production of Lithium Silver Fluoride LiAgF 2
A solution of stoichiometric quantities of lithium hydroxide and silver acetate is glacial acetic acid is converted with hydrofluoric acid (HF) being in excess upon exclusion of light and the complex metal salt LiAgF 2 thereby precipitates out. The complex salt is extracted after the addition of the same volume of ethanol, is washed with ethanol and dried.
EXAMPLE 3
Production of Lithium Barium Fluoride LiBaF 3
An aqueous solution of stoichiometric quantities of lithium hydroxide and barium hydroxide is converted with hydrofluoric acid (HF) being in excess. The complex metal salt LiBaF 3 precipitates out when chilled (cooling with ice) and it is extracted, repeatedly washed with ethanol and then dried.
The complex metal salt LiCaF 3 is produced in a corresponding way, whereby the reaction solution is constricted as warranted.
The complex metal salt LiMgF 3 can be produced in the same way and lithium methylate and magnesium methylate are then utilized as the initial substances.
EXAMPLE 4
Manufacture of a Traditional OLED Display 10 With a Mg/Ag Cathode (see FIG. 1 )
An ITO layer 12 having a thickness of approximately 100 nm is applied onto a glass substrate 11 . This layer is then photolithographically structured in such a way that a stripe-shaped structure is produced. A layer 13 of m-TPD having a thickness of approximately 100 nm is first applied by thermal evaporation onto the coated substrate pre-treated in this way, followed by a layer 14 of Alq 3 having a thickness of approximately 65 nm.
A layer 15 of a magnesium-silver alloy (Mg:Ag mixing ratio 10:1) having a thickness of approximately 150 nm is applied onto the organic layer 14 by thermal evaporation with two simultaneously operated evaporator sources, and a layer 16 of pure silver having a thickness of approximately 150 nm is applied on the layer 15 , likewise by thermal evaporation. The metal layers are thereby vapor-deposited through a mask with stripe-shaped openings, so that cathode stripes that lie perpendicular to the ITO stripes are produced. Organic light-emitting diodes with an active area of 2×2 mm 2 respectively are produced in this way at the intersections of the ITO tracks with the metal tracks—together with the organic layers lying therebetween. During operation, the ITO layer is positively contacted and the metal tracks are negatively contacted.
EXAMPLE 5
Manufacture of an OLED Display 20 of the Invention (See FIG. 2 )
An ITO layer 22 having a thickness of approximately 100 nm is applied onto a glass substrate 21 . This layer is then photolithographically structured in such a way that a stripe-shaped structure is produced. A layer 23 of m-TPD having a thickness of approximately 100 nm is first applied by thermal evaporation onto the coated substrate pre-treated in this way, followed by a layer 24 of Alq 3 having a thickness of approximately 65 nm. An electron transport layer 29 is shown on the layer 24 ; however, the layer 29 may be omitted.
A layer 25 of LiAlF 4 having a thickness of approximately 1 nm is applied by thermal evaporation onto the layer 29 , if it is present, or, if not present, then onto the layer 24 , and a layer 26 of aluminum—serving as a top electrode—having a thickness of approximately 150 nm is applied onto said layer 25 , likewise by thermal evaporation. The two layers 25 and 26 are thereby vapor-deposited through a mask with stripe-shaped openings, corresponding to Example 4, so that organic light-emitting diodes are produced. During operation, the ITO layer is positively contacted and the top electrode is negatively contacted.
The results of measurements at the OLEDs corresponding to Examples 4 and 5 are compiled in Table 1. The threshold voltage (of the electroluminescence), the voltage and the efficiency (respectively given a luminance of 1500 cd/m 2 ), the maximum luminance and the luminance given a current density of 50 mA/cm 2 ) are thereby recited as characteristic data.
TABLE 1
Lumi-
Efficiency
nance
Voltage [V]
[lm/W]
Maximum
[cd/m 2 ]
Threshold
at 1500
at 1500
luminance
at 50
Example
voltage [V]
cd/m 3
cd/m 2
[cd/m 2 ]
mA/cm 2
4
2.08
14.48
0.677
15957
1544
5
1.87
14.12
0.720
18801
1605
It can be seen that the threshold voltage and the operating voltage of the display of the invention (Example 5) lie below the corresponding values given the traditional display (Example 4), even though the thickness of the LiAlF 4 was not optimized. The values for the efficiency and the luminances that are achieved given the display of the invention lie above the corresponding values of the traditional display.
FIG. 3 shows the luminance/voltage characteristics of the displays according to Examples 4 and 5. The increased luminance of the display of the invention can be clearly seem from this illustration.
The following can be stated overall:
The display of the invention (Example 5) employs a cathode of aluminum with which efficiencies are normally achieved that lie approximately 40 to 50% below the corresponding values given Mg/Ag cathodes (Example 4). Aluminum, on the other hand, is more stable than magnesium vis a vis environmental influences such as atmospheric oxygen and moisture.
Due to the introduction of a thin LiAlF 4 between the organic function layers and the Al cathode, however, the efficiency of OLEDs having an Al cathode can be increased, namely even above the corresponding values of OLEDs with Mg/Ag cathode. In this way, high-efficiency OLEDs with stable cathode can be constructed.
EXAMPLE 6
Manufacture of an OLED Display With a Mg/Ag Cathode
An ITO layer having a thickness of approximately 100 nm is applied onto a glass substrate. This layer is then photolithographically structured in such a way that a stripe-shaped structure is produced. A layer of naphdata having a thickness of approximately 55 nm is first applied by thermal evaporation onto the coated substrate pre-treated in this way, followed by a layer of α-NPD having a thickness of approximately 5 nm, and, finally, a layer of Alq 3 having a thickness of approximately 65 nm.
A layer of a magnesium-silver alloy (Mg:Ag mixing ratio 10:1) having a thickness of approximately 150 nm is applied onto the uppermost organic layer (of Alq 3 ) by thermal evaporation with two simultaneously operated evaporator sources, and a layer of pure silver having a thickness of approximately 150 nm is applied on the uppermost organic layer, likewise by thermal evaporation. The metal layers are thereby vapor-deposited through a mask with stripe-shaped openings, so that cathode stripes that lie perpendicular to the ITO stripes are produced. Organic light-emitting diodes with an active area of 2×2 mm 2 respectively are produced in this way at the intersections of the ITO tracks with the metal tracks—together with the organic layers lying therebetween. During operation, the ITO layer is positively contacted and the metal tracks are negatively contacted.
EXAMPLE 7
Manufacture of an OLED Display With an Al Cathode
Corresponding to Example 6, a display having three organic function layers is constructed. A layer of aluminum having a thickness of 150 nm is then applied in a corresponding way by thermal evaporation onto the uppermost organic layer (of Alq 3 ).
EXAMPLE 8
Manufacture of an OLED Display With an Al Cathode and an LiF Intermediate Layer
A display with three organic function layers is constructed corresponding to Example 6. A layer of LiF having a thickness of approximately 0.5 nm is then applied onto the uppermost organic layer (of Alq 3 ) by thermal evaporation, and a layer of aluminum having a thickness of approximately 150 nm is applied on the uppermost organic layer. The two layers are thereby vapor-deposited through a mask having stripe-shaped openings in conformity with Example 6, so that organic light-emitting diodes are produced. During operation, the ITO layer is positively contacted and the Al cathode is negatively contacted.
EXAMPLE 9
Manufacture of an OLED Display With an Al Cathode and a LiAlF 4 Charge Carrier Injection Layer
A display with three organic function layers is constructed corresponding to Example 8. A layer of LiAlF 4 having a thickness of approximately 0.5 nm is then applied by thermal evaporation onto the uppermost organic layer (of Alq 3 ), and a layer of aluminum—serving as top electrode—having a thickness of approximately 150 nm is applied onto the LiAlF 4 layer, likewise by thermal evaporation. The structuring and the contacting ensue in conformity with Example 8.
EXAMPLE 10
Manufacture of an OLED Display With an Al Cathode and a LiAgF 2 Charge Carrier Injection Layer
A display with three organic function layers is constructed corresponding to Example 6. A layer of LiAgF 2 having a thickness of approximately 0.5 nm is then applied by thermal evaporation onto the uppermost organic layer (of Alq 3 ), and a layer of aluminum—serving as a top electrode—having a thickness of approximately 150 nm is applied onto said LiAlF 4 layer, likewise by thermal evaporation. The structuring and the contacting ensue in conformity with Example 8.
EXAMPLE 11
Manufacture of an OLED Display With an Al Cathode and a LiBaF 3 Charge Carrier Injection Layer
A display with three organic function layers is constructed corresponding to Example 6. A layer of LiBaF 3 having a thickness of approximately 0.5 nm is then applied by thermal evaporation onto the uppermost organic layer (of Alq 3 ), and a layer of aluminum—serving as a top electrode—having a thickness of approximately 150 nm is applied onto the LiAlF 4 layer, likewise by thermal evaporation. The structuring and the contacting ensue in conformity with Example 8.
The results of measurements at the OLEDs corresponding to Examples 6 through 11 are compiled in Table 2. The threshold voltage (of the electroluminescence), the voltage and the efficiency (respectively given a luminance of 1500 cd/m 2 ), the maximum luminance and the luminance given a current density of 50 mA/cm 2 ) are thereby recited as characteristic data.
TABLE 2
Voltage [V]
Efficiency
Luminance
Threshold
at 1500
[lm/W] at
[cd/m 2 ]
Example
voltage [V]
cd/m 3
1500 cd/m 2
at 50 mA/cm 2
6
3.19
9.96
1.08
1722
7
7.15
16.52
0.48
1275
8
3.17
9.47
1.19
1809
9
4.23
11.97
0.88
1684
10
3.49
10.86
1.00
1745
11
2.56
9.58
1.26
1948
It can be seen that the threshold voltages and the operating voltages of the displays of the invention (Examples 9 through 11) that comprise an Al cathode and a charge carrier injection layer composed of a complex metal salt are comparable to the values that are obtained given displays with a Mg/Ag cathode or, respectively, with an Al cathode and a LiF intermediate layer (Examples 6 and 8) and lie clearly below the corresponding values given a display with a pure Al cathode (Example 7). The displays of the invention are also comparable to the Mg/Ag and Al—LiF displays in view of the efficiency and the luminance, whereby a display with a LiBaF 3 charge carrier injection layer (Example 11), in particular, exhibits high values.
FIG. 4 shows the efficiency/luminance characteristics of the Examples 6 through 11. In particular, the superior position of an Al—LiBaF 3 of the invention can be clearly seen from this illustration.
It can be stated overall that the efficiency of LEDs with an Al cathode can be boosted above the corresponding values of OLEDs with a Mg/Ag cathode by introducing thin layers of a complex metal salt such as LiAlF 4 , LiAgF 2 and LiBaF 3 between the organic function layers and the cathode. High-efficiency OLEDS with stable contact can be constructed in this way.
The values for the luminance (given a current density of 50 mA/cm 2 ) of the materials according to Examples 6 through 11 are compared to one another in FIG. 5 . The good results that can be achieved with the displays of the invention also can be derived therefrom. | The organic electroluminescent component of the invention has a transparent bottom electrode situated on a substrate; a top electrode composed of a metal that is inert to oxygen and moisture; at least one organic function layer arranged between the bottom electrode and the top electrode; and a charge carrier injection layer containing a complex metal salt of the composition (Me1)(Me2) F m+n , whereby the following applies:
m and n are respectively a whole number corresponding to the valence of the metals Me1 and Me2 (the metal Me1 thereby has the valence m, the metal Me2 the valence n),
Me1 is selected from a group consisting of Li, Na, K, Mg and Ca,
Me2 is selected from a group consisting of Mg, Al, Ca, Zn, Ag, Sb, Ba, Sm and Yb,
with the prescription: Me1≠Me2. | 7 |
BACKGROUND
[0001] 1. Field of Invention
[0002] The present invention relates to a memory controlling method. More particularly, the present invention relates to a memory controlling method with an advanced high-performance bus interface.
[0003] 2. Description of Related Art
[0004] In the digital signal processing systems or media video systems, a large amount of memory is needed to store the data the system requires. Therefore, SDRAM is extensively used in this kind of system because of its high capacity and low cost quality. However, when SDRAM accesses memory, the latency is very long.
[0005] Several SDRAM controllers have been proposed to make efficient use of the SDRAM. One is to schedule the requests of data access, and allow the accesses in the same row of a specific bank can be performed together as most as possible. This method reduces the switching frequency of transfers between different rows. Another approach focuses on data arrangement in memory. By analysis of data access for specific applications, the data arrangement can be optimized for reducing the data access latency. A history-based predictive approach is also proposed to reduce frequency of row activation. This approach predicts the next operation mode based on the history of memory reference. Thus, the row opening frequency is decreased and the latency reduced when the historical distribution is used.
[0006] In SDRAM, one reading transfer needs to issue a read command and the read data are available after the delay of the column address strobe (CAS) latency. In the advanced high-performance bus (AHB) bus, a transfer is separately composed of an address phase and a data phase, and the data phase of current transfer is overlapped with the address phase of next transfer. Hence, the address of the impending non-sequential transfer is not available before the data phase of the last transfer in a sequential access. Therefore when accessing the non-continuous address, the data can not be outputted continuously, meaning that each time when accessing a non-continuous address, there will be CAS latency at least that causes a low access rate.
[0007] Therefore, an optimizing scheme to enhance memory access efficiency with SDRAM traits is a problem in the known technique.
SUMMARY
[0008] It is therefore an objective of the present invention to provide a memory controlling method. This system includes an embedded address generator to overcome the limitation of the fact that the address cannot be known earlier in the communication standard of the advanced high-performance bus.
[0009] It is another objective of the present invention to provide a memory controlling method, including burst terminates burst (BTB) and anticipative row activation (ARA) in order to reduce the latency of the memory accessing.
[0010] According to the aforementioned objectives of the present invention, a memory controlling method is provided. In accordance with one embodiment of the present invention, allocating a memory mapped space larger than physical memory size for getting additional addressing bits used to transfer the mode control information (MCI), and using the mode control information to setup a stride value and a sequential data length for a 2-dimensional (2-D) data access. Then, an embedded address generator is used to obtain the non-sequential addresses of a 2-dimensional data accessing in advance. Then we can overcome the communication restriction from AHB interface and reduce the latency, in order to enhance the memory access efficiency and offer the access expansion mode.
[0011] According to another objective of the present invention, a memory controlling method is disclosed. In one embodiment of the present invention, the continuous data length and the succeeding non-continuous accessing address is known in advance, this invention proposes a memory controlling method, Burst Terminates Burst (BTB), which issues the SDRAM read/write command of impending non-continuous access to terminate the current burst transfer to reduce the latency of the non-continuous data, and then raise the data accessing efficiency in a fixed period of time.
[0012] The present invention proposes an anticipative row activating (ARA) method, storing the image/pixel data in the order of interlaced banks with sequential rows. In other words, this kind of memory organization limits the 2-dimensional data access into two situations. First, the next non-continuous data lie in the present memory row, and we can utilize the accessing method of BTB in order to reduce latency in this situation. Second, the next non-continuous data lie in the memory row of a different bank, in this case, this invention utilizes the waiting period for the SDRAM commands to activate the memory row in which the next non-sequential data located in advance. This fact reduces the latency of the accesses switched over different memory banks and rows. According to the above-mentioned contents, this invention has the following advantages:
[0013] 1. This invention applies to the advanced high-performance bus as a scheme to optimize the accessing efficiency in order to reduce the latency when the accessing addresses are non-continuous.
[0014] 2. This invention utilizes the controlling of ARA to reduce the latency induced by the frequent switches of memory bank/row.
[0015] It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings,
[0017] FIG. 1 is a schematic block diagram of SDRAM controller of the preferred embodiment of the present invention;
[0018] FIG. 2( a ) is a schematic diagram of an 8 MB memory address bus of the preferred embodiment of the present invention;
[0019] FIG. 2( b ) is a schematic diagram of mode control information definition of the preferred embodiment of the present invention;
[0020] FIG. 3 is a schematic diagram of SDRAM data organization of the preferred embodiment of the present invention;
[0021] FIG. 4 is a flow chart of memory controlling flow of the preferred embodiment of the present invention;
[0022] FIG. 5 is a flow chart of ARA controlling flow of the preferred embodiment of the present invention;
[0023] FIG. 6( a ) is a schematic diagram of conventional timing waveform; and
[0024] FIG. 6( b ) is a schematic diagram of timing waveform of the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
[0026] While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the figures, in which like reference numerals are carried forward.
[0027] Refer to FIG. 1 . FIG. 1 shows a schematic block diagram of SDRAM controller of the preferred embodiment of the present invention. According to the address and controlling information, the AHB interface 110 accepts the AHB master accessing requests to determine whether EAG 120 is enabled or not. If it is enabled, it means low latency accessing mode. If it is not enabled, it is the general reading/writing mode.
[0028] In the low latency accessing mode the BTB control unit 132 and ARA control unit 133 are enabled through main control unit 131 in the memory control core 130 to achieve the optimization scheme. In the general reading/writing mode, only the partial functions of the BTB control unit 132 are enabled.
[0029] The controlling procedures are based on the counting information from the counter unit 140 and send the required actions to the command generator 150 in order to meet the requirements for generating controlling signals of SDRAM.
[0030] Reference is made to FIG. 2( a ), which shows a schematic diagram of an 8 MB memory address bus of a preferred embodiment of the present invention. The width of AHB address bus is 32 bits. This invention gains bits used as mode control information 220 by allocating a memory-mapped space larger than the physical memory size. When the allocated space is larger than the addressing space of the physical memory, the corresponding address bits are larger than the bits the physical memory space needs. The redundant address bits are used to transfer the mode control information in the low latency accessing mode. Bit 0 to Bit 22 are physical memory addresses 210 . This invention uses bit 23 to bit 27 for the mode controlling information 220 . The mode controlling information 220 includes two columns, mode selection 221 and stride control 222 . Bit 28 to bit 31 are unused address bits 230 .
[0031] Refer to FIG. 2( b ). FIG. 2( b ) shows a schematic diagram of mode control information definition of the preferred embodiment of the present invention. FIG. 2( b ) shows the details of mode selection 221 and stride control 222 . When mode selection 221 is set as 0, it means the general reading/writing mode is enabled. In this mode, the address information refers to the AHB address bus and ignores the mode controlling information 220 . When the mode selection 221 is not set as 0, the low latency 2-dimensional accessing mode is enabled. In this mode, the value of mode selection 221 indicates the length of the continuous data (in terms of word). The embedded address generator generates the next non-continuous address in advance according to the stride control 222 . The MS[2:0] in FIG. 2( b ) shows the mode selection 221 uses 3 bits and 3'b000˜3′b111 denotes the 3-bit binary digits of mode selection 221 .
[0032] The stride control 222 can be divided into four kinds of controlling methods: half-stride (½), single-stride (1×), double-stride (2×) and stride-update. The SC[1:0] in FIG. 2( b ) shows the stride control 222 totally uses 2 bits and 2′b00˜2′b11 shows the 2-bit binary digits of the stride control 222 .
[0033] If the stride control 222 is set as stride-update, the write data of current AHB write transfer is saved as the stride value. Supporting half-stride and double-stride types facilitates the 2-D block access of chrominance data and interlaced data in image/video applications. The bit widths of physical memory address and mode control information can be adjusted according to how large the memory is and the user requirement, respectively. If the used modes need to be increased (for example, MS is expanded to 4 bits to define 16 modes), unused bit 230 can be used to achieve the expansion goal and make the memory controller flexibly support various kinds of modes.
[0034] Refer to FIG. 3 . FIG. 3 shows a schematic diagram of SDRAM data organization of the preferred embodiment of the present invention. The order of memory address is based on the consecutive row address with interlaced banks. In other words, this kind of data arrangement limits the non-continuous accessing of the 2-dimensional data to two states if the stride value is no larger than the size of N- 1 row in an N bank memory device. The first state is the next non-continuous data are now located in the row of present accessing. In this case, the accessing method of BTB can be used directly to avoid latency. The second state is that the next non-continuous data are located in the rows of the different memory banks. In this case, this invention utilizes the latency or time interval between successive DRAM commands and activates the next accessing row in a particular bank in advance in order to reduce the controlling latency needed when switching into a different memory bank.
[0035] In digital signal processing and video decoding applications, the block size of 2-dimensional accessing is not fixed. Therefore, the length of continuous data accessing may not consist with the burst length of SDRAM. When the burst length is longer than the length of the accessing data, the burst terminating command can finish burst accessing early in order to achieve a higher transmitting rate and avoid incorrect writing operations. However, the burst terminate command still consumes a command delay for next transfer. When in low latency 2-dimensional data accessing mode, the sequential access length and next non-sequential access address are both available from mode control information 220 and embedded address generator 120 . In this case, the burst of present sequential accesses can be terminated by the burst starts from the impending non-sequential access. However, the impending non-sequential access may not map to the row/bank of present access. Hence, finding the slots among SDRAM commands and exploiting these slots to activate the row of next non-sequential access beforehand is helpful for reducing the latency.
[0036] By analysis of the commands and properties of SDRAM, the command slots can be found in precharge, activate, burst access, and CAS latency. The number of available slots depends on the working frequency, burst length, and the delay time of commands.
[0037] Refer to FIG. 4 . FIG. 4 shows a flow chart of the memory controlling flow of the preferred embodiment of the present invention. This controlling process includes BTB and ARA. In this controlling process, the precharge command is not issued immediately after burst read/write for diminishing the frequency of row activation. That is, if an accessed row is not opened (or activated), the precharge 411 command has to be issued to deactivate the row already opened in the bank before activating the desired row. After initiation of SDRAM and transfer ready, activate 412 command is issued for a particular row according to the address. The command slots leaded from row activate 412 are checked for ARA 421 control. When finishing the activation, the read or write (Read/Write 413 ) command is issued for column access. At this time, the counter unit is set to accumulate the length of read or write operations. In the meanwhile, the command slots of CAS latency and burst transfer are checked to entering ARA 422 control until the value of counter is matched with the desired sequential access length. After that, the controller checks whether next transfer is pending or not 415 . If it is not, burst terminate 423 command is issued and then goes to the idle state (NOP). Otherwise, the status of the row of next access is checked. If the row of access is not opened, then entering the flow for activating this row. On the other hand, the read or write (Read/Write 413 ) command is issued directly to terminate the current burst access.
[0038] Reference is made to FIG. 5 , which shows a flow chart of ARA controlling flow of the preferred embodiment of the present invention. In ARA control flow, which includes several steps. The accessing mode is checked first. If general reading/writing mode is detected, go to idle state (NOP) and then exit ARA control.
[0039] Step 510 checks whether a low-latency 2-dimensinal accessing mode (LL 2-D mode) is detected. Then step 520 checks if the row of the address generated from EAG is activated. If the row is not opened, then step 530 checks if it needs precharge. If yes, then issue precharge command at step 540 and exit ARA control. Otherwise, check whether the activate command is allowed to be issued or not at step 550 . If it is allowed, the activate command is issued at step 560 and then exit ARA control, else go to the idle state (NOP) and then exit ARA control. Be sure to notice the step 560 that the activate command is not allowed to be issued when precharge or row activation is not completed.
[0040] Refer to FIG. 6( a ) and 6 ( b ). This timing waveform is based on the access of a 2 (word) by 2 block data with the assumption that the address A and address B are not mapped to the same memory row. FIG. 6( a ) shows the timing waveform of generic memory controller with optimized finite state machine (FSM). Although the precharge command is issued coincident with the validation of address of the second non-sequential transfer, i.e., B 0 , the latency is still long so that it is inefficient. The timing waveform of the present invention is shown in FIG. 6( b ). It can be seen that the precharge and activation commands forth e row of address B is issued at T 2 and T 5 respectively. Therefore, the read command for address B can be issued at T 9 in the present invention. The cycles required for accessing a 2 (word) by 2 block data in the present invention is reduced from 21 to 13.
[0041] In conclusion, the present low-latency memory controlling scheme reduces the latency of 2-D data access, and also diminishes the required memory bandwidth. Furthermore, the proposed memory controlling scheme can be applied to multi-dimension array data access by extending the mode control information.
[0042] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention covers the modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents. | A method for memory controlling is disclosed. It includes an embedded address generator and a controlling scheme of burst terminates burst, which could erase the latency caused by bus interface during the access of non-continuous addresses. Moreover, it includes a controlling scheme of anticipative row activating, which could reduce the latency across different rows of memory by data access. The method could improve the access efficiency and power consumption of memory. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to process and apparatus for forming containers from extruded sheet thermoplastic material with the utilization of plug-assisted pressure and/or vacuum forming techniques. It is known in the art to form tub-like containers by continuous rotary means from sheet stock such as shown in U.S. Pat. No. 3,027,596. The instant invention likewise provides thermoforming apparatus that rotates about a horizontal axis but, unlike the previously mentioned patent, performs thermoforming on vertically extruded thermoplastic material in a vertical plane between opposed rotating discs. Product uniformity has been made possible by the utilization of a wedge-shaped thermoplastic feedstock to compensate for the variation in tangential speed of the material being processed. U.S. Pat. Nos. 3,181,202, 3,518,725 and 3,771,938 illustrate rotary drum thermoforming wherein flat feedstock is fed to the surface of a rotating thermoforming drum. The instant invention differs from all of the above-mentioned patents in that molten sheet is extruded downwardly in the vertical direction between substantially parallel plates parallel to their plane of rotation and normal to their axis of rotation. Further, the instant invention does not use preformed sheet, which is reheated and fed horizontally onto the surface of a thermoforming drum as shown in the above-mentioned references. U.S. Pat. Nos. 3,578,735 and 3,600,753 illustrate flat bed plug-assisted thermoforming apparatus. These types of devices likewise require horizontal sheet stock and when used with such materials as polypropylene, which is highly plastic at thermoforming temperatures, require special devices to tenter the material and prevent it from stretching before thermoforming. The instant invention avoids material handling problems encountered in all of the above-mentioned patents by extruding a sheet of material vertically downwardly between vertical discs which rotate about a horizontal axis. By this means, the effect of gravity on the material is utilized beneficially rather than creating a problem that must be compensated for. Because the tangential speed of any point on the disc varies from the center of rotation to the extreme periphery of the forming discs, the sheet of material that is extruded is wedge-shaped in cross-section.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide process and apparatus for thermoforming thermoplastic sheets into containers at very high speeds.
It is another object of the instant invention to pressure thermoform containers directly from molten thermoplastic sheet material.
It is yet another object of the instant invention to provide apparatus that can thermoform plastic articles utilizing high forming pressure to achieve high quality surface finish on the articles.
SUMMARY OF THE INVENTION
It is the purpose of the instant invention to provide apparatus for continuously pressure/vacuum thermoforming plastic containers using the direct application of molten thermoplastic sheet produced by a sheet die. To accomplish this purpose, the instant invention provides a molding machine having two opposed discs rotating in unison on a common axis at a point adjacent to an extrusion die admitting a molten sheet of thermoplastic material vertically downwardly between and to one quadrant of the discs. Mold cavities are contained within one of said discs and opposing the said cavities movable plug assemblies are mounted in said other disc. The movable plug assemblies extend during the molding cycle to plug the molten sheet material into the cavities, thus effecting an air-tight seal around the cavities at which point compressed air and/or vacuum is applied internally into the cavities to thermoform the material. Also contained within the co-rotating discs are shear tools which are a part of the plug assemblies and function to shear the molded parts from the plastic sheet to form a finished container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the thermoforming apparatus of the instant invention.
FIG. 2 is a side view of the apparatus shown in FIG. 1.
FIG. 3 is a partial sectional view taken along line 3--3 of FIG. 1.
FIG. 4 is a partial sectional view taken along line 4--4 of FIG. 1.
FIG. 5 is a partial sectional view taken along line 5--5 of FIG. 1.
FIG. 6 is a partial sectional view taken along line 6--6 of FIG. 1.
FIG. 7 is a partial sectional view taken along line 7--7 of FIG. 1.
FIG. 8 is an enlarged sectional view similar to FIG. 3 taken along line 3--3 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown a machine in accordance with the present invention for producing thin wall plastic containers. FIGS. 1 and 2 show co-rotating discs 1 and 3 which revolve around spindle 5 in the direction 7 (see FIG. 1). Extrusion die 9 extrudes a molten sheet of thermoplastic material 11 between the discs 1 and 3. The molten sheet 11 is wedge-shaped in cross-section and is thickest at edge 13. The wedge-shaped cross-section provides additional material across the radius of discs 1 and 3 to accommodate stretching of the material caused by the tangential velocity differential across the radii of the discs to thereby present a uniform thickness of formable material to the surface of said discs, the thermoforming cavities and their respective plugs.
FIG. 1 illustrates in phantom lines 15 one of several cavity geometric lay-outs that are useful in the instant invention. The exact configuration of the cavities and their lay-out with respect to spindle 5 and extrusion die 9 will depend upon the desired container. The cavities 15 are interchangeable for production and construction purposes. Only one cavity 15 is illustrated in FIG. 2, along with its complementary movable plug 17. Manifolding means 19 are integral with spindle 5 to provide discs 1 and 3 with vacuum, cooling fluid, compressed air and high pressure hydraulic fluid from external schematically illustrated sources 21, 23, 25 and 27, respectively. Spindle 5 is rotated by rotational means 29.
FIG. 3 is a sectional view taken along section lines 3--3 of FIG. 1 which illustrates a more detailed view of a plug 17 and a cavity 15 as arranged in retracted position in discs 1 and 3 respectively. Cavity 15 is connected to vacuum source 21, air source 25 and cooling fluid source 23 as they appear in FIG. 2. Plug 17 is connected to air source 25 and cooling fluid source 23. Plug 17 has contact area 31 and shear tool 23 mounted concentric with respect to contact area 31. Shear tool 33 is connected to hydraulic fluid source 27. Shear tool 33 moves axially and at a slower rate with respect to plug contact area 31 as will be discussed later. The exact details of connection to such sources have been omitted in FIGS. 3-7 for purposes of clarity.
In FIG. 4, plug 17 is closing with respect to cavity 15 and vacuum via vacuum source 21 is being applied to the inner surface of disc 3 to pull the molten sheet 11 into contact with disc 3. Specifically, vacuum is applied within cavity 15 through knock out pin 16 and on the surface of disc 3 at the circumference of cavity 15 as noted generally at 18.
In FIG. 5, contact area 31 has forced molten sheet 11 into cavity 15. Shear tool 33 has been moved at a linear speed slower than contact area 31 and is shown in FIG. 5 to be in contact with sheet 11. Plug 17 extends during the molding cycle as shown in FIG. 5 to "plug" the molten sheet and shear tool 33 is about to seat upon the opening of cavity 15 to effect an air-tight seal around the cavity. Once sealed, vacuum is applied through knock out pin 16 via passage 22 to draw the molten sheet 11 into the cavity 15. Compressed air from source 25 may optionally be applied internally through the plug 17 to force the molten sheet 11 in close contact with the mold surfaces. In this way, vacuum in the cavities 15 and/or pressure from the plugs 17 will cause the molten material to come into absolute contact with the inside surfaces of the cavity 15. Contact area 31 and cavity 15 are fluid cooled to harden sheet 11.
With reference to FIG. 6, near the end of the molding cycle shear tool 33 is forced further against the sheet 11 and opposing disc 3, thus shearing the molded part from the plastic sheet. Plug 17 then retracts, as shown in FIG. 7, and the formed sheared part and sheared sheet 11 are subjected to removal means such as knock out pin 16 and means to strip the sheared sheet of material. The sheared sheet may be wound up or transferred directly to a grinder for reprocessing. It is within the scope of the invention to use compressed air alone to dislodge the finished container 20. In such a situation, the knock out pin 16 would be eliminated and an opening would be provided for vacuum or compressed air as desired. Contact area 31 in FIG. 6 is retracted while shear tool 33 severs sheet 11. The molding cycle as discussed above is repeated in a continuous fashion as the discs 1 and 3 rotate through 360°.
FIG. 8 illustrates a detailed cross-section of discs 1 and 3. The specific manifolding of vacuum cooling fluid, compressed air and high pressure fluid to discs 1 and 3 are not shown in detail. The connection of such fluids is shown schematically in the instant invention as rotatable fluid connectors and manifolding means are well known in the art. With reference to FIG. 8, plug 17 has a contact area 31 that is fluid cooled by cooling fluid source 23. Contact area 31 is moved by compressed air source 25. Plug 17 also has a shear tool 33 that is actuated by high pressure hydraulic fluid source 27.
Cavity 15 is cooled by cooling fluid source 23. Vacuum is provided by vacuum source 21 to the surface of disc 3 at the circumference 18 of cavity 15. Vacuum is also connected to knock out pin 16 via passage 22. Cavity 15 is provided with a replaceable shear surface 24 that is complementary with shear tool 33.
It will be understood that numerous changes may be made in the design and construction hereof without departing from the spirit and scope of the invention. | The invention is a process and apparatus for continuously thermoforming plastic containers wherein opposed co-rotating discs process a molten sheet of thermoplastic material having a wedge-shaped cross-section, said discs transporting said thermoplastic material through a plug-assisted pressure and/or vacuum forming station, a shear station and a part removal station. | 1 |
FIELD OF THE INVENTION
The invention generally relates to techniques for monitoring the effectiveness of medical therapies and dosage formulations, and in particular to techniques for monitoring therapy effectiveness using viral load measurements.
BACKGROUND OF THE INVENTION
It is often desirable to determine the effectiveness of therapies, such as those directed against viral infections, including therapies involving individual drugs, combinations of drugs, or other related therapies. One conventional technique for monitoring the effectiveness of a viral infection therapy is to measure and track a viral load associated with the viral infection, wherein the viral load is a measurement of a number of copies of the virus within a given quantity of blood, such per milliliter of blood. The therapy is deemed effective if the viral load is decreased as a result of the therapy. A determination of whether any particular therapy is effective is helpful in determining the appropriate therapy for a particular patient and also for determining whether a particular therapy is effective for an entire class of patients. The latter is typically necessary in order to obtain FDA approval of any new drug or medical device therapy. Viral load monitoring is also useful for research purposes such as for assessing the effectiveness of new antiviral compounds determine, for example, whether it is useful to continue developing particular antiviral compounds or to attempt to gain FDA market approval.
A test to determine the viral load can be done with blood drawn from T-cells or from other standard sources. The viral load is typically reported either as an absolute number, i.e., the number of virus particles per milliliter of blood or on a logarithmic scale. Likewise, decreases in viral load are reported in absolute numbers, logarithmic scales, or as percentages.
It should be noted though that a viral load captures only a fraction of the total virus in the body of the patient, i.e., it tracks only the quantity of circulating virus. However, viral load is an important clinical marker because the quantity of circulating virus is the most important factor in determining disease outcome, as changes in the viral load occur prior to changes in other detectable factors, such as CD4 levels. Indeed, a measurement of the viral load is rapidly becoming the acceptable method for predicting clinical progression of certain diseases such as HIV.
Insofar as HIV is concerned, HIV-progression studies have indicated a significant correlation between the risk of acquiring AIDS and an initial HIV baseline viral load level. In addition to predicting the risk of disease progression, viral load testing is useful in predicting the risk of transmission. In this regard, infected individuals with higher viral load are more likely to transmit the virus than others.
Currently, there are several different systems for monitoring viral load including quantitive polymerase chain reaction (PCR) and nucleic acid hybridization. Herein, the term viral load refers to any virological measurement using RNA, DNA, or p24 antigen in plasma. Note that viral RNA is a more sensitive marker than p24 antigen. p24 antigen has been shown to be detectable in less than 50% asymptomatic individuals. Moreover, levels of viral RNA rise and fall more rapidly than levels of CD4+ lymphocytes. Hence, changes in infection can be detected more quickly using viral load studies based upon viral RNA than using CD4 studies. Moreover, viral load values have to date proven to be an earlier and better predictor of long term patient outcome than CD4-cell counts. Thus, viral load determinations are rapidly becoming an important decision aid for anti-retro viral therapy and disease management. Viral load studies, however, have not yet completely replaced CD+ analysis in part because viral load only monitors the progress of the virus during infection whereas CD4+ analysis monitors the immune system directly. Nevertheless, even where CD4+ analysis is effective, viral load measurements can supplement information provided by the CD4 counts. For example, an individual undergoing long term treatment may appear stable based upon the observation of clinical parameters and CD4 counts. However, the viral load of the patient may nevertheless be increasing. Hence, a measurement of the viral load can potentially assist a physician in determining whether to change therapy despite the appearance of long term stability based upon CD4 counts.
Thus, viral load measurements are very useful. However, there remains considerable room for improvement. One problem with current viral load measurements is that the threshold level for detection, i.e., the nadir of detection, is about 400-500 copies per milliliter. Hence, currently, if the viral load is below 400-500 copies per milliliter, the virus is undetectable. The virus may nevertheless remain within the body. Indeed, considerable quantities of the virus may remain within the lymph system. Accordingly, it would be desirable to provide an improved method for measuring viral load which permits viral load levels of less than 400-500 copies per milliliter to be reliably detected.
Another problem with current viral load measurement techniques is that the techniques are typically only effective for detecting exponential changes in viral loads. In other words, current techniques will only reliably detect circumstances wherein the viral load increases or decreases by an order of magnitude, such by a factor of 10. In other cases, viral load measurements only detect a difference between undetectable levels of the virus and detectable levels of the virus. As can be appreciated, it would be highly desirable to provide an improved method for tracking changes in viral load which does not require an exponential change in the viral load for detection or which does not require a change from an undetectable level to a detectable level. Indeed, with current techniques, an exponential or sub-exponential change in the viral load results only in a linear change in the parameters used to measure the viral load. It would instead be highly desirable to provide a method for monitoring the viral load which converts a linear change in the viral load into an exponential change within the parameters being measured to thereby permit very slight variations in viral load to be reliably detected. In other words, current viral load detection techniques are useful only as a qualitative estimator, rather than as a quantative estimator.
One reason that current viral load measurements do not reliably track small scale fluctuations in the actual number of viruses is that a significant uncertainty in the measurements often occurs. As a result, individual viral load measurements have little statistical significance and a relatively large number of measurements must be made before any statistically significant conclusions can be drawn. As can be appreciated it would be desirable to provide a viral load detection technique which can reliably measure the viral load such that the statistical error associated with a single viral load measurement is relatively low to permit individual viral load measurements to be more effectively exploited.
Moreover, because individual viral load measurements are not particularly significant when using current methods, treatment decisions for individual patients based upon the viral load measurements must be based only upon long term changes or trends in the viral load resulting in a delay in any decision to change therapy. It would be highly desirable to provide an improved method for measuring and tracking viral load such that treatment decisions can be made much more quickly based upon short term trends of measured viral loads.
As noted above, the current nadir of viral load detectability is at 400-500 copies of the virus per milliliter. Anything below that level is deemed to be undetectable. Currently the most successful and potent multi-drug therapies are able to suppress viral load below that level of detection in about 80-90 percent of patients. Thereafter, viral load is no longer an effective indicator of therapy. By providing a viral load monitoring technique which reduces the nadir of detectability significantly, the relative effectiveness of different multi-drug therapies can be more effectively compared. Indeed, new FDA guidelines for providing accelerated approval of a new drug containing regimen requires that the regimen suppress the viral load below the current nadir of detection in about 80 to 85 percent of cases. If the new regimen suppresses the viral load to undetectable levels in less than 80 to 85 percent of the cases, the new drug will gain accelerated approval only if it has other redeeming qualities such as a preferable dosing regimen (such as only once or twice per day), a favorable side effect profile, or a favorable resistance or cross-resistance profile. Thus, the ability of a regimen to suppress the viral load below the level of detection is an important factor in FDA approval. However, because the level of detectability remains relatively high, full approval is currently not granted by the FDA solely based upon the ability of the regimen to suppress the viral load below the minimum level of detection. Rather, for full approval, the FDA may require a further demonstration of the durability of the regimen, i.e., a demonstration that the drug regimen suppresses the viral load below the level of detectability and keeps it below the level of detectability for some period of time.
As can be appreciated, if a new viral load measurement and tracking technique were developed which could reliably detect viral load at levels much lower than the current nadir of detectability, the FDA may be able, using the new technique, to much more precisely determine the effectiveness of a drug regimen for the purposes of granting approval such that a demonstration of the redeeming evalities will no longer be necessary.
For all of these reasons, it would be highly desirable to provide an improved technique for measuring and tracking viral load capable of providing much more precise and reliable estimates of the viral load and in particular capable of reducing the nadir of detectability significantly. The present invention is directed to this end.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the invention, a method is provided for determining the effectiveness of a therapy, such as an anti-viral therapy, by analyzing biochip output patterns generated from biological samples taken at different sampling times from a patient undergoing the therapy. In accordance with the method, a viral diffusion curve associated with a therapy of interest is generated and each of the output patterns representative of hybridization activity is then mapped to coordinates on the viral diffusion curve using fractal filtering. A degree of convergence between the mapped coordinates on the viral diffusion curve is determined. Then, a determination is made as to whether the therapy of interest has been effective based upon the degree of convergence.
In an exemplary embodiment, the viral diffusion curve is spatially parameterized such that samples map to coordinates near the curve maxima, if the viral load is increasing (i.e., therapy or dosage is ineffective). In this manner, any correlation between rate and extent of convergence across different patient samples is exploited to provide a quantitative and qualitative estimate of therapy effectiveness.
Also in the exemplary embodiment, the biological sample is a DNA sample. The output pattern of the biochip is quantized as a dot spectrogram. The viral diffusion curve is generated by inputting parameters representative of viral load studies for the therapy of interest, generating a preliminary viral diffusion curve based upon the viral load studies; and then calibrating a degree of directional causality in the preliminary viral diffusion curve to yield the viral diffusion curve. The parameters representative of the viral load studies include one or more of baseline viral load (BVL) set point measurements at which detection is achieved, BVL at which therapy is recommended and viral load markers at which dosage therapy is recommended. The step of generating the preliminary viral diffusion curve is performed by selecting a canonical equation representative of the viral diffusion curve, determining expectation and mean response parameters for use in parameterizing the equation selected to represent the viral diffusion curve and parameterizing the equation selected to represent the viral diffusion curve to yield the preliminary viral diffusion curve.
Also, in the exemplary embodiment, each dot spectrogram is mapped to the viral diffusion curve using fractal filtering by generating a partitioned iterated fractal system IFS model representative of the dot spectrogram, determining affine parameters for IFS model, and then mapping the dot spectrogram onto the viral diffusion curve using the IFS. Before the dot spectrograms is mapped to the viral diffusion curve, the dot spectrograms are interferometrically enhanced. After the mapping, any uncertainty in the mapped coordinates is compensated for using non-linear information filtering.
In accordance with a second aspect of the invention, a method is provided for determining the viral load within a biological sample by analyzing an output pattern of a biochip to which the sample is applied. In accordance with the method, a viral diffusion curve associated with a therapy of interest is generated and then calibrated using at least two viral load measurements. Then the output pattern for the sample is mapped to coordinates on the calibrated viral diffusion curve using fractal filtering. The viral load is determined from the calibrated viral diffusion curve by interpreting the coordinates of the viral diffusion curve.
Apparatus embodiments are also provided. By exploiting aspects of the invention, disease management decisions related to disease progression, therapy and dosage effectiveness may be made by tracking the coordinates on the viral diffusion curve as successive DNA-/RNA-based microarray samples are collected and analyzed.
BRIEF DESCRIPTION OF THE DRAWINGS
The features, objects, and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout and wherein:
FIG. 1 is a flow chart illustrating an exemplary method for determining the effectiveness of a viral therapy in accordance with the invention.
FIG. 2 is a flow chart illustrating an exemplary method for generating Viral Diffusion Curves for use with the method of FIG. 1 .
FIG. 3 is a flow chart illustrating an exemplary method for mapping dot spectrograms onto Viral Diffusion Curves using fractal filtering for use with the method of FIG. 1 .
FIG. 4 is a block diagram illustrating the effect of the fractal filtering of FIG. 3 .
FIG. 5 is a flow chart illustrating an exemplary method for compensating for uncertainty using non-linear information filtering for use with the method of FIG. 1 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
With reference to the figures, exemplary method embodiments of invention will now be described. The exemplary method will be described primarily with respect to the determination of changes in viral loads based upon the output patterns of a hybridized biochip microarray using DNA samples, but principles of the invention may be applied to other protein-based samples or to other types of output patterns as well.
With reference to FIG. 1, steps will be described for generating viral diffusion curves for use is processing DNA biomicroarray output patterns to determine the effectiveness of therapies imposed upon a patient providing samples for which the outputs are generated. Then, steps will be described for processing the specific output patterns using the VDC's.
An underlying clinical hypothesis of the exemplary method is that antiviral treatment should inhibit viral replication and lower an individual's viral load from baseline or suppress rising values. A stationary or rising viral load after the introduction of antiviral therapy indicates a lack of response to the drug(s) or the development of drug resistance. The VDC exploits the underlying hypothesis in part by correlating the rate of disease progression to a sample point value such that a change in sample point indicates progression.
The Method
At step 100 , parameters representative of viral load studies for the therapy of interest are input. A preliminary viral diffusion curve is generated, at step 102 , based upon the viral load studies. The parameters representative of the viral load studies include baseline viral load (BVL) set point measurements at which detection is achieved, BVL at which therapy is recommended and viral load markers at which dosage therapy is recommended. At step 104 , a degree of directional causality in the preliminary viral diffusion curve is calibrated to yield the final viral diffusion curve.
Steps 100 - 104 are performed off-line for setting up the VDC's. These steps need be performed only once for a given therapy and for a given set of baseline viral load measurements. Thereafter, any number of DNA biomicroarray output patterns may be processed using the VDC's to determine the effectiveness of the therapy. Preferably, VDC's are generated for an entire set of therapies that may be of interest such that, for any new DNA biomicroarray output pattern, the effectiveness of any of the therapies can be quickly determined using the set of VDC's. In general, the aforementioned steps need be repeated only to update the VDC's based upon new and different baseline viral load studies or if new therapies of interest need to be considered.
In the following, steps will be summarized for processing DNA biomicroarray output patterns using the VDC's to determine whether any therapies of interest represented by the VDC's are effective. To determine the effectiveness of therapy at least two samples of DNA to be analyzed are collected from a patient, preferably taken some time apart, and biomicroarray patterns are generated therefrom. In other cases though, the different samples are collected from different patients.
The output patterns for the DNA biomicroarray are referred to herein as dot spectrograms. A dot spectrogram is generated using a DNA biomicroarray for each sample from an N by M DNA biomicroarray. An element of the array is an “oxel”: o(i,j). An element of the dot spectrogram is a hixel: h(i,j). The dot spectrogram is represented by cell amplitudes given by Φ(i,j) for i: 1 to N, and j: 1 to M.
Dot spectrograms are generated from the samples taken at different times using a prefabricated DNA biomicroarray at step 106 . The dot spectrograms are interferometrically enhanced at step 108 . Each dot spectrogram is then mapped to coordinates on the viral diffusion curves using fractal filtering at step 110 . After the mapping, any uncertainty in the mapped coordinates is compensated for at step 112 using non-linear information filtering.
VDC coordinates are initialized at step 114 , then updated in accordance with filtered dot spectrograms at step 116 . A degree of convergence between the mapped coordinates on the viral diffusion curves is then determined at step 118 and a determination is made as to whether the therapy of interest has been effective. The determination is based upon whether the degree of convergence increases from one DNA sample to another. An increase in degree of convergence is representative of a lack of effectiveness of the therapy of interest. Hence, if the degree of convergence decreases, then execution proceeds to step 120 , wherein a signal is output indicating that the therapy is effective. If the degree of convergence increases, then execution proceeds to step 122 wherein VDC temporal scale matching is performed. Then a determination is made at step 124 whether an effectiveness time scale has been exceeded. If exceeded, then a conclusion is drawn that the effectiveness of the viral therapy cannot be established even if more samples are analyzed. If not exceeded, then execution returns to step 106 wherein another sample taken from the same patient at a latter time is analyzed by repeating steps 106 through 118 .
Viral Load Studies
Viral load studies for therapies of interest are parameterized at step 100 as follows. The therapy of interest is selected from a predetermined list of therapies for which viral load studies have been performed. Measurements from viral load studies are input for therapy of interest. As noted, the viral load measurements include one or more of Baseline Viral Load (BVL) set point measurements at which detection is achieved; BVL at which therapy is recommended; and VL markers at which dosage change recommended.
Data for the viral load measurements are obtained, for example, from drug qualification studies on a minimum include dosages, viral limits as well as time cycles within which an anti-viral drug is deemed effective. The data is typically qualified with age/weight outliers and patient history. Attribute relevant to this claim is the γ l or BVL LOW which corresponds to the lowest detection limit shown for a therapy to be effective using conventional assays or any other diagnostic means. BVL NP−LOW denotes the lowest threshold at which viral load is achieved using a nucleotide probe. Using interferometric enhancement technique, BVL NP−LOW <<BVL LOW .
Generation of Viral Diffusion Curves
Referring now to FIG. 2, the viral diffusion curves are generated as follows. An equation is selected for representing the VDC at step 200 . Expectation (μ) and mean response parameters are determined at step 202 for use in parameterizing the selected equation. Then the equation selected to represent the VDC is parameterized at step 204 to yield a numerical representation of the VDC. These steps will now be described in greater detail.
These steps populate a canonical machine representation, denoted as VDC(i, Γ, γ, κ) (which is a special case of Fokker-Planck equation) to calibrate responses from a viral load detection DNA-array based hybridization biomicroarray.
i is the index for a diagnostic condition/therapy of interest,
Γ denotes the parameter vector characterizing the VDC,
λ denotes the clinical endpoints vector that indicates detectability thresholds for a specific DNA-hybridization array implementation
κ correspond to the uncertainty interval estimates.
An example of an equation selected for representing the VDC is: ∂ ρ ∂ t = div ( ∇ Ψ ( x ) ρ ) + Δρ β , ρ ( x , 0 ) = ρ 0 ( x )
The potential (x): n →[0, ∞) is a smooth function, β>0 is selected constant, and ρ 0 (x) is a probability density on n .
Preferably, the diffusion potential of the equation and the BVL data are such that:
Ψ( x )< c.[BVL NP — LOW |BVL LOW ]
the constant c is generally set to
c =[number of amplitude discretization levels][log( PCR amplification factor)*avg(oligonucleotides/oxel)*┌tagging efficiency┐*└binding efficiency┘]
Binding efficiency is difficult to quantify analytically for a biomicroarray device technology. Hence, for use in the above equation, an estimate of the binding efficiency is preferably employed. A binding efficiency of 30% (0.3) is appropriate, though other values may alternatively used. Depending upon the specific biomicroarray used, the constant c typically ranges between 0.0001 to 0.5.
Expectation and Mean Response Parameters
The expectation (μ) and mean response parameters are then determined at step 202 for use in parameterizing the equation selected to represent the VDC. The expectation and mean response values are determined by: 1) performing conventional PCR amplification; 2) obtaining calibrated viral counts from the PCR amplification; 3) determining enhanced and normalized hybridization amplitude mean and variance values corresponding to the calibrated viral counts; and 4) matching the enhanced and normalized hybridization amplitude mean and variance values.
Two synthetic amplification techniques (in addition to PCR and any designer tagging) are used to achieve VL estimation above the BVL limit set for the exemplary embodiment of the method, namely (a) readout pre-conditioning, and (b) nonlinear interferometric enhancement. Moreover, the expectation match condition implies that:
Expectation┌Log(└interferometrically enhanced image┘)┐ v[expression set of interest] /Expectation[preconditioned image amplitude] v[expression set of interest ≡1
Variance matching is done similarly with respect to biomicroarray readout. The lower bound of mean response value can be given by:
Variance[Log(└interferometrically enhanced image┘)┐ v[expression set of interest] /≡1Variance[preconditioned image amplitude] v[expression set of interest
Using the above expression, a conservative lower bound for interferometric enhancement is estimated for each nucleotide expression of interest. Since the array fabrication device is assumed to have (i) an identical oligonucleotide density per oxel and (ii) equal length oligonucleotides, the same mean response amplitude can be assumed. If these two assumptions are not met then bounds need to be individually calculated and averaged using the above formula. Another assumption is that the binding efficiency is statistically independent of the actual oligonucleotide sequence. If this assumption does not hold for the specific device technology then the binding efficiency should be provided as well for each expressed sequence of interest. So the computational analysis method uses the analytically derived lower bounds, as computed using the above equation. This is a one-time calculation only and is done offline at design time.
Parameterization of the VDC
The equation selected to represent the VDC is then parameterized using the expectation and mean response values at step 204 to yield a numerical representation of the VDC using
y ( x )=β 0 +β 1 x+β 2 x 2
subject to constraints x . = γ sin k [ ω α ( β 0 + β 1 x + β 2 x 2 ) ] sin ω t + ɛ ( t )
with constants α, β, γ and ε<<1.
This utility of this parameterization is established as follows. The VDC canonical representation is based on a variational formulation of the Fokker-Planck. The Fokker-Planck (FP) equation, or forward Kolmogorov equation, describes the evolution of the probability density for a stochastic process associated with an Ito stochastic differential equation. The exemplary method exploits the VDC to model a physical time-dependent phenomena in which randomness plays a major role. The specific variant used herein is one for which the drift term is given by the gradient of a potential. For a broad class of potentials (that correspond to statistical variability in therapy response), a time discrete, iterative variational is constructed whose solutions converge to the solution of the Fokker-Planck equation. The time-step is governed by the Wasserstein metric on probability measures. In this formulation the dynamics may be regarded as a gradient flux, or a steepest descent for the free energy with respect to the Wasserstein metric. This parameterization draws from theory of stochastic differential equations: wherein a (normalized) solution to a given Fokker-Planck equation represents the probability density for the position (or velocity) of a particle whose motion is described by a corresponding Ito stochastic differential equation (or Langevin equation). The drift coefficient is a gradient. The method exploits “designer conditions” on the drift and diffusion coefficients so that the stationary solution of a Fokker-Planck equation satisfies a variational principle. It minimizes a certain convex free energy functional over an appropriate admissible class of probability densities.
A physical analogy is to an optimal control problem which is related to the heating of a probe in a kiln. The goal is to control the heating process in such a way that the temperature inside the probe follows a certain desired temperature profile. The biomolecular analogy is to seek a certain property in the parameterized VDC—namely, an exponential jump in the VDC coordinate position for “small linear changes in the viral count”.
This method is in contradistinction to conventional calibration strategies which obtain a linear or superlinear shift in quantization parameter for an exponential shift in actual viral count.
As noted, the form of FP equation chosen is ∂ ρ ∂ t = div ( ∇ Ψ ( x ) ρ ) + Δρ β , ρ ( x , 0 ) = ρ 0 ( x )
where the potential (x): n →[0, ∞) is a smooth function, β>0 is selected constant, and ρ 0 (x) is a probability density on n . The solution ρ(t,x) is a probability density on n for almost every fixed time t. So the distribution ρ(t,x)≧0 for almost every (t,x)ε(0, ∞) X n , and
∫ n ρ( t,x ) dx= 1
for almost every t, ε(0, ∞).
It is reasonably assumed that hybridization array device physics for the DNA biomicroarray (i.e., corresponding to the potential ψ) has an approximately linear response to the nucleotide concentration and the response is monotonic with bounded drift. So, ρ s ( x ) = 1 Z ( - βψ ( x ) )
where the partition function Z is given by Z = ∫ n ( - βψ ( x ) ) x
In this model the basis for device physics design is that the potential needs to be modulated such that it grows rapidly enough for Z to be finite. This is not achieved by conventional methods. However, a technique which does achieve this result is described in U.S. Pat. Nos. 6,136,541, 253,789, 6,136,541 entitled “Method and Apparatus for Analyzing Hybridized Biochip Patterns Using Resonance Interactions Employing Quantum Expressor Functions”, which is incorporated by reference herein.
The probability measure ρ s (x)dx is the unique invariant measure for the Markov random field (MRF) fit to the empirical viral load data.
The method exploits a special dynamical effect to design ρ. The method restricts the FP equation form above to a more restricted case: random walk emulating between critical equilibrium points.
To aid in understanding this aspect of the invention, consider the diffusion form ∂ ρ ( x , t ) ∂ t = 1 2 D 2 ∂ 2 ρ ( x , t ) ∂ 2 t
where
D 2 =πα 2
and α is constant.
A specific VDC shape is parameterized by:
y ( x )=β 0 +β 1 x+β 2 x 2
subject to constraints x . = γ sin k [ ω α ( β 0 + β 1 x + β 2 x 2 ) ] sin ω t + ɛ ( t )
with constants α, β, γ and ε<<1.
These constants are set based upon the dynamic range expected for the viral load. Thus, if the viral load is expected to vary only within a factor of 10, the constants are set accordingly. If the viral load is expected to vary within a greater range, different constants are employed. The actual values of the constants also depend upon the particular disease.
Where the following conditions are met
Expectation match: E(x)=∫ −∞ ∞ xf(x)dx=μ Variance: σ 2 = ∫ - ∞ ∞ ( x - μ ) 2 f x x And ∫ - ∞ ∞ f ( x ) = 1
The expectation and mean response parameters for use in these equations are derived, from matching the enhanced and normalized hybridization amplitude mean and variance that correspond to calibrated viral counts (via classical PCR amplification).
A distribution represented by the above-equations then satisfies the following form with a prescribed probability distribution x . = γ sin k [ ω α y ( x ) ] sin ω t + ɛ ( t )
Assuming: y ′ = y x > β > 0 , β = constant
and
ε( t )=ε 0 ay
such that
{dot over (a)}=a ⅓ ( y− 1)( y+ 1)−ε 0 a
and the distribution controlling equation is
ƒ( x )=0.5| y ′( x )|
such that y(−1)<X<y(1).
The characteristic timescale of response for this system is given by T * = 1 ω arccos [ 1 - B ( 1 / 3 , 1 / 3 ) 2 3 α ω γ ]
the successive points must show a motion with characteristic timescale. The VDC is designed such that sampling time falls well within characteristic time.
As noted the actual information used for populating above the parameters is available from the following: Baseline viral load (BVL) set point measurements at which detection is achieved; BVL at which therapy is recommended; and VL markers at which dosage change recommended.
The following provides an example of preclinical data that is available to to assist in parameterizing the VDC.
NOTIONAL VIRAL LOAD MANAGEMENT EXAMPLE
This is a synthetic example to illustrate how data from clinical studies may be used to calibrate the VDC.
Viral Load analysis studies, using conventional assays, in HIV progression have shown that neither gender, age, HCV co-infection, past history of symptomatic HIV-1 infection, duration of HIV-1 infection nor risk group are associated with a higher risk of increasing baseline viral load (BVL) to the virologic end-point. However, patients with a high (BVL) between 4000 to 6000 copies had a 10-fold higher risk of increasing the level of viral load than patients with a BVL below 1500 copies/ml. Thus, baseline viral load set point measurements provide an important indicator for onset of disease.
Initiation of antiretroviral therapy is generally recommended when the CD4 + T-cell count is <600 cells/mL and the viral load level is >6,000 copies/mL. When the viral load is >28000 copies/mL, initiation of therapy is recommended regardless of other laboratory markers and clinical status.
Effective antiretroviral treatment may be measured by changes in plasma HIV RNA levels. The ideal end point for effective antiviral therapy is to achieve undetectable levels of virus (<400 copies/mL). A decrease in HIV RNA levels of at least 0.5 log suggests effective treatment, while a return to pretreatment values (±0.5 log) suggests failure of drug treatment.
When HIV RNA levels decline initially but return to pretreatment levels, the loss of therapy effectiveness has been associated with the presence of drug-resistant HIV strains.
The therapy-specific preclinical viral load markers (such as low and high limits in the above example) are used to establish actual BVL boundaries for the VDC associated with a particular therapy. In this regard, the deterimination of the BVL parameters is disease specific. For example, in HIV methods such as RT-PCR, bDNA or NASBA are used. Other diseases use other assays. Typically, once the parameters of the VDC equation have been set (i.e. constants α, β, γ and ε), only two viral load markers are needed to complete the parameterization of the VDC. This is in contrast to previous techniques whereby expensive and laborious techiques are required to determine the shape of a viral diffusion curve. The present invention succeeds in using only two viral load markers in most cases by exploiting the canonical VDC described above which has predefined properties and which is predetermined based upon the particular biochip being used.
Calibration of Viral Diffusion Curves
Referring again to FIG. 1, the directional causality of the VDC is calibrated at step 104 in the context of an NIF discussed in greater detail below. At least arbitrarily selected three sample points are used execute the NIF calibration computation. The resulting polynomial is used to extracting qualitative coherence properties of the system.
The spectral [Θ] and temporal coherence [] is incrementally estimated and computed for each mutation/oligonucleotide of interest by a NIF forward estimation computation (described further below). The two estimates are normalized and convolved to yield cross-correlation function over time. The shape index (i.e., curvature) of the minima is used as a measure for directional causality. Absence of curvature divergence is used to detect high directional causality in the system.
Sample Collection
Samples are collected at step 106 subject to a sample point collection separation amount. The separation amount for two samples is preferably within half a “drug effectiveness mean time” covering 2σ population level wherein σ denotes the standard deviation in period before which a effectiveness for a particular drug is indicated. The following are some general guidelines for sample preparation for use with the exemplary method:
It is important that assay specimen requirements be strictly followed to avoid degradation of viral RNA.
A baseline should be established for each patient with two specimens drawn two to four weeks apart.
Patients should be monitored periodically, every three to four months or more frequently if therapy is changed. A viral load level that remains at baseline or a rising level indicates a need for change in therapy.
Too much significance should not be given to any one viral load result. Only sustained increases or decreases of 0.001-0.01 log [conventional methods typically require a 0.3-0.5 log change] or more should be considered significant. Biological and technical variation of up to 0.01 log [typical conventional limit: 0.3 log] is possible. Also, recent immunization, opportunistic infections and other conditions may cause transient increases in viral load levels.
A new baseline for each patient should be established when changing laboratories or methods.
Recommendations for frequency of testing are as follows:
establish baseline: 2 measurements, 2 to 4 weeks apart
every 3 to 4 months or in conjunction with CD4 + T-cell counts
3 to 4 weeks after initiating or changing antiretroviral therapy
shorter intervals as critical decisions are made.
measurements 2-3 weeks apart to determine a baseline measurement.
repeat every 3-6 months thereafter in conjunction with CD4 counts to monitor viral load and T-cell count.
avoid viral load measurements for 3-4 weeks following an immunization or within one month of an infection.
a new baseline for each patient should be established when changing laboratories or methods.
The samples are applied to a prefabricated DNA biomicroarray to generate one or more dot spectrograms each denoted Φ(i,j) for i:1 to N, and j:1 to M. The first sample is referred to herein as the k=1 sample, the second as the k=2 sample, and so on.
Interferometric Enhancement of the Dot Spectrogram
Each dot spectrogram provided by the DNA biomicroarray is filtered at step 108 to yield enhanced dot spectrograms Φ(κ) either by performing a conventional Nucleic Assay Amplification or by applying preconditioning and normalization steps as described in the U.S. Pat. Nos. 6,136,541, 09,253,789 entitled “Method And Apparatus For Analyzing Hybridized Biochip Patterns Using Resonance Interactions Employing Quantum Expressor Functions”. The application is incorporated by reference herein, particularly insofar as the descriptions of the use of preconditioning and normalization curves are concerned.
Fractal Filtering
Each enhanced dot spectrogram is then mapped to the VDC using fractal filtering at step 110 as shown in FIG. 3 by generating a partitioned iterated fractal system 302 , determining affine parameters for the IFS 304 and then mapping the enhanced dot spectrogram onto the VDC using the IFS, step 306 .
The VDC representation models a stochastic process given by W ( f ) ( x , y ) = { γ i · f ( 1 σ i ( x - x D i y - y D i ) + x R i y R i ) + τ ( x - x D i y - y D i ) + β i , if ( x , y ) ∈ μ i - 1 ( 1 ) , for some 1 ≤ i ≤ m ; 0 , otherwise ;
for any (x,y)ε 2 and fε( 2 )
An exemplary partitioned iterated fractal system (IFS) model for the system is
W={Φ i =(μ i , T i )} i =1,2 , . . . , m
where the affine parameters for the IFS transformation are given by T i = ( ( x D i , y D i ) , ( x R i , y R i ) , σ i = ( s 00 i s 01 i s 10 i s 11 i ) , τ i = ( t 0 i , t 1 i ) , γ i , β i , )
where the D-origin is given by (x D i , y D i ),
the R-origin is given by (x R i , y R i )
spatial transformation matrix is given by σ i
the intensity tilting vector is given by τ i
the contrast adjuctment is given by γ i,
the brightness adjustment is given by β i,
and wherein Φ represents the enhanced dot spectrogram and wherein μ represents the calculated expectation match values
This IFS model maps the dot spectrogram to a point on the VDC wherein each VDC coordinate is denoted by VDC(t,Θ) such that
W[Φ, k]→VDC ( k , Θ)
Wherein k represents a sample.
In the above equation, Θ represent the parameters of the IFS map.
Thus the output of step 110 , is a set of VDC coordinates, identified as VDC(k, Φ), with one set of coordinates for each enhanced dot spectrogram k=1, 2 . . . n.
The effect of the steps of FIG. 3 is illustrated in FIG. 4 which shows a set of dot spectrograms 450 , 451 and 452 and a VDC 454 . As illustrated, each dot spectrogram is mapped to a point on the VDC. Convergence toward a single point on the VDC implies ineffectiveness of the viral therapy. A convergence test is described below.
Uncertainty Compensation
With reference to FIG. 5, any uncertainty in the coordinates VDC(k, Θ) is compensated using Non-linear Information Filtering as follows. Biomicroarray dispersion coefficients, hybridization process variability values and empirical variance are determined at step 402 . The biomicroarray dispersion coefficients, hybridization process variability values and empirical variance are then converted at step 404 to parameters for use in NIF. The NIF is then applied at step 406 to the VDC coordinates generated at step 106 of FIG. 1 .
Nonlinear information filter (NIF), is a nonlinear variant of the Extended Kalman Filter. A nonlinear system is considered. Linearizing the state and observation equations, a linear estimator which keeps track of total state estimates is provided. The linearized parameters and filter equations are expressed in information space. This gives a filter that predicts and estimates information about nonlinear state parameters given nonlinear observations and nonlinear system dynamics.
The information Filter (IF) is essentially a Kalman Filter expressed in terms of measures of the amount of about the parameter of interest instead of tracking the states themselves, i.e., track the inverse covariance form of the Kalman filter. Information here is in the Fisher sense, i.e. a measure of the amount of information about a parameter present in the observations.
Uncertainty bars are estimated using NIF algorithm. The parameters depend on biomicroarray dispersion coefficients, hybridization process variability and empirical variance indicated in the trial studies.
One particular advantage of the method of the invention is that it can also be used to capture the dispersion from individual to individual, therapy to therapy etc. It is extremely useful and enabling to the method in that it can be apriori analytically set to a prechosen value and can be used to control the quality of biomicroarray output mapping to VDC coordinates.
The biomicroarray dispersion coefficients, hybridization process variability values and empirical variance are determined as follows. Palm generator functions are used to capture stochastic variability in hybridization binding efficacy. This method draws upon results in stochastic integral geometry and geometric probability theory.
Geometric measures are constructed to estimate and bound the amplitude wanderings to facilitate detection. In particular we seek a measure for each mutation-recognizer centered (MRC-) hixel that is invariant to local degradation. Measure which can be expressed by multiple integrals of the form
m ( Z )=∫ z ƒ( z ) dz
where Z denotes the set of mutations of interest. In other words, we determine the function f(z) under the condition that m(z) should be invariant with respect to all dispersions ξ. Also, up to a constant factor, this measure is the only one which is invariant under a group of motions in a plane. In principle, we derive deterministic analytical transformations on each MRC-hixel., that map error-elliptic dispersion bound defined on 2 (the two dimension Euclidean space—i.e., oxel layout) onto measures defined on . The dispersion bound is given by
Log 4 ( Ô (i,j) | z ).
Such a representation of uniqueness facilitates the rapid decimation of the search space. It is implemented using a filter constructed using measure-theoretic arguments. The transformation under consideration has its theoretical basis in the Palm Distribution Theory for point processes in Euclidean spaces, as well as in a new treatment in the problem of probabilistic description of MRC-hixel dispersion generated by a geometrical processes. Latter is reduced to a calculation of intensities of point processes. Recall that a point process in some product space E×F is a collection of random realizations of that space represented as {(e i , f i ), |e I εE, f i εF }.
The Palm distribution, π of a translation (T n ) invariant, finite intensity point process in n is defined to the conditional distribution of the process. Its importance is rooted in the fact that it provides a complete probabilistic description of a geometrical process.
In the general form, the Palm distribution can be expressed in terms of a Lebesgue factorization of the form
E p N*=ΛL N X π
Where π and Λ completely and uniquely determine the source distribution P of the translation invariant point process. Also, E p N* denotes the first moment measure of the point process and L N is a probability measure.
Thus a determination of π and Λ is needed which can uniquely encode the dispersion and amplitude wandering associated with the MRC-hixel. This is achieved by solving a set of equations involving Palm Distribution for each hybridization (i.e., mutation of interest). Each hybridization is treated as a manifestation of a stochastic point process in 2 .
In order to determine π and Λ we have implemented the following measure-theoretic filter:
Determination of Λ
using integral formulae constructed using the marginal density functions for the point spread associated with MRC-hixel(i,j)
The oligonucleotide density per oxel ρ m(i,j) , PCR amplification protocol (σ m ), fluorescence binding efficiency (η m ) and imaging performance ({overscore (ω)} m ) provide the continuous probability density function for amplitude wandering in the m-th MRC-hixel of interest. Let this distribution be given by (ρ m(i,j) , σ m , η m , {overscore (ω)} m ).
The method requires a preset binding dispersion limit to be provided to compute
(ρ m(i,j) , σ m , η m , {overscore (ω)} m )
ζ. The second moment to the function
at SNR=0 condition is used to provide the bound.
Determination of π
Obtained by solving the inverse problem
π=Θ*P
where
P=∫ τ1 τ2 (ρ m(i,j) ,σ m ,η m ,{overscore (ω)} m )∂τ
where τ 1 and τ 2 represent the normalized hybridization dispersion limits.
The number are empirically plugged in. The values of 0.1 and 0.7 are appropriate for, respectively, signifying loss of 10%-70% hybridization. Also, Θ denotes the distribution of known point process. The form 1/(1+exp(( . . . ))) is employed herein to represent Θ.
The biomicroarray dispersion coefficients, hybridization process variability values and empirical variance are then converted to parameters at step 304 for use in NIF as follows.
The NIF is represented by:
Predicted State= f (current state, observation model, information uncertainty, information model)
Detailed equations are given below.
In the biomicroarray context, NIF is an information-theoretic filter that predicts and estimates information about nonlinear state parameters (quality of observable) given nonlinear observations (e.g., post hybridization imaging) and nonlinear system dynamics (spatio-temporal hybridization degradation). The NIF is expressed in terms of measures of the amount of information about the observable (i.e., parameter of interest) instead of tracking the states themselves. It has been defined as the inverse covariance of the Kalman filter, where the information is in the Fisher sense, i.e, a measure of the amount of information about o I present in the observations Z k where the Fisher information matrix is the covariance of the score function.
In a classical sense the biomicroarray output samples can be described by the nonlinear discrete-time state transition equation of the form:
VDC ( k )=ƒ( VDC ( k− 1),Φ( k− 1), k )+ v ( k )
where
VDC(k−1) is the state at time instant (k−1),
Φ(k−1) is the input vector (embodied by dosage and/or therapy)
v(k) is some additive noise; corresponds to the biomicroarray dispersion as computed by the Palm Generator functions above.
VDC(k) is the state at time k,
f(k, . . . ,) is the nonlinear state transition function mapping previous state and current input to the current state. In this case it is the fractal mapping that provides the VDC coordinate at time k.
The observations of the state of the system are made according to a non-linear observation equation of the form
z ( k )= h ( VDC ( k ))+ w ( k )
where
z(k) is the observation made at time k
VDC(k) is the state at time k,
w(k) is some additive observation noise
and h( . . . ,k) is the current non-linear observation model mapping current state to observations, i.e., sequence-by-hybridization made at time k,
v(k) and w(k) are temporally uncorrelated and zero-mean. This is true for the biomicroarray in how protocol uncertainties, binding dynamics and hybridization degradation are unrelated and additive. The process and observation noises are uncorrelated.
E[v ( i ) w T ( j )]=0 , ∀i,j.
The dispersion coefficients together define the nonlinear observation model.
The nonlinear information prediction equation is given by
ŷ ( k|k− 1)= Y ( k|k− 1) f ( k,{circumflex over (V)}DC ( k− 1 |k− 1), u ( k− 1))
Y ( k|k− 1)=[∇ƒ( k ) Y −1 ( k− 1 |k− 1)∇ƒ x T ( k )+ Q ( k )] −1
The nonlinear estimation equations are given by
ŷ ( k|k )= ŷ ( k|k− 1)+ i ( k )
Y ( k|k )= Y ( k|k− 1)+ I ( k )
where
I ( k )=∇ h x T ( k ) R −1 ( k )∇ h x ( k )
i ( k )=∇ h x T ( k ) R −1 ( k )[ v ( k )+∇ h x ( k ) {circumflex over (V)}DC ( k|k− 1)]
where
v ( k )= z ( k )− h ( {circumflex over (x)} ( k|k− 1)).
In this method NIF helps to bind the variability in the VDC coordinate mapping across sample to sample so that dosage and therapy effectiveness can be accurately tracked.
The NIF is then applied to enhanced, fractal-filtered dot spectrogram at step 306 as follows. States being tracked correspond to post-hybridization dot spectrogram in this method. NIF computation as described above specifies the order interval estimate associated with a VDC point. It will explain and bound the variability in Viral load estimations for the same patient from laboratory to laboratory.
The NIF also specifies how accurate each VDC coordinate is given the observation model and nucleotide set being analyzed.
Convergence Testing
Referring again to FIG. 1, once any uncertainty is compensated, the VDC coordinates are renormalized at step 114 . The renormalized VDC coordinates are patient specific and therapy specific. Alternately the coordinates could be virus/nucleotide marker specific. The NIF-compensated VDC coordinates are renormalized to the first diagnostic sample point obtained using the biomicroarray. Thus a patient can be referenced to any point on the VDC.
This renormalization step ensures that VDC properties are maintained, notwithstanding information uncertainties as indicated by the NIF correction terms. The approach is drawn from “renormalization-group” approach used for dealing with problems with many scales. In general the purpose of renormalization is to eliminate an energy scale, length scale or any other term that could produce an effective interaction with arbitrary coupling constants. The strategy is to tackle the problem in steps, one step for every length scale. In this method the renormalization methodology is abstracted and applied during a posteriori regularization to incorporate information uncertainty and sample-to-sample variations.
This is in contradistinction to current viral load measurement calibration methods that either generate samples with same protocol and same assumptions of uncertainty or use some constant correction term. Both existing approaches skew the viral load readout so that measurements are actually accurate only in a limited “information” and “observability” context. This explains the large variations in readings from different laboratories and technicians for the same patient sample.
Specifically, we include the dynamic NIF correction function to the gradient of the VDC at the sample point normalized in a manner such that when the information uncertainty is null, the correction term vanishes. As discussed in the above steps, the NIF correction terms is actually derived from the noise statistics of the microarray sample.
< VDC ′( k ,Θ)>= VDC ( k ,Θ)+[∇ NIF ( Y,I ) k ]
where ∇NIF(Y,I) k denotes the gradient of nonlinear information prediction function. Under perfect observation model this term vanishes.
Once initialized, the VDC coordinates are then updated at step 116 applying the IFS filter W[ ] on k+1th sample, by
VDC ( k +1,Θ)← W [Biomicroarray Output, K +1];
A direction convergence test is next performed at step 118 to determine whether the selected therapy has been effective. If convergence establishes that the viral load for the patient is moving in a direction representative of a lower viral load, then the therapy is deemed effective. The system is deemed to be converging toward a lower viral load if and only if: VDC ( t k ) - VDC ( t k - j ) VDC ( t k - 1 ) - VDC ( t k - j ) > 1 ⋀ VDC peak - VDC ( t k ) VDC peak - VDC ( t k - 1 ) < 1 for k > 2 and j > 0
The above relationships needs to be monotonically persistent for at least two combinations of k and j.
Also, date[k]−date[j]<κ*characteristic time, {haeck over (t)}(in days)
Where κ captures the population variability. Typically, κ<1.2.
The peak VDC value is determined based on the VDC. The peak amplitude is an artifact of the specific parameterization to the Fokker-Planck equation used in deriving the VDC. It is almost always derived independent of the specific sample.
In connection with step 118 , a VDC Shift factor A may be specified at which a dosage effectiveness decision and/or disease progression decision can be made. The VDC shift factor is applied to estimate the VDC curvature traversed between two measurements.
If the system is deemed to be converging toward a lower viral load, an output signal is generated indicating that the therapy of interest is effective at step 120 . If not, then the execution proceeds to step 122 wherein VDC scale matching is performed. A key assumption underlying this method is that movement along VDC is significant if and only if the sample points are with a constant multiple of temporal scale characterizing the VDC. This does not in any way preclude the pharmacological relevance associated with the datapoints. But complete pharmacological interpretation of the sample points is outside the scope of this method. The process is assumed to be cyclostationary or at a large time scale and two or more sample points have been mapped to VDC coordinates. The coordinates are then plugged into an analytic to estimate the empirical cycle time ({haeck over (t)}). This is implemented as described in the following sections.
Again the empirical cycle time ({haeck over (t)}) is used to establish decision convergence.
Scale Matching
Select a forcing function of the form:
= k. m cos ω t
where k is a constant and m is a small odd integer (m<7).
The phase space for this dynamical system is represented by: x . = γ sin [ ω α erf m ( x σ 2 ) ] k k + 2 sin ω t
where erf m ( x ) = { - 1 if x < - N erf ( x ) if x ≤ N 1 x > N
and erf m(.) denotes the error function.
K is set to 1; where o<α, γ, ω<1 are refer to constants.
Let τ emp denote the cycle-time-scale for this empirical system.
If log e (τ emp /T)>1 (in step 10 ) then we claim that time-scales do not match:
Time Scale Testing
Next a determination has been made as to whether an effectiveness timescale has been exceeded at step 124 by:
Checking if a time step between successive sampling has exceeded T by
determining if Time k+1 −Time k >T
such that VDC(k+1,Θ)−VDC(k,Θ)< where
is set to 0.0001 and wherein
T is given by T * = 1 ω arccos [ 1 - B ( 1 / 3 , 1 / 3 ) 2 3 α ω γ ]
B(1/3,1/3) represents the Beta function around the coordinates (1/3,1/3), We can actually use all B(1/2i+1,1/2i+1) for i>1 and i<7.
If Time k+1 −Time k >T then output signal at step 126 indicating that either
no change in viral load concluded, OR
therapy deemed ineffective, OR
dosage deemed suboptimal.
If Time k+1 −Time k <T then process another sample by repeating all steps beginning with Step 4 wherein a dot spectrogram is generated for a new sample.
If the effectiveness time scale has been exceeded then a signal is output indicating that no determination can be as to whether the therapy of interest is effective. If the time scale is not exceeded, then execution returns to step 106 for processing another sample. If available, and the processing steps are repeated.
Alternative Implementations
Details regarding a related implementation may be found in U.S. Pat. No. 6,136,541, herewith, entitled “Method and Apparatus for Interpreting Hybridized Bioelectronic DNA Microarray Patterns Using Self Scaling Convergent Reverberant Dynamics”, and incorporated by reference herein.
The exemplary embodiments have been primarily described with reference to flow charts illustrating pertinent features of the embodiments. Each method step also represents a hardware or software component for performing the corresponding step. These components are also referred to herein as a “means for” performing the step. It should be appreciated that not all components of a complete implementation of a practical system are necessarily illustrated or described in detail. Rather, only those components necessary for a thorough understanding of the invention have been illustrated and described in detail. Actual implementations may contain more components or, depending upon the implementation, may contain fewer components.
The description of the exemplary embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art and the generic principles defined herein may be applied to other embodiments without the use of the inventive faculty. Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A technique is described for determining the effectiveness of medical therapy and dosage formulations by analyzing dot spectrograms representative of quantized hybridization activity in biological samples, such as DNA, RNA, or other protein biomolecular array samples, taken at different times from a patient undergoing the medical therapy. This technique enables disease progression analysis based on surrogate markers such as viral load. In accordance with the technique, a viral diffusion curve associated with a therapy of interest is generated and each dot spectrogram is then mapped to a viral diffusion curve using fractal filtering. Next, degree of convergence towards the peak of VDC, between the sample points on a filtered viral diffusion curve is determined. The technique allows for point-of-care viral load detection biosensors to accurately and reliably predict the likelihood of disease progression. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. application Ser. No. 14/849,981, filed Sep. 10, 2015, which is a Divisional of U.S. application Ser. No. 13/933,623, filed Jul. 2, 2013, which is a Continuation of U.S. application Ser. No. 13/548,446, filed Jul. 13, 2012, which is a Continuation of U.S. application Ser. No. 12/334,731, filed Dec. 15, 2008, which claims priority from U.S. Provisional Patent Application 61/014,232, filed Dec. 17, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to a process for producing prostacyclin derivatives and novel intermediate compounds useful in the process.
[0003] Prostacyclin derivatives are useful pharmaceutical compounds possessing activities such as platelet aggregation inhibition, gastric secretion reduction, lesion inhibition, and bronchodilation.
[0004] Treprostinil, the active ingredient in Remodulin®, was first described in U.S. Pat. No. 4,306,075. Treprostinil, and other prostacyclin derivatives have been prepared as described in Moriarty, et al in J. Org. Chem. 2004, 69, 1890-1902, Drug of the Future, 2001, 26(4), 364-374, U.S. Pat. Nos. 6,441,245, 6,528,688, 6,765,117 and 6,809,223. Their teachings are incorporated by reference to show how to practice the embodiments of the present invention.
[0005] U.S. Pat. No. 5,153,222 describes use of treprostinil for treatment of pulmonary hypertension. Treprostinil is approved for the intravenous as well as subcutaneous route, the latter avoiding septic events associated with continuous intravenous catheters. U.S. Pat. Nos. 6,521,212 and 6,756,033 describe administration of treprostinil by inhalation for treatment of pulmonary hypertension, peripheral vascular disease and other diseases and conditions. U.S. Pat. No. 6,803,386 discloses administration of treprostinil for treating cancer such as lung, liver, brain, pancreatic, kidney, prostate, breast, colon and head-neck cancer. U.S. patent application publication No. 2005/0165111 discloses treprostinil treatment of ischemic lesions. U.S. Pat. No. 7,199,157 discloses that treprostinil treatment improves kidney functions. U.S. patent application publication No. 2005/0282903 discloses treprostinil treatment of neuropathic foot ulcers. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008, discloses treprostinil treatment of pulmonary fibrosis. U.S. Pat. No. 6,054,486 discloses treatment of peripheral vascular disease with treprostinil. U.S. patent application Ser. No. 11/873,645 filed Oct. 17, 2007 discloses combination therapies comprising treprostinil. U.S. publication No. 2008/0200449 discloses delivery of treprostinil using a metered dose inhaler. U.S. publication No. 2008/0280986 discloses treatment of interstitial lung disease with treprostinil. U.S. application Ser. No. 12/028,471 filed Feb. 8, 2008 discloses treatment of asthma with treprostinil. U.S. Pat. Nos. 7,417,070, 7,384,978 and U.S. publication Nos. 2007/0078095, 2005/0282901, and 2008/0249167 describe oral formulations of treprostinil and other prostacyclin analogs.
[0006] Because Treprostinil, and other prostacyclin derivatives are of great importance from a medicinal point of view, a need exists for an efficient process to synthesize these compounds on a large scale suitable for commercial production.
SUMMARY
[0007] The present invention provides in one embodiment a process for the preparation of a compound of formula I, hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof.
[0000]
[0008] The process comprises the following steps:
[0009] (a) alkylating a compound of structure II with an alkylating agent to produce a compound of formula III,
[0000]
[0010] wherein
w=1, 2, or 3; Y 1 is trans-CH═CH—, cis-CH═CH—, —CH 2 (CH 2 ) m —, or —C≡C—; m is 1, 2, or 3; R 7 is (1) —C p H 2p —CH 3 , wherein p is an integer from 1 to 5, inclusive, (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 ) alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R 7 is phenoxy or substituted phenoxy, only when R 3 and R 4 are hydrogen or methyl, being the same or different, (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, (4) cis-CH═CH—CH 2 —CH 3 , (5) —(CH 2 ) 2 —CH(OH)—CH 3 , or (6) —(CH 2 ) 3 —CH═C(CH 3 ) 2 ; wherein —C(L 1 )—R 7 taken together is (1) (C 4 -C 7 )cycloalkyl optionally substituted by 1 to 3 (C 1 -C 5 )alkyl; (2) 2-(2-furyl)ethyl, (3) 2-(3-thienyl)ethoxy, or (4) 3 -thienyloxymethyl; M 1 is α-OH:β-R 5 or α-R 5 :β-OH or α-OR 2 :β-R 5 or α-R 5 :β-OR 2 , wherein R 5 is hydrogen or methyl, R 2 is an alcohol protecting group, and L 1 is α-R 3 :β-R 4 , α-R 4 :β-R 3 , or a mixture of α-R 3 :β-R 4 and α-R 4 :β-R 3 , wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro.
[0027] (b) hydrolyzing the product of step (a) with a base,
[0028] (c) contacting the product of step (b) with a base B to for a salt of formula I s
[0000]
[0029] (d) reacting the salt from step (c) with an acid to form the compound of formula I.
[0030] The present invention provides in another embodiment a process for the preparation of a compound of formula IV.
[0000]
[0031] The process comprises the following steps:
[0032] (a) alkylating a compound of structure V with an alkylating agent to produce a compound of formula VI,
[0000]
[0033] (b) hydrolyzing the product of step (a) with a base,
[0034] (c) contacting the product of step (b) with a base B to for a salt of formula IV s , and
[0000]
[0035] (d) reacting the salt from step (b) with an acid to form the compound of formula IV.
DETAILED DESCRIPTION
[0036] The various terms used, separately and in combinations, in the processes herein described are defined below.
[0037] The expression “comprising” means “including but not limited to.” Thus, other non-mentioned substances, additives, carriers, or steps may be present. Unless otherwise specified, “a” or “an” means one or more.
[0038] C 1-3 -alkyl is a straight or branched alkyl group containing 1-3 carbon atoms. Exemplary alkyl groups include methyl, ethyl, n-propyl, and isopropyl.
[0039] C 1-3 -alkoxy is a straight or branched alkoxy group containing 1-3 carbon atoms. Exemplary alkoxy groups include methoxy, ethoxy, propoxy, and isopropoxy.
[0040] C 4-7 -cycloalkyl is an optionally substituted monocyclic, bicyclic or tricyclic alkyl group containing between 4-7 carbon atoms. Exemplary cycloalkyl groups include but not limited to cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl.
[0041] Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintains the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein.
[0042] As used herein, the term “prodrug” means a derivative of a compound that can hydrolyze, oxidize, or otherwise react under biological conditions (in vitro or in vivo) to provide an active compound. Examples of prodrugs include, but are not limited to, derivatives of a compound that include biohydrolyzable groups such as biohydrolyzable amides, biohydrolyzable esters, biohydrolyzable carbamates, biohydrolyzable carbonates, biohydrolyzable ureides, and biohydrolyzable phosphate analogues (e.g., monophosphate, diphosphate or triphosphate).
[0043] As used herein, “hydrate” is a form of a compound wherein water molecules are combined in a certain ratio as an integral part of the structure complex of the compound.
[0044] As used herein, “solvate” is a form of a compound where solvent molecules are combined in a certain ratio as an integral part of the structure complex of the compound.
[0045] “Pharmaceutically acceptable” means in the present description being useful in preparing a pharmaceutical composition that is generally safe, non-toxic and neither biologically nor otherwise undesirable and includes being useful for veterinary use as well as human pharmaceutical use.
[0046] “Pharmaceutically acceptable salts” mean salts which are pharmaceutically acceptable, as defined above, and which possess the desired pharmacological activity. Such salts include acid addition salts formed with organic and inorganic acids, such as hydrogen chloride, hydrogen bromide, hydrogen iodide, sulfuric acid, phosphoric acid, acetic acid, glycolic acid, maleic acid, malonic acid, oxalic acid, methanesulfonic acid, trifluoroacetic acid, fumaric acid, succinic acid, tartaric acid, citric acid, benzoic acid, ascorbic acid and the like. Base addition salts may be formed with organic and inorganic bases, such as sodium, ammonia, potassium, calcium, ethanolamine, diethanolamine, N-methylglucamine, choline and the like. Included in the invention are pharmaceutically acceptable salts or compounds of any of the formulae herein.
[0047] Depending on its structure, the phrase “pharmaceutically acceptable salt,” as used herein, refers to a pharmaceutically acceptable organic or inorganic acid or base salt of a compound. Representative pharmaceutically acceptable salts include, e.g., alkali metal salts, alkali earth salts, ammonium salts, water-soluble and water-insoluble salts, such as the acetate, amsonate (4,4-diaminostilbene-2,2-disulfonate), benzenesulfonate, benzonate, bicarbonate, bisulfate, bitartrate, borate, bromide, butyrate, calcium, calcium edetate, camsylate, carbonate, chloride, citrate, clavulariate, dihydrochloride, edetate, edisylate, estolate, esylate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexafluorophosphate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, 3-hydroxy-2-naphthoate, oleate, oxalate, palmitate, pamoate (1,1-methene-bis-2-hydroxy-3-naphthoate, einbonate), pantothenate, phosphate/diphosphate, picrate, polygalacturonate, propionate, p-toluenesulfonate, salicylate, stearate, subacetate, succinate, sulfate, sulfosalicylate, suramate, tannate, tartrate, teoclate, tosylate, triethiodide, and valerate salts.
[0048] The present invention provides for a process for producing treprostinil and other prostacyclin derivatives and novel intermediate compounds useful in the process. The process according to the present invention provides advantages on large-scale synthesis over the existing method. For example, the purification by column chromatography is eliminated, thus the required amount of flammable solvents and waste generated are greatly reduced. Furthermore, the salt formation is a much easier operation than column chromatography. Moreover, it was found that the product of the process according to the present invention has higher purity. Therefore the present invention provides for a process that is more economical, safer, faster, greener, easier to operate, and provides higher purity.
[0049] One embodiment of the present invention is a process for the preparation of a compound of formula I, or a hydrate, solvate, prodrug, or pharmaceutically acceptable salt thereof.
[0000]
[0050] The process comprises the following steps:
[0051] (a) alkylating a compound of formula II with an alkylating agent to produce a compound of formula III,
[0000]
[0052] wherein
w=1, 2, or 3; Y 1 is trans-CH═CH—, cis-CH═CH—, —CH 2 (CH 2 ) m —, or —C≡C—; m is 1, 2, or 3; R 7 is (1) —C p H 2p —CH 3 , wherein p is an integer from 1 to 5, inclusive, (2) phenoxy optionally substituted by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 ) alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, with the proviso that R 7 is phenoxy or substituted phenoxy, only when R 3 and R 4 are hydrogen or methyl, being the same or different, (3) phenyl, benzyl, phenylethyl, or phenylpropyl optionally substituted on the aromatic ring by one, two or three chloro, fluoro, trifluoromethyl, (C 1 -C 3 )alkyl, or (C 1 -C 3 )alkoxy, with the proviso that not more than two substituents are other than alkyl, (4) cis-CH═CH—CH 2 —CH 3 , (5) —(CH 2 ) 2 —CH(OH)—CH 3 , or (6) —(CH 2 ) 3 —CH═C(CH 3 ) 2 ; wherein —C(L 1 )-R 7 taken together is (1) (C 4 -C 7 )cycloalkyl optionally substituted by 1 to 3 (C 1 -C 5 )alkyl; (2) 2-(2-furyl)ethyl, (3) 2-(3-thienyl)ethoxy, or (4) 3 -thienyloxymethyl; M 1 is α-OH:β-R 5 or α-R 5 :β-OH or α-OR 2 :β-R 5 or α-R 5 :β-OR 2 , wherein R 5 is hydrogen or methyl, R 2 is an alcohol protecting group, and L 1 is α-R 3 :β-R 4 , α-R 4 :β-R 3 , or a mixture of α-R 3 :β-R 4 and α-R 4 :β-R 3 , wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is fluoro only when the other is hydrogen or fluoro.
[0069] (b) hydrolyzing the product of step (a) with a base,
[0070] (c) contacting the product of step (b) with a base B to for a salt of formula I s
[0000]
[0071] (d) reacting the salt from step (c) with an acid to form the compound of formula I.
[0072] In one embodiment, the compound of formula I is at least 90.0%, 95.0%, 99.0%.
[0073] The compound of formula II can be prepared from a compound of formula XI, which is a cyclization product of a compound of formula X as described in U.S. Pat. No. 6,441,245.
[0000]
Wherein n is 0, 1, 2, or 3.
[0074] The compound of formula II can be prepared alternatively from a compound of formula XIII, which is a cyclization product of a compound of formula XII as described in U.S. Pat. No. 6,700,025.
[0000]
[0075] One embodiment of the present invention is a process for the preparation of a compound having formula IV, or a hydrate, solvate, or pharmaceutically acceptable salt thereof.
[0000]
[0076] The process comprises
[0077] (a) alkylating a compound of structure V with an alkylating agent such as ClCH 2 CN to produce a compound of formula VI,
[0000]
[0078] (b) hydrolyzing the product of step (a) with a base such as KOH,
[0079] (c) contacting the product of step (b) with a base B such as diethanolamine to for a salt of the following structure, and
[0000]
[0080] (d) reacting the salt from step (b) with an acid such as HCl to form the compound of formula IV.
[0081] In one embodiment, the purity of compound of formula IV is at least 90.0%, 95.0%, 99.0%, 99.5%.
[0082] In one embodiment, the process further comprises a step of isolating the salt of formula IV s .
[0083] In one embodiment, the base B in step (c) may be ammonia, N-methylglucamine, procaine, tromethanine, magnesium, L-lysine, L-arginine, or triethanolamine.
[0084] The following abbreviations are used in the description and/or appended claims, and they have the following meanings:
[0085] “MW” means molecular weight.
[0086] “Eq.” means equivalent.
[0087] “TLC” means thin layer chromatography.
[0088] “HPLC” means high performance liquid chromatography.
[0089] “PMA” means phosphomolybdic acid.
[0090] “AUC” means area under curve.
[0091] In view of the foregoing considerations, and specific examples below, those who are skilled in the art will appreciate that how to select necessary reagents and solvents in practicing the present invention.
[0092] The invention will now be described in reference to the following Examples. These examples are not to be regarded as limiting the scope of the present invention, but shall only serve in an illustrative manner.
EXAMPLES
Example 1
Alkylation of Benzindene Triol
[0093]
[0000]
Name
MW
Amount
Mol.
Eq.
Benzindene Triol
332.48
1250
g
3.76
1.00
K 2 CO 3 (powder)
138.20
1296
g
9.38
2.50
CICH 2 CN
75.50
567
g
7.51
2.0
Bu 4 NBr
322.37
36
g
0.11
0.03
Acetone
—
29
L
—
—
Celite ® 545
—
115
g
—
—
[0094] A 50-L, three-neck, round-bottom flask equipped with a mechanical stirrer and a thermocouple was charged with benzindene triol (1250 g), acetone (19 L) and K 2 CO 3 (powdered) (1296 g), chloroacetonitrile (567 g), tetrabutylammonium bromide (36 g). The reaction mixture was stirred vigorously at room temperature (23±2° C.) for 16-72 h. The progress of the reaction was monitored by TLC. (methanol/CH 2 Cl 2 ; 1:9 and developed by 10% ethanolic solution of PMA). After completion of reaction, the reaction mixture was filtered with/without Celite pad. The filter cake was washed with acetone (10 L). The filtrate was concentrated in vacuo at 50-55° C. to give a light-brown, viscous liquid benzindene nitrile. The crude benzindene nitrile was used as such in the next step without further purification.
Example 2
Hydrolysis of Benzindene Nitrile
[0095]
[0000]
Name
MW
Amount
Mol.
Eq.
Benzindene Nitrile
371.52
1397
g*
3.76
1.0
KOH
56.11
844
g
15.04
4.0
Methanol
—
12
L
—
—
Water
—
4.25
L
—
—
*Note:
This weight is based on 100% yield from the previous step. This is not isolated yield.
[0096] A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of benzindene nitrile in methanol (12 L) and a solution of KOH (844 g of KOH dissolved in 4.25 L of water). The reaction mixture was stirred and heated to reflux (temperature 72.2° C.). The progress of the reaction was monitored by TLC (for TLC purpose, 1-2 mL of reaction mixture was acidified with 3M HCl to pH 1-2 and extracted with ethyl acetate. The ethyl acetate extract was used for TLC; Eluent: methanol/CH 2 Cl 2 ; 1:9, and developed by 10% ethanolic solution of PMA). After completion of the reaction (˜5 h), the reaction mixture was cooled to −5 to 10° C. and quenched with a solution of hydrochloric acid (3M, 3.1 L) while stirring. The reaction mixture was concentrated in vacuo at 50-55° C. to obtain approximately 12-14 L of condensate. The condensate was discarded.
[0097] The aqueous layer was diluted with water (7-8 L) and extracted with ethyl acetate (2×6 L) to remove impurities soluble in ethyl acetate. To aqueous layer, ethyl acetate (22 L) was added and the pH of reaction mixture was adjusted to 1-2 by adding 3M HCl (1.7 L) with stirring. The organic layer was separated and the aqueous layer was extracted with ethyl acetate (2×11 L). The combined organic layers were washed with water (3×10 L) and followed by washing with a solution of NaHCO 3 (30 g of NaHCO 3 dissolved in 12 L of water). The organic layer was further washed with saturated solution of NaCl (3372 g of NaCl dissolved in water (12 L)) and dried over anhydrous Na 2 SO 4 (950-1000 g), once filtered.
[0098] The filtrate was transferred into a 72-L reactor equipped with mechanical stirrer, a condenser, and a thermocouple. To the solution of treprostinil in reactor was added activated carbon (110-130 g). The suspension was heated to reflux (temperature 68-70° C.) for at least one hour. For filtration, a pad of Celite® 545 (300-600 g) was prepared in sintered glass funnel using ethyl acetate. The hot suspension was filtered through the pad of Celite® 545. The Celite® 545 was washed with ethyl acetate until no compound was seen on TLC of the washings.
[0099] The filtrate (pale-yellow) was reduced to volume of 35-40 L by evaporation in vacuo at 50-55° C. for direct use in next step.
Example 3
Conversion of Treprostinil to Treprostinil Diethanolamine Salt (1:1)
[0100]
[0000]
Name
MW
Amount
Mol
Eq
Treprostinil
390.52
1464
g*
3.75
1.0
Diethanolamine
105.14
435
g
4.14
1.1
Ethanol
—
5.1
L
—
—
Ethyl acetate
—
35
L**
—
—
Treprostinil Diethanolamine
—
12
g
—
—
Salt (seed)
*Note:
This weight is based on 100% yield from benzindene triol. It is not isolated yield. The treprostinil was carried from previous step in ethyl acetate solution and used as such for this step.
**Note:
The total volume of ethyl acetate should be in range of 35-36 L (it should be 7 times the volume of ethanol used). Approximately 35 L of ethyl acetate was carried over from previous step and additional 1.0 L of ethyl acetate was used for rinsing the flask.
[0101] A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with a solution of treprostinil in ethyl acetate (35-40 L from the previous step), anhydrous ethanol (5.1 L) and diethanolamine (435 g). While stirring, the reaction mixture was heated to 60-75° C., for 0.5-1.0 h to obtain a clear solution. The clear solution was cooled to 55±5° C. At this temperature, the seed of polymorph B of treprostinil diethanolamine salt (˜12 g) was added to the clear solution. The suspension of polymorph B was stirred at this temperature for 1 h. The suspension was cooled to 20±2° C. overnight (over a period of 16-24 h). The treprostinil diethanolamine salt was collected by filtration using Aurora filter equipped with filter cloth, and the solid was washed with ethyl acetate (2×8 L). The treprostinil diethanolamine salt was transferred to a HDPE/glass container for air-drying in hood, followed by drying in a vacuum oven at 50±5° C. under high vacuum.
[0102] At this stage, if melting point of the treprostinil diethanolamine salt is more than 104° C., it was considered polymorph B. There is no need of recrystallization. If it is less than 104° C., it is recrystallized in EtOH-EtOAc to increase the melting point.
[0103] Data on Treprostinil Diethanolamine Salt (1:1)
[0000]
Wt. of
Wt. of Treprostinil
Melting
Benzindene
Diethanolamine
Yield
point
Batch No.
Triol (g)
Salt (1:1) (g)
(%)
(° C.)
1
1250
1640
88.00
104.3-106.3
2
1250
1528
82.00*
105.5-107.2
3
1250
1499
80.42**
104.7-106.6
4
1236
1572
85.34
105-108
*Note:
In this batch, approximately 1200 mL of ethyl acetate solution of treprostinil before carbon treatment was removed for R&D carbon treatment experiments.
**Note:
This batch was recrystallized, for this reason yield was lower.
Example 4
Heptane Slurry of Treprostinil Diethanolamine Salt (1:1)
[0104]
[0000]
Name
Batch No.
Amount
Ratio
Treprostinil Diethanolamine Salt
1
3168
g
1
Heptane
—
37.5
L
12
Treprostinil Diethanolamine Salt
2
3071
g
1
Heptane
—
36.0
L
12
[0105] A 50-L, cylindrical reactor equipped with a heating/cooling system, a mechanical stirrer, a condenser, and a thermocouple was charged with slurry of treprostinil diethanolamine salt in heptane (35-40 L). The suspension was heated to 70-80° C. for 16-24 h. The suspension was cooled to 22±2° C. over a period of 1-2 h. The salt was collected by filtration using Aurora filter. The cake was washed with heptane (15-30 L) and the material was dried in Aurora filter for 1 h. The salt was transferred to trays for air-drying overnight in hood until a constant weight of treprostinil diethanolamine salt was obtained. The material was dried in oven under high vacuum for 2-4 h at 50-55° C.
[0106] Analytical Data on and Treprostinil Diethanolamine Salt (1:1)
[0000]
Test
Batch 1
Batch 2
IR
Conforms
Conforms
Residue on Ignition (ROI)
<0.1% w/w
<0.1% w/w
Water content
0.1% w/w
0.0% w/w
Melting point
105.0-106.5° C.
104.5-105.5° C.
Specific rotation [α] 25 589
+34.6°
+35°
Organic volatile impurities
Ethanol
Not detected
Not detected
Ethyl acetate
Not detected
<0.05% w/w
Heptane
<0.05% w/w
<0.05% w/w
HPLC (Assay)
100.4%
99.8%
Diethanolamine
Positive
Positive
Example 5
Conversion of Treprostinil Diethanolamine Salt (1:1) to Treprostinil
[0107]
[0108] A 250-mL, round-bottom flask equipped with magnetic stirrer was charged with treprostinil diethanolamine salt (4 g) and water (40 mL). The mixture was stirred to obtain a clear solution. To the clear solution, ethyl acetate (100 mL) was added. While stirring, 3M HCl (3.2 mL) was added slowly until pH ˜1 was attained. The mixture was stirred for 10 minutes and organic layer was separated. The aqueous layer was extracted with ethyl acetate (2×100 mL). The combined organic layers was washed with water (2×100 mL), brine (1×50 mL) and dried over anhydrous Na 2 SO 4 . The ethyl acetate solution of treprostinil was filtered and the filtrate was concentrated under vacuum at 50° C. to give off-white solid. The crude treprostinil was recrystallized from 50% ethanol in water (70 mL). The pure treprostinil was collected in a Buchner funnel by filtration and cake was washed with cold 20% ethanolic solution in water. The cake of treprostinil was air-dried overnight and further dried in a vacuum oven at 50° C. under high vacuum to afford 2.9 g of treprostinil (Yield 91.4%, purity (HPLC, AUC, 99.8%).
[0109] Analytical Data on Treprostinil from Treprostinil Diethanolamine Salt (1:1) to Treprostinil
[0000]
Batch No.
Yield
Purity (HPLC)
1
91.0%
99.8% (AUC)
2
92.0%
99.9% (AUC)
3
93.1%
99.7% (AUC)
4
93.3%
99.7% (AUC)
5
99.0%
99.8% (AUC)
6
94.6%
99.8% (AUC)
Example 6
Comparison of the Former Process and a Working Example of the Process According to the Present Invention
[0110]
[0000]
Working example
of the Process according
Step
Former Process
to the present invention
No.
Steps
(Batch size: 500 g)
(Batch size: 5 kg)
Nitrile
1
Triol weight
500
g
5,000
g
2
Acetone
20
L (1:40 wt/wt)
75
L (1:15 wt/wt)
3
Potassium carbonate
1,300
g (6.4 eq)
5,200
g (2.5 eq)
4
Chloroacetonitrile
470
g (4.2 eq)
2,270
g (2 eq)
5
Tetrabutylammonium
42
g (0.08 eq)
145
g (0.03 eq)
bromide
6
Reactor size
72-Liter
50-gallon
7
Reflux time
8
hours
No heating,
Room temperature
(r.t.) 45 h
8
Hexanes addition
Yes (10 L)
No
before filtration
9
Filter
Celite
Celite
10
Washing
Ethyl acetate (10 L)
Acetone (50 L)
11
Evaporation
Yes
Yes
12
Purification
Silica gel column
No column
Dichloromethane: 0.5 L
Ethyl acetate: 45 L
Hexane: 60 L
13
Evaporation after
Yes
No
column
14
Yield of nitrite
109-112%
Not checked
Treprostinil (intermediate)
15
Methanol
7.6
L
50
L
(50-L reactor)
(50-gal reactor)
16
Potassium hydroxide
650
g (8 eq)
3,375
g (4 eq)
17
Water
2.2
L
17
L
18
% of KOH
30%
20%
19
Reflux time
3-3.5
h
4-5
h
20
Acid used
2.6
L (3 M)
12
L (3 M)
21
Removal of impurities
3 × 3
L Ethyl acetate
2 × 20
L Ethyl acetate
22
Acidification
0.7
L
6.5
L
23
Ethyl acetate
5 × 17
L = 35 L
90 + 45 + 45 = 180 L
extraction
24
Water washing
2 × 8
L
3 × 40
L
25
Sodium bicarbonate
Not done
120 g in 30 L water + 15 L brine
washing
26
Brine washing
Not done
1 × 40
L
27
Sodium sulfate
1
kg
Not done
28
Sodium sulfate
Before charcoal, 6 L
N/A
filtration
ethyl acetate
29
Charcoal
170 g, reflux for 1.5 h,
Pass hot solution (75° C.) through
filter over Celite, 11 L
charcoal cartridge and clean
ethyl acetate
filter, 70 L ethyl acetate
30
Evaporation
Yes, to get solid
Yes, adjust to 150 L solution
intermediate treprostinil
Treprostinil Diethanolamine Salt
31
Salt formation
Not done
1,744 g diethanolamine, 20 L
ethanol at 60-75° C..
32
Cooling
N/A
To 20° C. over weekend; add
40 L ethyl acetate; cooled to
10° C.
33
Filtration
N/A
Wash with 70 L ethyl acetate
34
Drying
N/A
Air-dried to constant wt., 2 days
Treprostinil (from 1.5 kg Treprostinil diethanolamine salt)
35
Hydrolysis
N/A
15 L water + 25 L ethyl acetate +
HCl
36
Extraction
N/A
2 × 10
L ethyl acetate
37
Water wash
N/A
3 × 10
L
38
Brine wash
N/A
1 × 10
L
39
Sodium sulfate
N/A
1
kg, stir
40
Filter
N/A
Wash with 6 L ethyl acetate
41
Evaporation
N/A
To get solid, intermediate
Treprostinil
42
Crude drying on tray
1 or 3 days
Same
43
Ethanol & water for
5.1 L + 5.1 L
10.2 L + 10.2 L (same %)
cryst.
44
Crystallization in
20-L rotavap flask
50-L jacketed reactor
45
Temperature of
2 h r.t., fridge −0° C. 24 h
50° C. to 0° C. ramp, 0° C.
crystallization
overnight
46
Filtration
Buchner funnel
Aurora filter
47
Washing
20% (10 L) cooled
20% (20 L) cooled
ethanol-water
ethanol-water
48
Drying before oven
Buchner funnel (20 h)
Aurora filter (2.5 h)
Tray (no)
Tray (4 days)
49
Oven drying
15 hours, 55° C.
6-15 hours, 55° C.
50
Vacuum
<−0.095
mPA
<5
Torr
51
UT-15 yield weight
~535
g
~1,100
g
52
% yield from triol)
~91%
~89%
53
Purity
~99.0%
~99.9%
[0111] The quality of treprostinil produced according to this invention is excellent. The purification of benzindene nitrile by column chromatography is eliminated. The impurities carried over from intermediate steps (i.e. alkylation of triol and hydrolysis of benzindene nitrile) are removed during the carbon treatment and the salt formation step. Additional advantages of this process are: (a) crude treprostinil salts can be stored as raw material at ambient temperature and can be converted to treprostinil by simple acidification with diluted hydrochloric acid, and (b) the treprostinil salts can be synthesized from the solution of treprostinil without isolation. This process provides better quality of final product as well as saves significant amount of solvents and manpower in purification of intermediates.
[0112] Although the foregoing refers to particular preferred embodiments, it will be understood that the present invention is not so limited. It will occur to those of ordinary skill in the art that various modifications may be made to the disclosed embodiments and that such modifications are intended to be within the scope of the present invention.
[0113] All of the publications, patent applications and patents cited in this specification are incorporated herein by reference in their entirety. | This present invention relates to an improved process to prepare prostacyclin derivatives. One embodiment provides for an improved process to convert benzindene triol to treprostinil via salts of treprostinil and to purify treprostinil. | 0 |
BACKGROUND OF THE INVENTION
As the connections between healthy teeth and gums, and general overall health, have become increasingly evident in the past 100 years, oral rare ha become an important part of people's daily health maintenance regimens. In the process, as healthy looking smile has become representative of one's level of personal grooming and even social status, with straight, white and well shaped teeth being promoted in advertising and by cosmetic dentists as an integral part of one's self-image. Over the past 20 years, the availability of tooth whitening products and services has exploded in the marketplace, ranging from low priced over-the-counter (OTC) self-applied trays, strips, pens, mouthwashes and toothpastes, to expensive professionally applied or monitored products and procedures capable of effectively whitening teeth in as little as 45 minutes. In general, professionally applied products and services administered to a patient in a dental office or other clinical setting are seen to achieve the best teeth whitening results in the shortest amount of time. This is primarily due to the concentration of active ingredient, usually hydrogen peroxide or a hydrogen peroxide precursor, found in professionally applied whitening compositions. Such high concentrations, typically above 15% hydrogen peroxide by weight and often as high as 50% hydrogen peroxide by weight, can only be safely administered in a controlled setting where a professionally trained individual can isolate soft tissues from contact with these highly oxidative compositions. Frequent monitoring of a patient's progress over, for instance, a one-hour period is also critical in maintaining a high degree of safety when working with such high hydrogen peroxide concentrations. Optionally, light or heat energy may be applied in conjunction with these strong oxidizing compositions, in order to accelerate the process beyond that which is possible using just the compositions on their own. In general, these professionally-monitored products and services applied in a dental office or clinic will be referred to collectively as in-office or chairside whitening procedures.
Chairside whitening procedures are generally performed during a dental appointment scheduled specifically for the purpose of whitening the patient's teeth, or as an adjunct following a professional teeth cleaning, formally known as a dental prophylaxis or “prophy”. When tooth whitening is conducted immediately following a prophy, the total amount of time that the patient must remain in a dental chair can often exceed two hours.
A professional tooth cleaning is recommended by the American Dental Association as a means to prevent gum disease. Gum disease, or periodontitis, is the primary cause of tooth loss in adults over the age of 40. Gum disease has also been linked to other health problems, such as heart disease, osteoporosis, respiratory diseases, and other more serious systemic diseases. According to the Center for Disease Control and Prevention, approximately 68% of adults in the United States have at least one professional tooth cleaning annually (2008). There is speculation as to the reasons why so many adults neglect the benefits obtainable from regular tooth cleanings, ranging from lack of health insurance to the tear of dental procedures. Luck of patient knowledge is a problem that can be managed, however studies have shown that better education of patients only leads to modest changes in behavior and attitudes towards preventative dentistry.
In general, a typical teeth cleaning dental appointment comprises the following procedural steps:
(1) A dental hygienist or dental assistant may or may not take x-rays of a patient's teeth. (2) The dental hygienist or dental assistant will generally take between 15 and 60 minutes to work on the teeth and gums (the exact time depending upon both the amount of accumulation present, as well as the teeth cleaning method chosen), using a variety of tools, including manual or ultrasonic scalers to remove the tartar and plaque from the patient's teeth. (3) The hygienist will then floss between the teeth and generally complete the cleaning procedure by polishing the front (buccal) and back (lingual) surfaces of the teeth with an abrasive composition known as a prophylaxis (“prophy”) paste. Tooth polishing leaves a smooth tooth surface that is more resistant to the adhesion and buildup of dental plaque between dental cleaning appointments.
Despite the apparent benefits of preventative teeth cleaning as described above, nearly 80% of the population has some form of gum disease ranging from early stage gingivitis to advanced periodontitis. Symptoms of gum disease may include one or more of the following: bleeding gums, halitosis (bad breath), bad taste in the mouth, tooth sensitivity, sore gums, loose adult teeth, abscessed teeth or gums pulling away from the teeth, changes in the way the teeth fit together or dentures fitting poorly, exudates between the gums and teeth, sores in the mouth, and actual tooth loss. Such a high rate of chronic or acute gum disease indicates a low level of compliance when it comes to scheduling of a regular dental cleaning, and any means of increasing such compliance would clearly be beneficial to the patient's general oral health.
BRIEF DESCRIPTION OF THE INVENTION
The inventive tooth cleaning and whitening method comprises novel compositions and procedural steps that allow for the simultaneous performance of a dental prophylaxis and tooth whitening procedure. The procedure involves steps performed at least partially in parallel or contemporaneously with a typical dental prophylaxis procedure during which a significant amount of plaque, tartar and acquired pellicle are removed. In general, these steps may include, but are not limited to, chemical, mechanical and/or chemomechanical tooth surface conditioning, contact or impregnation of one or more teeth with as catalyst, contact or impregnation of one or more teeth with an oxidizing agent, exposure of one or more teeth to actinic energy comprising heat, light, sound, ultrasound, air or mechanical pressure (and combinations thereof), and contact or impregnation of one or more teeth with a tooth remineralizing, opacifying or pigmenting composition. Combinations of the above procedural steps have been developed that accomplish significant whitening of stained teeth in less than about 90 minutes when performed in conjunction with or during a dental prophylaxis procedure.
The ability of the inventive compositions and methods to simultaneously whiten teeth in parallel with a dental cleaning procedure is highly dependent upon the ability of the oxidizing agent to penetrate into tooth enamel and dentin. Both tooth enamel and dentin are composite structures comprising both organic and inorganic phases as well as interstitial spaces that are occupied by fluid. These interstitial spaces can accommodate fluid movement, which is generally in an outward direction, in other words from the interior of the tooth towards the enamel surface. However, fluids and other materials in contact with the enamel surface can influence fluid movement through tooth enamel and dentin with concentration gradients and/or capillary action, as well as in conjunction with pressure, heat, light and other external physical forces that can change the dynamic relationship between the tooth and the fluid in contact with the tooth.
Mathematical models have been constructed to predict the ability of fluids to penetrate into porous substrates. The Lucas-Washburn equation is one such method of developing a comparative “Penetration Coefficient” for various fluids, based on their viscosity, surface tension (with air) and contact angle (with a porous substrate). The model assumes that the porous solid is a bundle of open capillaries, so in other words the Penetration Coefficient is a comparative predictor of capillary flow rate. The Lucas-Washburn equation
d 2 = ( γ cos θ 2 η ) r t
predicts the distance (d) traveled by a liquid in a porous substrate, where the liquid has a surface tension (γ) with air, a contact angle (θ) with the porous substrate surface and a dynamic viscosity (η), and where (r) is the capillary pore radius and (t) is the penetration time. The bracketed component of the Lucas-Washburn equation is the Penetration Coefficient, expressed as centimeters per second
PC
=
γ
cos
θ
2
η
The Lucas-Washburn equation predicts that the higher the PC, the faster as liquid will penetrate into a given porous capillary substrate. This means that, at least in theory, a high PC can be achieved for liquids with low viscosities, particularly for compositions also having a low contact angle (which is often, but not always, associated with a liquid having a low surface tension that will lead to efficient wetting of the porous substrate.
Penetration coefficients have been used recently to design improved dental materials, specifically sealants and low-viscosity composites intended to arrest the progression of carious lesions (Paris, et al, Penetration Coefficients of Commercially Available and Experimental Composites Intended to Infiltrate Enamel Carious Lesions , Dental Materials 23 (2007) 742-748). The authors show that low viscosity materials with high Penetration Coefficients (>50 cm/s) are capable of penetrating enamel canons lesions better than materials with low PCs (see corresponding patent application US 2006/0264532).
Prior art tooth whitening compositions have generally been formulated to have high viscosities for better retention in dental trays during the bleaching process, which prevents migration of the whitening composition from the tray due to salivary dilution. Moderate to high viscosities have also been the norm for chairside whitening procedures, in order to prevent the whitening composition from migrating away from the tooth enamel surface. According to the Lucas-Washburn equation, moderate to high viscosity tooth whitening compositions (greater than about 100 centipoise at 25 deg C.) will have low Penetration Coefficients and thus be predicted to have restricted movement into the whitening target, that is, the porous enamel substrate. It would thus be advantageous to design a tooth whitening carrier composition comprising an oxidizing agent with a low viscosity 100 cps) and a high Penetration Coefficient (>50 cm/s) in order to achieve rapid penetration into tooth enamel and dentin.
Other factors affecting the ability of as liquid penetrant to infiltrate enamel and dentin are (1) surface charge effects (which is related to pH of the micro environment within the tooth, as well as the pH and counter ion content of the liquid penetrant), (2) adhesion of the liquid penetrant to the tooth surface (which is related to the surface tension and wetting ability of the liquid penetrant), and (3) osmotic effects (which are related to the direction of diffusion of the interstitial fluid in the tooth structure in relation to the liquid penetrant in contact with the tooth). Under certain circumstances, tooth whitening composition having viscosities in excess of 100 cps are contemplated, for instance when auxiliary means of increasing the penetration rate are available. For example, a tooth whitening composition with a viscosity between 5,000 and 100,000 cps can be utilized if heat and/or light and/or vibrational energy is used to increase the penetration rate of the composition into the tooth enamel structure.
In general, one aspect of the inventive simultaneous tooth cleaning and whitening method comprises the following steps, preferably performed in a sequence of steps comprising:
applying an oxidizing composition to the surfaces of the teeth to be whitened; and performing a dental cleaning or hygiene procedure while the oxidizing composition is in contact with the teeth to be whitened.
In another aspect of the invention, a method for simultaneously cleaning and whitening teeth comprises the steps of:
applying a conditioning composition to the teeth surface; applying an oxidizing composition to the teeth surface; applying a sealant composition to the teeth surface; cleaning the teeth surface; polishing the teeth surface; and removing the condition compositions from the teeth.
In yet another aspect of the invention, a method for simultaneously cleaning and whitening teeth comprises the steps of:
applying a composition to the teeth surface, wherein said composition is comprised of at least a fluid carrier, a tooth conditioner, an oxidizing agent and a water-resistant polymer, cleaning said teeth surface; polishing said teeth surface; and removing said composition.
There is typically an extensive amount of scraping, scaling, and other modes of plaque and tartar removal performed during a dental cleaning or prophylaxis. During the cleaning procedure, the patient's mouth is usually open for an extended period of time during which excess saliva may accumulate in the oral cavity and come in contact with the tooth surfaces. Also, the patient is typically asked to rinse with water or a mouthwash at various times during the cleaning procedure in order to clear debris (plaque, tartar, blood, saliva, etc) from the oral cavity that accumulates from the cleaning process. It has been found that in order to achieve a desirable (that is, a noticeable) level of tooth whitening during said dental cleaning or prophylaxis, it is advantageous to prevent moisture from saliva or external sources (such as the rinsing solutions referred to above) from directly contacting the tooth surfaces that have been previously contacted with the oxidizing composition. By creating a barrier between extraneous moisture and the oxidizing composition, said moisture is prevented or limited in its ability to remove, dilute, neutralize or otherwise decrease the effectiveness of the oxidizing composition dining the cleaning procedure.
One means of limiting the contact of external moisture with the oxidizing composition is to utilize an oxidizing composition having hydrophobic (“water-repelling”) properties when in contact with the tooth surface.
An alternative means of preventing moisture contamination of the oxidizing composition on the tooth surface is to cover the oxidizing composition with a film of water-insoluble or water-resistance material. Such materials may include, but are not limited to, polymer films and water-resistant or water-insoluble fluids, gels, creams, waxes and solids.
Yet another alternative means of preventing moisture contamination of the oxidizing composition on the tooth surface is to cover the oxidizing composition with a curable composition that can be converted from a liquid or gel into a higher viscosity liquid, gel or solid upon exposure to an external source of energy. Said external energy source may be electromagnetic or light energy, sound or ultrasound energy, mechanical or vibrational energy, electrical energy, or combinations thereof.
A preferred tooth cleaning and whitening method comprises the following steps
1) Placing a cheek and lip retraction means into the oral cavity of a subject. Said means may include a cheek retractor and/or cotton rolls placed in such a way as to prevent the soft tissue of the inside of the lips and cheeks from coming into contact with the tooth surfaces, 2) Conditioning of the teeth surfaces to be whitened with a conditioning agent or conditioning composition, using chemical, mechanical, or chemo-mechanical means. 3) Contacting the conditioned tooth surfaces with one or more compositions comprising an oxidizing agent, 4) Contacting the tooth surfaces with a water-resistant coating or film-forming composition to protect the oxidizing agent from direct contact with external moisture during the tooth cleaning process, 5) Cleaning and scaling of subject's teeth in proximity to the gum line, gingival margins and crevicular spaces while the compositions of steps (3) and (4) above are in contact with the tooth surfaces, 6) Polishing the teeth with prophylaxis or polishing paste following completion of step (5), 7) Optionally repeating steps (3) and (4), and 8) Cleaning and rinsing all residual materials from tooth and gum surfaces that were applied or produced during the performance of steps (1) through (7).
Modifications to the above procedure are possible and are some cases preferable. For instance, the conditioning agent or conditioning composition may be combined with the oxidizing, composition of step (3) in order to reduce the amount of time required to perform the combined cleaning and whitening procedure. Also, water-resistant properties may be imparted to the oxidizing composition of step (3) in order to obviate the need for a separate step (4). Therefore, it is contemplated, but not required, that the compositions and/or agents of steps (2), (3) and (4) may be combined into a single composition (a) prior to packaging, (b) just prior to use, or (c) on the tooth surface during use. Optionally, a tooth-desensitizing agent, such as potassium nitrate, may be applied before, during, or after any of the steps outlined above. Such tooth-desensitizing agent may be applied as a stand-alone formulation or combined with the conditioning agent, oxidizing agent, water-resistant or film-forming composition, or any combination of these.
It is also contemplated within the scope of this invention to employ light energy and/or heat energy to accelerate the tooth whitening process through various means such as increasing the rate of oxidizing composition penetration into enamel and dentin, increasing the susceptibility of tooth stain chromogens to oxidation, and accelerating the oxidation process through advanced oxidation processes such as the photo-Fenton reaction. An added benefit of employing light energy, particularly that in the blue region of the light spectrum (approximately 400-500 nanometers), during the inventive simultaneous tooth cleaning and whitening process, is observed by the attenuation and/or killing of periodontal pathogens within the light energy exposure field. A particularly useful benefit to reducing the viability of periodontal pathogens prior to, during and/or after a tooth cleaning is the reduction in risk associated with a lower bacterial burden during a moderately invasive procedure (tooth cleaning) that can sometimes involve bleeding. Reduction of the available numbers and types of oral pathogens during a tooth cleaning process may be of significant benefit to the subject's overall oral and whole body health, since the association between the presence of periodontal pathogens, such as the black pigmented bacteria species Fusobacterium nucleatum and Porphyromonas gingivalis , and the incidence of systemic diseases (such as heart disease) has been shown in recent years to be quite strong. Light energy employed in the initial steps of the present inventive method is seen to be most beneficial, since pathogen reduction prior to the invasive cleaning process would occur. However, light energy applied at any point in time during the cleaning and whitening process can be of significant benefit to the patient's gingival and periodontal health.
Particularly useful is light energy having the following characteristics: wavelengths of between 380 and 700 nanometers (nm), between 400 and 500 nm, and between 410 and 460 nm; and light intensity (measured at the target surface, for example the tooth or gum surfaces, in terms of power density) of between 100 and 5,000 milliwatts per centimeter squared (mW/cm 2 ), between 100 and 2,000 mW/cm 2 , between 500 and 1,500 mW/cm 2 , and between 100 and 300 mW/cm 2 . Light sources such as light emitting diodes (LEDs), quartz halogen bulbs, tungsten halogen bulbs, plasma arc bulbs, and xenon hash lamps, to name a few, are contemplated to have utility in the present invention. Preferred light sources are LEDs with emission peaks between 400 and 500 nanometers.
BRIEF DESCRIPTION OF THE DRAWING
The objects of the invention will be better understood from the detailed description of its preferred embodiments which follows below, when taken in conjunction with the accompanying drawings, in which like numerals and letters refer to like features throughout. The following is a brief identification of the drawing figures used in the accompanying detailed description.
FIG. 1 is a schematic depiction of an over molded lens that can be attached to a hand-held dental curing lamp for enhancing whitening in accordance with one aspect of the present invention.
FIG. 2 is an isometric view of the over molded lens shown in FIG. 1 .
Those skilled in the art will readily understand that the drawings in some instances may not be strictly to scale and that they may further be schematic in nature, but nevertheless will find them sufficient, when taken with the detailed descriptions of preferred embodiments that follow, to make and use the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The compositions of the present invention are designed to provide a fast and effective means of whitening the teeth during the performance of a dental cleaning or prophylaxis. Various combinations of tooth conditioning compositions, oxidizing, compositions and sealant compositions are envisaged to have utility in the practice of the inventive method, and the properties of these individual compositions may be combined into a single composition for ease of use and application. Alternatively, a tooth conditioning function may be combined with an oxidizing function into a single composition. Another alternative is to combine a tooth sealing function with an oxidizing function to reduce the number of application steps.
The tooth conditioning composition may comprise a fluid carrier and one or more tooth conditioning ingredients. Fluid carriers include water, ethanol, diethyl ether, methoxypropane (methyl propyl ether), dimethyl isosorbide and combinations thereof. The tooth conditioning function, that is the ingredient or ingredients that remove the acquired pellicle and subsequently open the enamel porosities for better penetration of the oxidizing composition, may be provided by ingredients having an acidic and/or calcium chelating capabilities. Useful acidic compounds include both inorganic and organic acids such as phosphoric acid, hydrochloric acid, acetic acid, lactic acid, citric acid, and their salts. Useful calcium chelating compounds include both inorganic and organic chelating agents such as ethylenediaminetetraacetic acid (EDTA), phytic acid, 1-hydroxyethylidene-1,1′-diphosphonic acid, citric acid, and their salts. The tooth conditioning composition may also comprise colorants and/or pigments to assist in the placement and application of the tooth conditioning composition onto the teeth during the combination whitening and cleaning procedure.
The oxidizing composition comprises a fluid carrier and an oxidizing agent. Fluid carriers include water, ethanol, diethyl ether, methoxypropane (methyl propyl ether), dimethyl isosorbide and combinations thereof. Oxidizing agents include peroxides, metal chlorites, percarbonates, perborates, peroxyacids, hypochlorites and combinations thereof. Preferred oxidizing agents are hydrogen peroxide carbamide peroxide, poly(vinyl pyrrolidone)-hydrogen peroxide complex (Penoxydone®, ISP Corp, Wayne, N.J.), peroxyacetic acid, and sodium chlorite. The oxidizing composition preferably has a viscosity of less than about 100 centipoise and most preferably less than about 10 centipoise. The oxidizing composition may also comprise active components further related to the tooth whitening function (such as stabilizers, a secondary oxidizing agent, an oxidation catalyst, a pH-adjusting agent, and a calcium chelating agent), or to a non-tooth whitening function (such as remineralization of the tooth surface, prevention of tooth decay, tooth-desensitization, prevention of gingivitis and/or periodontal disease, and other diseases or conditions of the oral cavity). In addition, the oxidizing composition may comprise one or more colorants and/or pigments to assist in the placement and application of the sealant onto the teeth during the combination whitening and cleaning procedure. Such colorants and/or pigments may also be present to provide a stain masking effect that changes the appearance of the tooth while the oxidizing composition is in contact with the tooth surface during the procedure.
Preferred oxidation catalysts are chelated metal complexes, in particular complexes of iron and manganese. Particularly preferred chelated metal complexes are the family of tetraamido-N-macrocyclic ligand (TAML) iron catalysts described in U.S. Pat. Nos. 7,060,818, 6,241,779, 6,136,223, 6,100,394, 6,054,580, 6,099,58, 6,051,704, 6,011,152, 5,876,625, 5,853,428, and 5,847,120.
The oxidizing compositions of the present invention may also contain a surface active agent in order to lower the surface tension of the composition to provide for better wetting and adhesion of the liquid to the surface of the tooth. Anionic, cationic, non-ionic and zwitterionic surfactants are contemplated to have utility in providing the oxidizing compositions with a low surface tension. Preferred surfactants are sulfobetaines (such as amidosulfobetaine 3-16 and Lonzaine CS) and fluorosurfactants (such as Capstone 50 and Capstone FS-10).
Sealant compositions of the present invention may comprise a water-resistant polymer, copolymer or crosspolymer, and a fluid carrier. Hereinafter the term “polymer” and “polymers” shall be used to denote polymer(s) copolymer(s) or crosspolymer(s). Suitable water-resistant polymers include acrylate polymers, methacrylate polymers, modified cellulosic polymers, silicone polymers, urethane polymers, polyamide polymers, vinyl polymers, vinyl pyrrolidone polymers, maleic acid or itaconic acid polymers, and others. The water-resistant polymer should be soluble or dispersible in the fluid carrier. Particularly preferred polymers are poly(butyl methacrylate-co-(2-dimethylaminoethyl)methacrylate-co-methyl methacrylate), poly(ethyl acrylate-co-methyl methacrylate-co-trimethylaminomethyl methacrylate chloride), ethylcellulose, and esterified or crosslinked poly(methyl vinyl ether-co-maleic anhydride). The fluid carrier may be a volatile solvent which will evaporate after contacting the sealant composition with the tooth surface, leaving behind a liquid or solid coating or film. Said solvent should have an evaporation rate equal to or greater than that of water, and preferably equal to or greater than that of butyl acetate. Suitable, solvents include, but are not limited to, water, ethanol, diethyl ether, methoxypropane (methyl propyl ether), acetone, ethyl acetate, and other highly volatile solvents.
Alternatively, the sealant compositions may be curable liquids or gels, which are placed on the tooth surface and subsequently exposed to some form of activating energy which converts the liquid or gel sealant composition to a solid coating or film. Curable sealant compositions may also be chemically cured, whereby two or more components are combined just prior to use and placed on the tooth surface to cure, in other words, to change from a liquid or gel into a solid coating or film.
The sealant composition may also comprise active components related to as tooth whitening function (such as an oxidizing agent, an oxidation catalyst, a pH-adjusting agent, and a calcium chelating agent), or to a non-tooth whitening function (such as remineralization of the tooth surface, tooth-desensitization, prevention of tooth decay, prevention of gingivitis and/or periodontal disease, and other diseases or conditions of the oral cavity). In addition, the sealant composition may comprise one or more colorants and/or pigments to assist in the placement and application of the sealant onto the teeth during the combination whitening and cleaning procedure. Such colorants and/or pigments may also be present to provide a stain masking effect that changes the appearance of the tooth while the sealant composition is attached to the tooth surface in the form of a coating or film.
The combination whitening and cleaning method described herein may also be practiced by employing an additional source of energy to accelerate the oxidation process and further reduce the time needed to complete the procedure. External energy sources such as electromagnetic or light energy, sound or ultrasound energy, mechanical or vibrational energy, electrical energy, or combinations thereof may be advantageously employed at any point in time during the combination whitening and cleaning procedure to accelerate the process.
EXAMPLES
In order to achieve a significant degree of tooth whitening in an abbreviated time frame suitable for integration into the tooth cleaning (dental prophylaxis) process, ideal conditions for (1) oxidizer penetration into the tooth and (2) conversion of initial oxidizer form into active whitening species must be facilitated.
Time limitations are imposed on the additional steps required to achieve whitening during the tooth cleaning process by the realities of patient scheduling in the typical dental office, and such additional steps should not exceed 30 minutes beyond or in addition to the time required to perform a typical dental prophylaxis. Optimal conditions for penetration of an active whitening composition into tooth enamel must be present in order to reduce the amount of time and oxidizer concentration required to reach intrinsic stain depth. Important factors related to oxidizer penetration into the tooth are (1) the viscosity of the oxidizing composition, (2) the surface tension of the oxidizing composition and (3) the surface free energy (also called the critical surface tension) of the tooth surface.
The surface free energy of exposed tooth enamel is generally in the range of about 50-55 dynes/cm, however the acquired pellicle can lower this number significantly. In fact, one of the important functions of the acquired pellicle is to reduce the critical surface tension of the tooth surface in order to reduce the adhesion of bacteria. Liquid and gel compositions contacting the tooth surface penetrate into the tooth structure in relation to four primary factors: time, viscosity of the liquid or gel, surface tension of the liquid or gel, and surface free energy of the tooth at the point of contact.
The relationship of liquid surface tension to solid surface free energy, low contact angle (the tangential angle formed by a droplet deposited on a solid surface) and low viscosity, are all directly related to the Penetration Coefficient (as derived from the Lucas-Washburn equation) and must be optimized for the whitening, composition to (1) rapidly wet the surface of tooth enamel and (2) penetrate the available porosities and channels through enamel as quickly as physically possible.
EXAMPLE 1
The ability of various oxidizing compositions to penetrate intact enamel and dentin was determined as follows. Extracted molar and pre-molar teeth were obtained from orthodontists with patient consent and stored refrigerated in phosphate buffered saline (PBS) solution at pH 6.8 until use. In order to assess the ability of various liquid carrier fluids to penetrate tooth enamel, teeth were sectioned to remove their roots and a 3 mm diameter chamber was created in the center of the sectioned crown that was filled with PBS solution. The crowns were partially immersed (chamber with PBS solution facing up) in various liquid carrier fluids and a small (1 microliter) sample of the PBS solution was drawn every 60 seconds and placed on a peroxide test strip (EM Quant Strips 10337, EMD Chemicals, a division of Merck SA, Darmstadt, Germany) to determine the amount of time required for hydrogen peroxide to penetrate the tooth enamel and dentin from the outer surface of the crown to the interior chamber containing PBS.
Oxidizing compositions in Table 1 below were prepared and stored in 20 ml glass vials until use.
TABLE 1
Percent (w/w)
Ingredient
1A
1B
1C
1D
1E
1F
1G
1H
1I
1J
1K
1L
Water
75.0
65.0
75.0
65.0
85.0
75.0
65.0
75.0
65.0
75.0
65.0
100.0
Ethanol 200
10.0
20.0
5.0
15.0
5.0
15.0
Diethyl ether
5.0
5.0
Methoxypropane
5.0
5.0
Acetone
10.0
20.0
Dimethyl isosorbide
10.0
20.0
Hydrogen peroxide
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
0.0
Adjusted to pH 4.0 with potassium hydroxide 0.1M
Viscosity (cps @ 25 C.)
<1
<1
<1
<1
1.3
<1
<1
<1
<1
1.5
1.5
1
Surface tension
<40
<40
<40
<40
>50
<40
<40
<40
<40
<40
<40
>50
(dynes/cm)
Contact angle (deg)
<10
<10
<10
<10
30+
<10
<10
<10
<10
15
15
50+
PC (calculated)
>100
>100
>100
>100
<50
>100
>100
>100
>100
>100
>100
<30
H 2 O 2 detection (min)
13
12
12
10
20
14
12
14
14
15
15
ND*
*ND = Not detected
Oxidizing compositions in Table 1 trended towards faster penetration of the tooth when both contact angle and viscosity of the composition was low (Examples 1A, 1B, 1C, 1D, 1F, 1G, 1H, 1I, 1J, and 1K). Oxidizing with high contact angles (greater than 30 degrees) did not seem to penetrate as well as those with contact angles less than about 10 degrees.
EXAMPLE 2
The following multi-step process was developed to provide for rapid and effective whitening of the teeth during a dental cleaning procedure.
Step 1—Acquired Pellicle Removal
Facilitating oxidizer penetration into the tooth requires a thorough removal or modification of the acquired pellicle prior to contact with the oxidizer formulation. Therefore, whether integrated into a dental prophylaxis procedure or performed as a stand-alone process, the first step in the abbreviated whitening process (after determining a starting tooth shade) must be the removal of the acquired pellicle using chemical, mechanical or (preferably) chemo-mechanical means. Once the acquired pellicle has been removed, it is important that the “cleaned” tooth enamel surface has limited contact with the patient's saliva prior to application of the oxidizer composition (see Step 2) in order to prevent reformation of the pellicle film on the exposed enamel surface. Removal or modification of the acquired pellicle and optional micro-roughening of the exposed enamel surface will elevate the enamel surface free energy (preferably above about 60 dyne/cm), which promotes better wetting of the enamel surface by the oxidizing composition. Surface wetting is a key factor related to the speed at which a composition penetrates enamel, analogous to the effects of viscosity and surface tension on the penetration of bonding adhesives into conditioned enamel and sealants into caries lesions.
Step 1a Placement of Cheek Retractor or Other Means of Preventing Contact of the Lips and Interior Gum Surfaces with the Teeth.
Step 1b Application of Conditioner for 30-60 Seconds
Tooth Conditioner Composition
Ingredient
Percent (w/w)
Water
90.0
Poly (methyl vinyl ether-co-maleic anhydride)*
10.0
*Gantrez S-95 (ISP Corp, Wayne, NJ) (hydrolyzed, pH 2.0)
Step 2—Oxidizer Contact and Penetration
Once the acquired pellicle has been removed, the teeth surfaces are contacted with a low viscosity oxidizer composition with a sin lace tension significantly lower than that of the surface free energy of the exposed enamel surface. A low viscosity oxidizing composition that has a low surface tension will have a very low contact angle when placed on the enamel surface and thus be better suited to penetrate into the enamel porosities. The oxidizer composition should comprise hydrogen peroxide in an aqueous form (or mixed with viscosity-reducing solvents) and at a concentration between about 1% and 30% by weight (higher amounts being contemplated in situations where precise control and placement of the oxidizing composition is possible). The oxidizing composition should also have a pH within a range similar to that reported for the isoelectric point of tooth enamel, which is between about 3.8 and 4.7 although higher pH levels are possible with oxidizing compositions comprising ionized species capable of counteracting the influence of charged components in tooth enamel. The oxidizing composition is brushed repeatedly onto the tooth snakes to be whitened over the period of about 7-10 minutes to provide as much full strength hydrogen peroxide at the interface over the initial treatment phase.
Step 2a Application of Oxidizing Composition to Buccal and (Optionally) Lingual Surfaces of Teeth
Oxidizer Composition
EXAMPLE 1D
Step 3—Sealing Enamel Surface Prior to Dental Prophylaxis Procedure
In order to prevent dilution or removal of the oxidizing composition in or from the tooth enamel treated in accordance with Step 2 above, a water-resistant protective sealant is applied (and if solvent-based, allowed sufficient time for the carrier solvent to evaporate). The sealant composition may also comprise an additional oxidizing agent to provide an additional reservoir of whitening active, and/or an advanced oxidation catalyst in order to promote active oxidizing species such as hydroxyl radicals (.OH) and perhydroxyl anions (—OOH), and/or a desensitizing agent to reduce or eliminate any tooth sensitivity associated with the procedure.
Step 3a Application of Sealant to Buccal and (Optionally) Lingual Surfaces of Teeth
Sealant Composition
Ingredient
Percent (w/w)
Ethanol 200 proof
90.0
Poly (butyl methacrylate-co-(2-dimethylaminoethyl)
10.0
methacrylate-co-methyl methacrylate)*
*Eudragit E100 or EPO (Evonik Rohm GmbH, Darmstadt, Germany)
The sealant composition is applied onto the surfaces of the teeth previously contacted with the oxidizing composition and allowed to fully dry before proceeding to Step 4.
Step 4—Performance of the Dental Prophylaxis Procedure
Following the sealing process, a dental prophylaxis is performed using standard protocols and materials. Care should be taken to avoid excessive disruption of the sealant on the buccal and lingual (if coated) surfaces of the teeth during the cleaning procedure. The dental prophylaxis is otherwise performed in a standard fashion, including polishing of the teeth with a standard prophy paste (which will remove the Sealant applied in Step 3). A final tooth shade may be taken at this time.
Step 5—Final Treatment
If time permits. Steps 2 and 3 are repeated after prophy cleanup. No further intervention is required to remove the Sealant if applied after completion of the dental prophylaxis and dismissal of the patient. The Sealant may remain in place after the patient leaves the office and will slowly erode over time. The patient may also be supplied with as home-use version of the oxidizing composition and the sealant as an option for continued improvement in tooth color.
The above steps were performed on extracted molars and premolars (n=25 obtained through orthodontists with patient consent and stored refrigerated in phosphate buffered saline (PBS) solution at pH 6.8 until use. Individual teeth were removed from the PBS solution, allowed to air dry for 60 seconds and the roots inserted up to the cementoenamel junction into a high viscosity aqueous gel to keep the roots hydrated during the procedure. An initial tooth shade was taken using a Minolta CM504i chromameter (Konica-Minolta) and recorded. Steps 2 (total treatment time of 10 minutes) and 3 (total treatment time of 120 seconds) were performed on the extracted teeth, and a 32 minute period was allowed to elapse during which the teeth were rinsed with water every 8 minutes to simulate the rinsing process that typically occurs during the cleaning process. After the simulated cleaning process time had elapsed the teeth were polished with a medium grit prophy paste using a slow speed headpiece and prophy cup. Teeth were rinsed with water and a final tooth shade was taken using the method described above and recorded in Table 2 below (L, a b=Initial color readings. L*, a*, b*=final color readings).
TABLE 2
Tooth
L
a
b
L*
a*
b*
Delta L
Delta a
Delta b
Delta E
1
76.10
3.14
15.98
78.11
1.61
13.13
2.01
−1.53
−2.85
3.81
2
76.90
3.44
12.45
80.98
2.40
13.01
4.08
−1.04
0.56
4.25
3
74.23
3.32
16.05
78.33
1.98
12.77
4.10
−1.34
−3.28
5.42
4
74.25
2.00
16.21
77.21
1.74
12.12
2.96
−0.26
−4.09
5.06
5
78.21
3.24
14.76
80.43
1.99
11.26
2.22
−1.25
−3.50
4.33
6
75.21
3.01
15.90
77.77
2.45
14.01
2.56
−0.56
−1.89
3.23
7
74.79
1.82
13.88
78.23
1.43
13.20
3.44
−0.39
−0.68
3.53
8
72.24
3.32
16.43
75.20
2.99
13.95
2.96
−0.33
−2.48
3.88
9
73.19
3.87
15.81
78.81
2.33
10.32
5.62
−1.54
−5.49
8.01
10
77.31
3.66
14.73
77.60
1.84
9.99
0.29
−1.82
−4.74
5.09
11
71.89
3.97
17.68
76.39
2.77
14.02
4.50
−1.20
−3.66
5.92
12
74.54
3.58
14.32
78.40
2.87
13.13
3.86
−0.71
−1.19
4.10
13
73.29
3.82
14.65
78.41
2.02
13.03
5.12
−1.80
−1.62
5.66
14
74.03
3.92
16.33
76.75
2.36
14.56
2.72
−1.56
−1.77
3.60
15
71.99
2.98
15.03
77.90
1.75
11.82
5.91
−1.23
−3.21
6.84
16
73.98
3.92
15.57
78.02
1.99
11.08
4.04
−1.93
−4.49
6.34
17
73.12
3.22
16.23
76.19
1.56
13.84
3.07
−1.66
−2.39
4.23
18
76.00
3.42
15.48
78.88
1.98
10.63
2.88
−1.44
−4.85
5.82
19
73.94
3.73
14.14
78.58
2.02
10.73
4.64
−1.71
−3.41
6.01
20
74.74
3.46
15.02
77.33
2.38
13.05
2.59
−1.08
−1.97
3.43
21
70.95
3.98
17.43
75.02
2.97
12.83
4.07
−1.01
−4.60
6.22
22
73.49
4.03
18.55
77.91
3.13
13.43
4.42
−0.90
−3.12
5.48
23
76.03
3.10
18.30
78.73
1.57
13.22
2.70
−1.53
−5.08
5.95
24
73.83
3.28
17.43
77.00
1.22
10.15
3.17
−2.06
−7.28
8.20
25
74.17
2.98
15.12
78.36
2.09
11.03
4.19
−0.89
−4.09
5.92
Average
73.84
3.46
16.03
77.63
2.06
11.98
3.79
−1.40
−4.04
5.72
EXAMPLE 3
The following whitening method was used to demonstrate the ability of a high viscosity tooth whitening composition to remove an artificial stain from the surface of a bovine enamel substrate in vitro when light energy is use to enhance penetration.
Staining of Bovine Enamel Slabs
1. Substrates
a. 10 mm×10 mm bovine incisor (enamel) fragments mounted in clear resin b. 600 grit finished surface c. Unsealed
2. Storage of Substrates
a. Always store substrates at 100% relative humidity, or at 4° C. in Double Distilled H 2 O or Phosphate Buffered Saline solution b. Never allow substrates to fully dry out as surface will change, dry only as part of staining procedure and never for extended periods.
3. Staining Solution
a. 3 g of fine ground leaf Tea b. 3 g of fine ground Coffee c. 300 ml of boiling ddH 2 O d. Infuse for 10 min with stirring (use magnetic stirrer) e. Filter solution through tea strainer with additional filter paper f. Cool to 37° C.
4. Preparation of Tooth Samples
a. Labelling: Label the bovine samples on one side of the resin with permanent marker (to track the samples if using more than one) b. Rub the surface of the enamel with wet wipe and then grit finish is on the wet surface with orbital motion covering the whole surface for nearly 10 sec c. Wash the surface with water and make it dry with Kimwipe d. Sealing: Seal all the surfaces of the resin, excluding the enamel surface of bovine fragment (i.e., all four sides and bottom) with clear nail varnish e. Leave it on bench top for air drying with the enamel surface touching the bovine for 30-45 min f. Etching: sequential immersion in 0.2 m HCl saturated Na 2 CO 3 , 1% Phytic Acid (30 seconds each) and finally rinse with double distilled H 2 O g. Make it dry with Kimwipe and then they are ready for staining
5. L*a*b Measurement
Measurement before and after staining.
6. Staining Procedure
a. Prepare the staining broth (Section 3) and fill a glass bottle with 200 ml of the broth b. Keep the samples to be stained in the broth continuously for four days c. Tighten the cap of the bottle to ensure that the broth is not evaporating from the bottle d. Gently mix the broth every day to make sure that the particles are not settling at the bottom of the bottle e. After staining the samples, rinse substrate with Millipore water (wipe it) and measure LAB values
Samples of the stained bovine enamel slabs were contacted with a tooth whitening composition shown in Table 3.
TABLE 3
Ingredient
Percent
Deionized water
35.40
Glycerin
20.00
Etidronic acid
0.30
Potassium stannate
0.10
Hydrogen peroxide
12.00
Carbopol 974P-NF
2.00
Sucralose
0.30
PEG-60 hydrogenated castor oil
3.00
Flavor
1.00
Ammonium Hydroxide 29% (to pH 5.0)
1.10
Total
100.00
The above composition is a transparent gel having a viscosity of approximately 10,000 cps@25 deg C. and a pH of 5.0.
The tooth whitening composition of Table 3 was brushed on to the surfaces of stained bovine enamel slabs prepared as described above. Immediately after contacting the slabs with the tooth whitening composition, light energy was applied using a hand-held dental curing light with a high-powered LED emitting approximately 500 mW/cm 2 of blue light with a peak wavelength of approximately 450 nm. The hand-held curing light used a lens cup 10 depicted schematically in FIGS. 1 and 2 as having a lens 12 over which a thermoplastic elastomer cup 14 was molded to provide, a mechanism for spacing the curing light energy L (represented notionally in FIG. 1 ) at the same distance from the surface of the bovine slab for each sample. The over molded cup forms a small chamber that controls the positioning and movement of the gel on the tooth surface, while simultaneously emitting light energy through the lens onto the tooth surface to accelerate the penetration of the tooth whitening composition into the tooth structure.
The resulting changes in L, a and b values, together with the composite delta E change in tooth color, is shown in Table 4 below.
TABLE 4
dL
da
db
dE*ab
tooth 1
8.15
−4.17
−6.17
11.04
tooth 2
6.91
−3.56
−5.71
9.65
tooth 3
2.69
−1.76
−5.18
6.09
tooth 4
5.53
−2.89
−2.45
6.71
As can be seen by the changes in L, a and b values, as well as the composite delta E value changes, significant tooth color changes may be effected by utilizing a high viscosity tooth whitening composition when combined with as high intensity light source adapted with a lens comprising an over molded thermoplastic elastomer spacer cup. It is anticipated that the inclusion of a light exposure step, as demonstrated in the Example, would be of significant advantage in improving the tooth whitening effect observed in Examples 1 and 2. Exposing the tooth surfaces and their surrounding soft tissue will also lead to an improvement in periodontal health through the reduction of periodontal pathogens such as black pigmented bacteria.
SUMMARY
It will be understood that the embodiments of the invention described above can be modified in myriad ways other than those specifically discussed without departing from the scope of the invention. General variations to these embodiments may include different tooth whitening compositions, light sources, methods of applying compositions and/or light, and contact and/or exposure time of tooth whitening compositions and/or light on the tooth surface.
Those skilled in the art will readily recognize that only selected preferred embodiments of the invention have been depicted and described, and it will be understood that various changes and modifications can be made other than those specifically mentioned above without departing from the spirit and scope of the invention, which is defined solely by the claims that follow. | Compositions and methods for whitening the teeth of a patient or subject include the application of at least one tooth whitening composition having a viscosity of at least 100 centipoise to the surface of a stained tooth, accompanied by the application of a sealant composition that forms protective film or coating on the tooth surface to resist moisture contamination of the oxidizing composition. The whitening procedure can be further enhanced by removal of acquired pellicle from the tooth surface prior to application of oxidizing and sealant compositions. The novel procedure allows for a high degree of tooth whitening by protecting the oxidizing composition while it is in contact with the tooth surface. | 0 |
This application is a continuation of U.S. patent application Ser. No. 12/929,928, filed Feb. 24, 2011, now U.S. Pat. No. 8,752,473, which is a continuation of U.S. patent application Ser. No. 12/220,725, filed Jul. 28, 2008, the disclosure of each of which is incorporated herein by reference, and hereby claims priority thereof to which it is entitled.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This present invention generally relates to self loading firearms, specifically to gas blocks for self loading firearms which facilitate user adjustment of the gas flow from the barrel into the operating system.
2. Description of the Related Art
The need to regulate the gas flow between the barrel and operating system of a firearm has been a concern since the introduction of autoloading firearms. Gas is generated during the combustion of gun powder present in the cartridges used in modern firearms. This gas expands violently to push the bullet out of the firearm's barrel. These expanding gases are utilized as a means to operate the action of the host firearm. In modern firearms the preferred method of facilitating the function of an autoloading weapon is as follows. A hole is placed thru the barrel, generally on the top. Location of this hole or gas port varies between operating systems. Generally a gas port size is chosen to allow a broad range of ammunition to be utilized while guaranteeing the reliable function of the host firearm.
Unfortunately due to varying lengths of barrels, ammunition variance, and other factors it is very difficult to choose a gas port size which universally works under all conditions. A popular way of dealing with these problems is to incorporate an adjustable gas block into the operating system.
An adjustable gas block allows for the flow of gas between the gas port in the barrel and the operating system of the firearm to be increased or decreased based on mitigating factors present at the time of use. These systems typically work by utilizing an oversized gas port with means to adjust the flow of gas into the operating system and by venting the unneeded gases from the barrel into the atmosphere thus generating flash and sound. Further, adjustment of the gas system typically requires a special tool and offers no way for the user to index the system and make adjustments due to mitigating circumstances quickly. Designs such as these are well known in the prior art and can be found on the Belgium FAL, Soviet SVD and the Yugoslavian M76 rifle.
Recent firearm designs such as the FN SCAR rifles have incorporated adjustable gas blocks to be used in conjunction with noise suppressors. Noise suppressors provide a means to redirect, cool and slow the expanding gases generated from the discharge of a firearm so that the resulting flash and sound generated by the firearm is minimized or eliminated. As a result, back pressure is generated forcing more gas into the firearm's operating system. This extra gas, or back pressure increases the firing rate of a weapon during its full auto function, fouls the weapon leading to premature malfunction and to a variety of feeding and extraction problems.
Modern rifle designs such as the FN SCAR rifles incorporate adjustable gas blocks which have selectable pre-set positions. Typically two or three positions of adjustment are afforded the user. A reduced gas flow setting on an adjustable gas block is generally present due to military and government agency requirements. Reducing the standard gas flow is desirable when a silencer is to be used. Silencers increase back pressure and the cyclic rate of the host firearm. By reducing the amount of gas directed to the operating system under normal circumstances, the silencer, with the increased pressure it generates, should not affect the weapon's operation adversely. While designs with an adjustable gas block mitigate the potential problems associated with the increase of back pressure and fouling a noise suppressor generate, gases are still vented out of the gas block thus generating flash and sound. Generating flash and sound from the gas block is counterproductive to the function of the silencer which is attempting to reduce the flash and sound from the muzzle of the host firearm.
The present invention offers several advantages over the prior art. Four positions of adjustment are provided for. Position one offers a “standard” flow of gas. This position is optimized for the firearm's barrel length and caliber. Position two reduces the flow of gas into the indirect gas operating system so that with the addition of a silencer the indirect gas operating system is still receiving an equivalent amount of gas as was being provided by position one when no silencer was being utilized. Position three blocks the flow of gas between the barrel gas port and the indirect operating system. This position optimizes the sound reduction capability of an attached noise suppressor. Position four increases the amount of gas being communicated to the operating system so that the firearm may operate properly while dirty or when underpowered ammunition is being utilized. Each of the aforementioned positions of adjustment are indexed with a spring and ball detent, and are pre-set at the factory. No tool is required to rotate the adjustment cylinder into one of the four positions. There is no vent in the gas block which allows for excess gas or un-burnt powder to exit.
SUMMARY OF THE INVENTION
Accordingly several objects and advantages of the present invention are
(a) To provide the user an indexing means to adjust the flow of gas into the operating system of a firearm. (b) To provide a device which restricts the flow of gas into the operating system without venting excess gas from the gas block. (c) To provide an adjustment mechanism which does not require the use of special tools. (d) To provide an adjustable gas block that may be utilized with an indirect gas system. (e) To provide an adjustable gas block with a means to provide gas that is in excess of what is required to help the weapon function in adverse conditions or with underpowered ammunition.
In accordance with one embodiment of the present invention, a firearm is provided comprising a receiver, a barrel, an adjustable gas block for an indirect gas operated firearm and an indirect gas system. The adjustable gas block is fixedly secured to the barrel and aligned with the gas port hole located thereon. A rotating cylinder provides an indexing, adjustment means for the gas block. By rotating the provided cylinder the flow of gas between the barrel and the indirect gas system is either increased or decreased. Four positions of adjustment are afforded the user: A standard gas flow, suppressed gas flow, no gas flow, and an adverse conditions gas flow setting. For adverse conditions the gas flow is increased over what the host weapon would typically require to compensate for a dirty operating system.
Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of the present invention, together with further advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which a preferred embodiment of the present invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended to define the limits of the invention.
FIG. 1 is a side perspective view of an adjustable gas block for an indirect gas operated firearm in accordance with the present invention;
FIG. 2 is an exploded view of the gas block shown in FIG. 1 ;
FIG. 3 is a partial cutaway view of the nozzle assembly and adjustment knob which are parts of the gas block shown in FIGS. 1 and 2 ;
FIG. 4 is a side cutaway view of the adjustable gas block for an indirect gas operated firearm shown in FIG. 1 ;
FIG. 5 is a side perspective view of the adjustable gas block for an indirect gas operated firearm shown with the firearm receiver and barrel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The adjustable gas block, generally designated by reference numeral 1 , for an indirect gas operated firearm is designed to provide four positions of adjustment, each of which affects the flow of gas from the barrel gas port into the operating system of the host firearm. The herein disclosed device is designed for an indirect gas operating system, but it should be noted that this device is not limited to such operating systems and in fact could be utilized with a gas impingement operating system such as is found on the M16 family of firearms.
As shown in FIG. 1 , which illustrates the preferred embodiment of the present invention, the adjustable gas block 1 for an indirect gas operated firearm is a replacement for a standard gas block, well known in the prior art, for an autoloading firearm. The adjustable gas block 1 for an indirect gas operated firearm is comprised of a housing 10 , an adjustment knob 20 , a nozzle assembly 30 , also referred to as a gas nozzle, and a front sight 60 .
In FIG. 2 , there is illustrated an exploded view of the adjustable gas block 1 for an indirect gas operated firearm and all of its components. The housing 10 has a gas nozzle receiving channel 13 which is located above the barrel receiving channel 12 . Near the distal end of the housing 10 is located a groove 14 for the adjustment knob 20 . The groove is transverse to the longitudinal axis of the barrel and is bounded on one side by a front surface of the gas block adjacent the gas nozzle receiving channel and on the other side by a solid rearwardly facing surface of the gas block. Located along the bottom of the housing 10 are two thru pin placements 15 which receive two taper pins that are utilized to secure the unit as a whole about the barrel 101 (see FIG. 5 ). A front sight 60 is provided for on the distal end of the housing 10 along with a bayonet lug 70 .
The preferred embodiment gas nozzle 30 consists of a front end 33 , a back end and a middle portion. The front end 33 of the gas nozzle 30 , which does not have an opening, protrudes from the front of the gas nozzle receiving channel 13 and into the groove 14 . The back end protrudes from the rear of the housing and has an opening 31 into the gas nozzle which is in communication with gas ports 35 , 36 and 37 (shown in FIG. 3 ). The middle area consists of the structural features between the front end 33 and the opening 31 at the back end. Structural features found on the middle area are the connecting member 39 , the radial flange 40 , an opening 34 for a pin 21 and the diameter-reducing transition portion 41 .
The adjustment knob 20 has a front face, a rear face, and a generally annular body surrounding a central opening or bore 29 , said rotatable knob being received within said transverse groove with the knob rear face adjacent the front side of the gas nozzle receiving channel cylindrical bore and the knob front face adjacent a rearwardly facing surface of the housing. The adjustment knob 20 includes a series of slots 25 - 28 located about the periphery of the rear face of the adjustment knob 20 . The central opening or bore 29 of the adjustment knob 20 receives a front portion of the gas nozzle 30 . An opening 24 is present on the exterior of the adjustment knob 20 and is designed to receive a pin 21 .
In FIG. 3 there is illustrated a view of the adjustment knob 20 assembled with the gas nozzle 30 . The gas nozzle 30 is partially cut away to reveal the three gas ports 35 , 36 and 37 . Gas port 36 is at a 90 degree angle with respect to each of gas ports 35 and 37 , and gas ports 35 and 37 are positioned 180 degrees from one another. Gas port one 35 , gas port two 36 , and gas port three 37 are each unique in size. These gas ports 35 - 37 all intersect in the center of the gas nozzle 30 . Each of the gas ports is in communication with the opening 31 located at the front of the gas nozzle 30 and the bore 38 therethrough.
FIG. 4 illustrates a cutaway view of the adjustable gas block 1 . The housing 10 houses a spring 22 and ball detent 23 in a void 19 . A gas port 44 thru the housing 10 is in communication with both the gas nozzle 30 and the gas port of the barrel 101 . The gas nozzle 30 has a bore 38 which is in communication with an opening 31 of the gas nozzle 30 and the gas port 44 located in the housing 10 . The adjustment knob 20 is secured about the gas nozzle 30 by means of a pin 21 which is inserted through an opening 24 in the adjustment knob 20 and then through the opening 34 located on the gas nozzle 30 .
FIG. 5 illustrates a perspective view of a firearm receiver 90 connected to a barrel 101 utilizing a removable rail 91 (also referred to as a handguard) which incorporates an indirect gas operating system 100 and the adjustable gas block 1 .
As used herein, the word “front” or “forward” corresponds to the direction right of the adjustable gas block 1 as shown in FIGS. 1 thru 5 ; “rear” or “rearward” or “back” corresponds to the direction opposite the front direction of the adjustable gas block 1 , i.e., to the left as shown in FIGS. 1 thru 5 ; “longitudinal” means the direction along or parallel to the longitudinal axis of the adjustable gas block 1 ; and “transverse” means a direction perpendicular to the longitudinal direction.
The adjustable gas block 1 is assembled as follows. The spring 22 and ball detent 23 are inserted in the void 19 located within the housing 10 . A placement area or groove 14 formed in the housing 10 receives the adjustment knob 20 therein and retains the spring 22 and ball detent 23 in place. The spring 22 provides a force to the ball detent 23 which interacts with the indexing notches 25 , 26 , 27 and 28 located about the adjustment knob 20 and provides an indexing means for the orientation of the gas nozzle 30 . The interaction between the ball detent 23 and the indexing notches 25 - 28 prevents the unintentional rotation of the adjustment knob 20 during routine use of the host firearm. The gas nozzle 30 is inserted through the gas nozzle receiving channel 13 and through the central opening 29 in the adjustment knob 20 . The gas nozzle 30 is initially oriented such that the openings 34 align with the openings 24 on the adjustment knob 20 where a pin 21 , preferably a roll pin type, is pushed through. This retains the adjustment knob 20 and the gas nozzle 30 in place. A portion of the barrel 101 is received by the barrel receiving channel 12 located on the housing 10 . Once the through pin placements 15 are aligned with the existing openings on the barrel 101 , two pins are then used to secure the adjustable gas block 1 to the barrel 101 and thus prevent the rotation and longitudinal movement of the housing 10 .
When a firearm is discharged, expanding gases travel down the barrel 101 with a small amount of this gas being vented through a gas port located on the top of the barrel 101 . This gas then travels through the gas port 44 located in the housing 10 into the bore 38 and out of the opening 31 of the gas nozzle 30 into the operating system 100 . A firearm equipped with the adjustable gas block 1 disclosed herein, through the use of the adjustment knob 20 , can rotate the gas nozzle 30 into a position which blocks gas from entering the bore 38 . This occurs when the adjustment knob 20 is rotated such that indexing notch 28 is in contact with the ball detent 23 thereby placing a non-ported portion of the gas nozzle 30 over the gas port 44 of the housing 10 . If the adjustment knob 20 and thereby the gas nozzle 30 are rotated in such a manner as to allow the flow of gas into the operating system 100 , one of the three gas ports 35 - 37 will be in direct communication with the gas port 44 located in the housing 10 .
Once the adjustable gas block 1 is fully assembled onto a rifle as shown in FIG. 5 , the adjustment knob 20 is received within the transverse groove 14 with the rear face of the knob adjacent the front end of the gas nozzle receiving channel cylindrical bore and the knob front face adjacent a rearwardly facing surface of the housing. When coupled to the gas nozzle 30 , the adjustment knob 20 may be used to regulate the flow of gas between the barrel 101 and the operating system 100 . In the preferred embodiment of the herein disclosed design, the adjustment knob 20 has four indexed positions 25 , 26 , 27 and 28 . Also provided are the three gas ports 35 , 36 and 37 which regulate the flow of gas into the bore 38 , through the gas nozzle 30 , and into the operating system 100 . The adjustment knob 20 and the gas nozzle 30 , when attached by the provided pin 21 , form an assembly where the rotation of the adjustment knob 20 rotates the gas nozzle 30 within the housing 10 . When the indexing notches 25 - 27 are in contact with the ball detent 23 , a specific gas port 35 - 37 of the gas nozzle 30 is in communication with the gas port 44 of the housing 10 . When indexing notch 28 is in contact with the ball detent 23 , the gas nozzle 30 is rotated to a position where there is no gas port to communicate with the gas port 44 of the housing 10 . Gas port three provides a flow of gas which is optimized for the proper functioning of the rifle based on its barrel length, caliber and operation under optimal conditions. Gas port three 37 is also referred to as the “standard” setting. Gas port one 35 has an opening which is larger than the opening of gas port three 37 , thereby providing an increased quantity of gas to the operating system 100 of the host firearm. Gas port one 35 is used when the host weapon is dirty or the firearm's rate of fire needs be increased. Gas port one 35 is also referred to as the “adverse condition setting”. The third gas port 36 , generally referred to as gas port two, has an opening which is smaller in diameter than the opening of the “standard” gas port 37 . Gas port two 36 is for use when a silencer is affixed to the muzzle of the barrel 101 . This gas port 36 is also referred to as the “silencer setting”.
In sum, an adjustable gas block is provided for an autoloading firearm which utilizes an indirect gas operating system. Four pre-set positions are afforded the user of this device. Gas settings which are optimized for suppressor use, harsh environments, dirty weapons or when firing under ideal circumstances are also provided for. A position which prevents the flow of gas into the operating system is provided for. This system does not vent excess gas from the gas block into the atmosphere around it. Instead excess gas is trapped within the barrel and vented from the muzzle where a flash hider or silencer might allow the gasses to expand and cool.
Another embodiment of the adjustable gas block could eliminate the increased gas flow setting or the setting which blocks the flow of gas.
Still another embodiment of the adjustable gas block could be adapted to work with a direct gas impingement system such as found on M16 style rifles. The nozzle assembled could be modified to receive the gas tube found on such system and thereby regulate the flow of gas from the barrel into the operating system.
While the above drawings and description contain much specificity, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof.
Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents. | A firearm including a barrel, receiver, indirect gas system and an adjustable gas block designed to interface with the indirect gas system is provided. Four indexable positions of adjustment are provided for on the adjustable gas block. Positions of adjustment are selected based on the use of a silencer, use of under-powered ammunition, the presence of un-burnt powder and debris in the host firearms operating system, or if the weapon is being fired under “ideal” circumstances. The provided gas block is designed to function with an indirect gas operating system. Excess gas from the operating system is not vented from the gas block thereby generating excess flash and sound. No tool is required to manipulate the adjustment mechanism of the gas. | 5 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to a lighting device having a plurality of illuminating structures. More particularly, the invention provides a lighting device having at least one connector structure that permanently affixes the plurality of illuminating structures.
2. Background Art
Illuminating structures are well known. These structures have been used to add interest to children's toys and jewelry, create items for temporary lighting, and even as fishing lures. The use of chemiluminescent chemicals is one common method of creating an illuminating structure and is well known in the art. In these devices, a semi-translucent tube contains two chemicals. The mixture of the two chemicals creates a temporary lighting effect. To prevent the chemicals from mixing prematurely, the tube is filled with one of the chemicals, and ampules (frequently glass or plastic) that contain the second chemical are inserted into the tube. A user can then break the ampule to allow the chemicals to mix, generating the luminescent effect. Depending on the chemicals used, color of the tube, etc. different colors can be created. Various combinations of chemicals can be used to obtain a desired color and are discussed, for example, in U.S. Pat. No. 4,061,910 issued on Dec. 6, 1977.
Multiple colors may be desired to further add interest or functionality to a particular illuminating structure. In this case, barriers are frequently inserted into the tube that separate multiple ampules that contain different chemicals in order to generate the different colors. The barriers prevent the various chemicals from mixing, which would lessen the creation of distinct color areas. However, this adds a great deal of complexity to the manufacturing process since the various fluids, ampules, and barriers must be alternately inserted into a tube. When several color schemes are desired, the complexity is further increased.
Alternatively, tubes of varying colors have been inserted into a structure having recesses that subsequently hold the tubes in place. However, using this process does not allow for a substantially uniform structure (e.g., an elongated rod having multiple colors) because the recesses must be of a wider diameter than the tubes to be inserted. Further, because of the circular design, the tubes may be prone to fall out.
As a result, there exists a need for a lighting device that includes a plurality of elongate structures that create a luminescent effect, and at least one connector for permanently affixing the elongate structures together. The connector can be such that it forms a contiguous surface with the elongate structures.
SUMMARY OF THE INVENTION
The current invention provides a lighting device that includes multiple elongate structures, that each create a luminescent effect, and a connector that permanently attaches the elongate structures, forming a larger structure.
A first aspect of the invention provides a lighting device, comprising: a plurality of elongate structures, wherein each of the plurality of elongate structures includes a first end and a second end, and wherein each of the plurality of elongate structures creates a luminescent effect; and at least one connector, wherein the at least one connector permanently affixes an end of a first elongate structure to an end of a second elongate structure.
A second aspect of the invention provides a lighting device, comprising: a plurality of tubes, each of the plurality of tubes including: a first end; a second end; a first solution within each tube; and an ampule within the first solution containing a second solution, wherein each ampule is breakable to allow the first solution to mix with the second solution to create a luminescent effect; at least one connector, the at least one connector including: a first protrusion for insertion into the first end of a first tube; a second protrusion for insertion into the first end of a second tube, wherein the at least one connector permanently affixes the first end of a first tube to the first end of a second tube and wherein the at least one connector forms a contiguous surface with the first tube and the second tube.
A third aspect of the invention provides a lighting device, comprising: a plurality of hollow elongate structures, wherein each of the plurality of elongate structures includes: an inner chamber; a first end having a first barrier element disposed within the inner chamber; a second end having a second barrier element disposed within the inner chamber; a first solution disposed between the first barrier element and the second barrier element within the inner chamber; and an ampule within the first solution containing a second solution, wherein the ampule is breakable to allow the first solution to mix with the second solution to create a luminescent effect; and at least one connector, wherein the at least one connector permanently affixes an end of a first elongate structure to an end of a second elongate structure.
The exemplary aspects of the present invention are designed to solve the problems herein described and other problems not discussed, which are discoverable by a skilled artisan.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of this invention will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings in which:
FIG. 1 depicts a cross-section of a connector according to one aspect of the invention;
FIG. 2 depicts a cross-section of a portion of a lighting device according one aspect of the invention;
FIG. 3 depicts a cross-section of a lighting device according to another aspect of the invention; and
FIG. 4 depicts a cross-section of a lighting device according to yet another aspect of the invention.
It is noted that the drawings of the invention are not to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The current invention provides a lighting device that includes a plurality of elongate structures that each creates a luminescent effect, and at least one connector that permanently affixes the elongate structures to form the lighting device.
Turning to FIG. 1, a cross-section of an exemplary connector 10 is shown. Connector 10 has a first protrusion 12 and a second protrusion 14 that each permanently affixes to an end of an elongate structure. While first protrusion 12 is shown opposing second protrusion 14 , it is understood that first protrusion 12 and second protrusion 14 can be disposed in any relation to each other. Further it is understood that connector 10 can comprise more than two protrusions for permanently affixing ends of elongate structures, and can affix any number of elongate structures in any relation to each other.
FIG. 2 shows a portion of a lighting device 20 that comprises a first elongate structure 22 and a second elongate structure 24 permanently affixed by connector 10 . When attached, connector 10 can form a contiguous outer surface 25 with elongate structures 22 , 24 . Alternatively, connector 10 can have an outer surface unique from elongate structures 22 , 24 . For example, connector 10 can include bumps for gripping lighting device 20 , form a widened portion of lighting device 20 , etc. Connector 10 can be attached to the surface of inner chamber 26 and/or end 27 of each elongate structure 22 , 24 using any means now known or later developed, including: an adhesive, fusion, etc.
While connector 10 is shown having a relative size and shape when compared with elongate structures 22 , 24 , it is understood that this size and shape is only exemplary, and the invention is not limited to any particular size or shape of connector 10 . Similarly, elongate structures 22 , 24 can have any desired shape. For example, elongate structures 22 , 24 can be tubular, rectangular, triangular, etc. Further, elongate structures 22 , 24 can be any width, and can have different widths. Elongate structures 22 , 24 can also have an inner chamber 26 or be solid.
Each elongate structure 22 , 24 creates a luminescent effect. For example, elongate structures 22 , 24 can be translucent and configured to create a chemiluminescent effect. Elongate structures 22 , 24 are shown having an inner chamber 26 and an ampule 28 disposed therein. Inner chamber 26 can also contain a first solution, and ampule 28 can contain a second solution. Ampule 28 can be breakable to allow the first solution to mix with the second solution to create the luminescent effect when desired. Various combinations of solutions can be used to generate the desired luminescent effect. Further, each elongate structure 22 , 24 can include different solutions to generate a different luminescent effect (i.e., a unique color). Additionally, elongate structures can comprise different colors (e.g., tinting) to vary the luminescent effect.
While elongate structures 22 , 24 are shown using the chemiluminescent effect described above, it is understood that elongate structures 22 , 24 can create the luminescent effect using any means now known or later developed. Similarly, connector 10 can also create its own luminescent effect and/or propagate the luminescent effect generated by elongate structures 22 , 24 using any means.
As shown in FIG. 2, connector 10 acts as a barrier to trap the first solution and ampule 28 within inner chamber 26 of elongate structures 22 , 24 . Alternatively, FIG. 3 depicts a lighting device 120 comprising elongate structures 122 , 124 and connector 110 . Similar to FIG. 2, each elongate structure includes an inner chamber 126 containing a first solution 127 and an ampule 128 containing a second solution 129 . However, each elongate structure 122 , 124 in FIG. 3 further includes a barrier element 130 .
Barrier element 130 can be used to trap first solution 127 and ampule 128 within inner chamber 126 . Barrier element 130 can be permanently affixed to the surface of inner chamber 126 using any means, including; an adhesive, fusion, etc. Alternatively, barrier element 130 can be placed in the desired position and secured by conforming to the shape of inner chamber 126 . When barrier element 130 is permanently affixed to elongate structure 122 , 124 , connector 110 can be permanently affixed to barrier element 130 in addition to, or alternative to being permanently affixed to elongate structures 122 , 124 using any means as described above.
Elongate structures 122 , 124 are shown having a closed end 132 for trapping first solution 127 and ampule 128 on the non-affixed end. Alternatively, FIG. 4 shows a lighting device 220 having elongate structures 222 , 224 with barrier elements 230 , 234 , 236 for trapping a first solution 227 and ampule 228 within inner chamber 226 . Barrier element 234 is configured to allow an additional connector 210 to be affixed to the end, while barrier element 236 is configured to provide similar surface as a closed end. While lighting devices 120 , 220 are shown having elongate structures having either an open end with a barrier and a closed end or two open ends with barriers, it is understood that a lighting device can include any combination of elongate structures. For example, a lighting device having three elongate structures affixed in a row by two connectors may use two elongate structures having a closed end for each end elongate structure, and an elongate structure having two open ends for the center elongate structure.
The foregoing description of various aspects of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of the invention as defined by the accompanying claims. | A multi-structure lighting device. The lighting device includes multiple elongate structures that create a luminescent effect, and at least one connector. Each elongate structure is permanently affixed to another elongate structure by the connector. The connector can be a cross-shaped connector that includes ends that are inserted into the ends of chemiluminescent tubes thereby permanently affixing the tubes. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 08/108,043 filed Aug. 16, 1993, now abandoned.
FIELD OF THE INVENTION
This invention relates to a bearing material and more particularly to a bearing material for rotary cone rock bits for drilling oil wells or the like.
BACKGROUND OF THE INVENTION
Heavy-duty rock bits are employed for drilling wells in subterranean formations for oil, gas, geothermal steam, and the like. Such bits have a body connected to a drill string and a plurality, typically three, of hollow cutter cones mounted on the body for drilling rock formations. The cutter cones are mounted on steel journals or pins integral with the bit body at its lower end. In use, the drill string and bit body are rotated in the bore hole, and each cone is caused to rotate on its respective journal as the cone contacts the bottom of the bore hole being drilled.
While such a rock bit is used in hard, tough formations, high pressures and temperatures are encountered. The total useful life of a rock bit in such severe environments is on the order of 20 to 200 hours for bits in sizes of about 6 to 28 inch diameter at depths of about 5,000 to 20,000 feet. Useful lifetimes of about 65 to 150 hours are typical.
When a rock bit wears out or fails as a bore hole is being drilled, it is necessary to withdraw the drill string for replacing the bit. Prolonging the time of drilling minimizes the lost time in "round tripping" the drill string for replacing bits.
Replacement of a drill bit can be required for a number of reasons, including wearing out or breakage of the structure contacting the rock formation. One reason for replacing the rock bits includes failure or severe wear of the journal bearings on which the cutter cones are mounted. The journal bearings are subjected to very high pressure drilling loads, high hydrostatic pressures in the hole being drilled, and high temperatures due to drilling, as well as elevated temperatures in the formation being drilled. Considerable development work has been conducted over the years to produce improved bearing structures and bearing materials that minimize wear and failure of such bearings.
A variety of bearing compositions have been employed in the past. Bearing compositions which have been used include cast or wrought forms of copper-based spinodal composites such as disclosed in U.S. Pat. No. 4,641,976, the disclosure of which is expressly incorporated herein by reference. These bearing compositions comprise ternary alloys of copper with nickel and tin but may contain other metals to further improve the metallurgical properties.
In order to further enhance properties of bearing material various additions to alloys have been proposed. However, some elements otherwise desirable for addition to improve properties are insoluble or only slightly soluble in copper solid solution and will form compounds that segregate during melting and subsequent thermomechanical processing. Metalloids such as Sb, As, S, Sn, Se, Te, Be, P, etc., are examples of elements having, at best, limited solid solubility in copper but which form stable compounds that would usefully improve strength and toughness of a copper alloy matrix through a combination of several of the phase transformations such as solid solution strengthening, precipitation hardening and spinodal decomposition. However, these metalloidic elements are highly surface active in a copper matrix and tend to segregate at the high energy areas such as grain boundaries, dislocations and other crystal defects.
In view of the foregoing, it is evident that it is desirable to provide a bearing material for rock bits that is less susceptible to premature wear or failure during service at the high temperatures, bearing pressures and rotational speeds often found in modern rock bits that combines high strength and other desirable metallurgical properties through a combination of several phase transformations such as solid solution strengthening, precipitation hardening and spinodal composition without undesirable segregation of ingredients.
SUMMARY OF THE INVENTION
The present invention provides a bearing material for a rock bit which comprises a sintered powder mixture, i.e. compact, of a copper base alloy and one or more other metals of limited solid solubility that avoids the problems of segregation during solidification and thermomechanical processing. Since the bearing material is made by sintering a powder mixture, segregation that results from solidification after melting is avoided. Thus, alloying ingredients that would segregate upon casting may be used. Furthermore, sintered compacts of a hardness suitable for bearing applications, e.g. HRc 30 to 40 or equivalent, are obtained.
Bearing components can also be manufactured by extrusion or a strip or plate forming, i.e. rolling, process which is more cost-effective as compared to conventional machining processes. Moreover, such processes also impart an amount of cold work into the compound which results in grain refinement and higher strength. Strip or plate can additionally be formed into bearing components such as sleeves or stamped to produce thrust washers. Similarly, spindle caps and sleeves, as well as other bearing components, can also be made by extrusion. Costly machining operations can be minimized or eliminated by forming the sintered compact into bearing components.
In accordance with the practice of the invention a bearing material for a rock bit is provided which comprises a sintered powder mixture comprising a copper base alloy with about 5-20 wt. % of a transition metal soluble in copper and in solid solution therewith, such as Fe, Co, Ni and Cr, and about 0.5-10 wt. % of at least one metalloid such as Sn, Se, Te, Be, P, Sb, As, S, etc., which has limited solid solubility in copper and forms a stable compound with the transition metal or copper that is substantially insoluble in solid solution with copper. Advantageously, about 0.1-0.8 wt. % of at least one strengthening agent may be added from the group consisting of Zr, Mo, Nb and Al, the amount of strengthening agent not exceeding about 5 wt. % of the sintered powder mixture.
Bearing components that may be made in sintered form in accordance with the invention include sleeves, thrust washers and spindle caps in rock bits such as are described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
A rock bit with such a bearing material is illustrated in semi-schematic perspective in FIG. 1 and in a partial cross-section in FIG. 2.
FIGS. 3-7 are photomicrographs illustrating the differences in microstructures of alloy compositions, as follows:
FIG. 3 is a microstructure of cast spinodal alloy (Cu-15Ni-8Sn) at 200×;
FIG. 4 is a microstructure of a cast spinodal alloy with second-phase segregation reduced by heat treatment, at 200×;
FIG. 5 is a microstructure of a powder metallurgically produced spinodal alloy (Cu-15Ni-8Sn) at 200×;
FIG. 6 is a microstructure of cast spinodal alloy of FIG. 3 at 500×; and
FIG. 7 is a microstructure of powder metallurgically produced spinodal alloy (Cu-15Ni-8Sn) of FIG. 5 at 750×.
DETAILED DESCRIPTION
A rock bit employing a sintered powder compact, i.e. sintered powder mixture, as a bearing material comprises a body 10 having three cutter cones 11 mounted on its lower end. A threaded pin 12 is at the upper end of the body for assembly of the rock bit onto a drill string for drilling oil wells or the like. A plurality of tungsten carbide inserts 13 are pressed into holes in the surfaces of the cutter cones for bearing on the rock formation being drilled. Nozzles 15 in the bit body introduce drilling mud into the space around the cutter cones for cooling and carrying away formation chips drilled by the bit.
FIG. 2 is a fragmentary, longitudinal cross section of the rock bit, extending radially from the rotational axis 14 of the rock bit through one of the three legs on which the cutter cones 11 are mounted. Each leg includes a journal pin 16 extending downward and radially inward on the rock bit body. The journal pin includes a cylindrical bearing surface having a hard metal insert 17 on a lower portion of the journal pin. An open groove 18 is provided on the upper portion of the journal pin. Such a groove may, for example, extend around 60% or so of the circumference of the journal pin, and the hard metal 17 can extend around the remaining 40% or so. The journal pin also has a cylindrical nose 19 at its lower end.
Each cutter cone 11 is in the form of a hollow, generally-conical steel body having tungsten carbide inserts 13 pressed into holes on the external surface. For long life, the inserts may be tipped with a polycrystalline diamond layer. Such tungsten carbide inserts provide the drilling action by engaging a subterranean rock formation as the rock bit is rotated. Some types of bits have hard-faced steel teeth milled on the outside of the cone instead of carbide inserts.
The cavity in the cone contains a cylindrical bearing surface including an insert 21 in the form of a sintered compact which is metallurgically bonded within the groove in the steel of the cone or as a floating insert in a groove in the cone. The sintered compact insert 21 in the cone engages the hard metal insert 17 on the leg and provides the main bearing surface for the cone on the bit body. The sintered powder material in compact form provides a good bearing surface that is both tough and ductile to enhance the longevity of the rock bit as it works in a bore hole. The sintered compact bearing surface runs against the journal bearing. The rock bit as it works in a bore hole exerts pressure to the loaded side of the journal, thus contacting the sintered bearing bonded to the cone against the hard metal surface 17.
A nose button 22 is between the end of the cavity in the cone and the nose 19 and carries the principal thrust loads of the cone on the journal pin and a thrust washer 22a, similar to 22, may be provided. A bushing 23 surrounds the nose and provides additional bearing surface between the cone and journal pin.
The nose button 22 and bushing 23 could be made as a single piece, i.e., as a spindle cap.
Other types of bits, particularly for higher rotational speed applications, have roller bearings instead of the exemplary journal bearings illustrated herein.
A plurality of bearing balls 24 are fitted into complementary ball races in the cone and on the journal pin. These balls are inserted through a ball passage 26, which extends through the journal pin between the bearing races and the exterior of the rock bit. A cone is first fitted on the journal pin, and then the bearing balls 24 are inserted through the ball passage. The balls carry any thrust loads tending to remove the cone from the journal pin and thereby retain the cone on the journal pin. The balls are retained in the races by a ball retainer 27 inserted through the ball passage 26 after the balls are in place. A plug 28 is then welded into the end of the ball passage to keep the ball retainer in place.
The bearing surfaces between the journal pin and cone are lubricated by a grease composition. Preferably, the interior of the rock bit is evacuated, and grease is introduced through a fill passage (not shown). The grease thus fills the regions adjacent the bearing surfaces plus various passages and a grease reservoir. The grease reservoir comprises a cavity 29 in the rock bit body, which is connected to the ball passage 26 by a lubricant passage 31. Grease also fills the portion of the ball passage adjacent the ball retainer, the open groove 18 on the upper side of the journal pin, and a diagonally extending passage 32 therebetween. Grease is retained in the bearing structure by a resilient seal 33 between the cone and journal pin.
A pressure compensation subassembly is included in the grease reservoir 29. This subassembly comprises a metal cup 34 with an opening 36 at its inner end. A flexible rubber bellows 37 extends into the cup from its outer end. The bellows is held in place by a cap 38 with a vent passage 39. The pressure compensation subassembly is held in the grease reservoir by a snap ring 41.
When the rock bit is filled with grease, the bearings, the groove 18 on the journal pin, passages in the journal pin, the lubrication passage 31, and the grease reservoir on the outside of the bellows 37 are filled with grease. If the volume of grease expands due to heating, for example, the bellows 37 is compressed to provide additional volume in the sealed grease system, thereby preventing accumulation of excessive pressures. High pressure in the grease system can damage the seal 33 and permit abrasive drilling mud or the like to enter the bearings. Conversely, if the grease volume should contract, the bellows can expand to prevent low pressures in the sealed grease systems, which could cause flow of abrasive and/or corrosive substances past the seal.
As an illustration of the bearing material in accordance with the present invention for rock bits, a ternary copper-based alloy is prepared which is especially suitable for tri-cone rotary petroleum and mining bits. These alloys are in the form of Cu-M-X where:
"M" is a transition metal, such as Fe, Co, Ni, Cr, present in the range of about 5-20 wt. %, which is readily soluble in the copper matrix and forms a solid solution with copper; and
"X" is a metalloid, such as Sb, As, S, Sn, Se, Te, Be, P, etc., present in the range of about 0.5-10 wt. % and which has a limited solid solubility in copper but forms stable compounds with the solute, i.e. the transition metal M and/or copper.
The compound forms may be described as M a X b , where a and b are stoichiometric coefficients, because of the thermodynamic interaction between the metalloid and the transition metal. These metalloidic elements are usually highly surface-active in a copper matrix and often tend to segregate at the high-energy areas such as grain boundaries, dislocations and other crystal defects.
It is also desirable to add one or more strengtheners from a group consisting of elements such as Zr, Mo, Nb and Al, in quantities of 0.1-0.8 wt. % with the total addition of these strengtheners not exceeding 5 wt. % in the sintered mixture. These elements add high strength and other desirable properties for bearing applications, largely through a combination of one or several of the phase transformations such as solid solution strengthening, precipitation hardening and spinodal decomposition. Presently preferred compositions include 9-15 wt. % Ni and 5-10 wt. % Sn, balance substantially copper, to which up to 5 wt. % strengthener may be added.
The combined addition of M and X along with one or more elements selected from the group Zr, Mo, Nb and Al in small quantities of 0.1-0.8 wt. % with total addition of these (apart from M and X) not exceeding 5 wt. % in copper, is believed to render high strength and other desirable properties for bearing applications. Such desirable properties result either through precipitation hardening or spinodal decomposition in combination with solid solution strengthening. For example, the Cu-Be-Co alloys offer a combination of high strength and desirable tribological properties mainly through precipitation hardening. The Cu-Ni-Sn alloys derive an excellent combination of these properties through spinodal decomposition. Other notable copper alloys such as aluminum bronze, Invar and Cu-Mn-Se systems obtain their desirable properties through a combination of precipitation and solid solution strengthening. In general, the same or similar compositions available for bearing use in cast or wrought form can also be made by powder metallurgical techniques with substantially less segregation of limited-solubility components.
Because of the limited solid solubility of metalloidic elements, their segregation during solidification and subsequent thermoprocessing would be difficult to control if the composition were made according to standard casting practices, since significant segregation would occur during solidification and subsequent heat treatments. However, it has been discovered that if these alloys are processed using powder metallurgical techniques, the segregation of the metalloids can be eliminated or limited to acceptable levels and can be exploited to impart useful mechanical properties for bearing applications.
Bearing material in accordance with the invention is produced by powder metallurgical processing wherein a powder metal mixture of the components is provided in the prescribed proportions, hot-pressed and sintered or cold-pressed and sintered at sintering temperatures using standard sintering and pressing equipment known to industry. The resulting sintered compact can be rolled into a strip or plate of desired thickness and heat treated to the desired combination of strength and ductility and used in that form or further machined to suitable dimensions for use in rock bits. The powder metal mixture may be provided in any suitable form such as alloy powder made by melting, atomization and comminuting one or more pre-alloyed mixtures. Production of sintered compacts and metal strips is performed by Ametek, Specialty Metal Products Division, Wallingford, Conn.
Using powder metallurgy to produce sintered compacts of the bearing material described avoids the problem of adverse segregation of the metalloidic elements and sparingly soluble components. The beneficial strengthening effect of the metalloidic compound can be achieved without the undesirable effects of segregation.
It has been determined that to achieve a strength level (tensile stress) of 150 Ksi or greater, which is desirable for bearing properties, a copper alloy system should incorporate a combination of one or more basic elements such as nickel, manganese, chromium, iron, aluminum, etc. However, such ternary or tertiary solute additions, especially in combination with any metalloid, such as tin, beryllium, lead or selenium, would restrict the solubility of these elements in copper. For instance, although nickel is 100% soluble in copper, the binary copper-nickel alloys seldom possess the required strength. However, a minor addition of a metalloid such as tin in combination with nickel increases the strength of the alloy considerably through a spinodal decomposition. Unfortunately, any metalloidic addition in excess of its solubility limit results in an undesirable segregation of metalloid or its compound. In the Cu-15Ni-8Sn spinodal bearing alloy, the segregation of gamma phase, which is primarily a compound of tin, at the grain boundaries, decreases the strength and ductility of the alloy and limits its performance in the bearing applications.
The differences in the microstructures of an illustrated spinodal alloy composition (Cu-15Ni-8Sn) are shown in FIGS. 3-7. The microstructures of cast spinodal alloy in FIGS. 3 and 4 exhibit significant gamma segregation. The microstructure shown in FIG. 3 is unacceptable for bearing applications since the severe segregation at the grain boundaries and subsequent solute depletion in the matrix lowers the strength and ductility. The microstructure of the cast alloy in FIG. 4 exhibits relatively lower solute segregation due to the improvement in the heat treatment conditions. The segregation is completely eliminated in the powder metallurgically (PM) processed alloy shown in FIG. 5. All these three micrographs are at the same magnification for the sake of comparison. It is evident that the grain size of the PM alloy is much finer and more uniform than the cast alloys shown in FIGS. 3 and 4.
The advantages of powder metallurgical processing are further illustrated in the photomicrographs of FIGS. 6 and 7 at relatively higher magnifications. The microstructure of the cast alloy shown in FIG. 6 indicates severe segregation and coarser grains than that of the PM alloy shown in FIG. 7.
Additional advantages of the powder metallurgically produced bearing alloys and the strip forming methodology include:
(1) Efficient utilization of material (minimization of waste in machining and subsequent operations), which offers greater cost savings.
(2) Strip forming of bearing components avoids expensive machining operations and enables incorporation of a desired amount of cold work for higher strength and microstructural refinements.
(3) Improved product consistency; any slight variation in the standard heat treatment conditions (solution treatment, quenching and aging) results in a greater variation in the end product's properties. Thus, stringent heat treatment conditions are essential for maintaining the product consistency in the cast alloy but not in PM alloys. The PM alloys are produced from the individual powder's exact composition, thus product homogeneity is an inherent advantage in these alloys.
(4) PM alloys are adaptable for further improvement by alloying additions because they are not bound by the solubility limitations. With the addition of more nickel or metalloidic elements it is possible to enhance the strength of these alloys, or with molybdenum one could modify the coefficient of thermal expansion closer to that of steel, for example, for enhanced bearing performance in the drill bits. In the case of cast alloys, the solute addition beyond the solubility limits results in an adverse segregation problem, thereby limiting further alloy addition to improve properties.
It is apparent from the foregoing that various changes and modifications may be made without departing from the invention. Accordingly, the invention should be limited only by the appended claims, wherein: | A method of making a bearing component for a rotary cone rock bit which obtains the beneficial strengthening effect of metalloids and their compounds without the undesirable effects of segregation. The method includes rolling a sintered compact to form a strip or plate of a particular composition that would be subject to segregation if produced by casting and thereafter forming the strip or plate into the bearing component. Additionally, the rolled sintered compact may be heat treated and machined after heat treating. A method of making a rotary cone rock bit is also disclosed. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 13/012,661, which was filed on Jan. 24, 2011, now U.S. Pat. No. 8,228,717, which issued on Jul. 24, 2012, which is a continuation of U.S. patent application Ser. No. 12/242,228, which was filed on Sep. 30, 2008, now U.S. Pat. No. 7,876,603, which issued on Jan. 25, 2011.
BACKGROUND
1. Field of Invention
The invention relates generally to current generators, and more particularly, to spin current generators for spintronics applications.
2. Description of Related Art
This section is intended to introduce the reader to various aspects of the art that may be related to various aspects of the present invention, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present invention. Accordingly, it should be understood that these statements are to be read in this light and not as admissions of prior art.
The development of microelectronics has led to large increases in integration density and efficiency. However, the conventional electronic methods of operation by applying voltage to control electron charge are fundamentally limited.
Further improvements in nonvolatility, speed, and size of electronic devices may require advancements in new technology. Spintronics, or spin electronics (also known as spin transport electronics and magnetoelectronics), refers to the study of the spin of an electron in solid state physics and the possible devices that may advantageously use electron spin properties instead of, or in addition to, the conventional use of electron charge.
The spin of an electron has two states and is characterized as being either “spin up” or “spin down.” Conventional spintronics devices have relied on systems that provide bidirectional current to alter the electron spins in the device. For example, one spintronics application involves data storage through a spintronics effect known as giant magnetoresistance (GMR). The GMR structure includes alternating ferromagnetic and nonmagnetic metal layers, and the magnetizations and electron spins in each of these magnetic layers provide resistance changes through the layers. The resistance of the GMR may change from low (if the magnetizations are parallel) to high (if the magnetizations are antiparallel), and the inducing and detecting of such magnetoresistance changes are the basis for writing and reading data. Another example of spintronics devices includes spin torque transfer magnetic random access memory (STT-MRAM). STT-MRAM also exploits electron spin polarity by utilizing the electron spin to switch the magnetization of ferromagnetic layers to provide two programmable states of low and high resistance.
This alteration of magnetization typically employs a bidirectional programming current to change the magnetizations of the layers in a memory cell. However, bidirectional programming logic requires more cell space. A transistor select device is required for each memory cell, and this also increases the cell area. Furthermore, bidirectional programming logic is generally more complicated and less efficient than unidirectional programming logic.
BRIEF DESCRIPTION OF DRAWINGS
Certain embodiments are described in the following detailed description and in reference to the drawings in which:
FIG. 1 depicts a block diagram of a processor-based system in accordance with an embodiment of the present technique;
FIG. 2 depicts a device architecture and method by which a spin current generator may enable a spintronics device in accordance with embodiments of the present technique;
FIG. 3 depicts a spin current generator capable of generating non-polarized or adjustably polarized current in accordance with embodiments of the present invention; and
FIG. 4 depicts a spin current generator capable of generating adjustably polarized current in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
Spintronics devices write and store information by manipulating electron spin in a particular orientation. As previously discussed, information may be stored by programming magnetic layers in a memory cell into low resistance and high resistance states. Switching between the two resistance states typically employs a bidirectional programming current, where a current passed in one direction may orient the magnetization of memory cell layers to a low resistance state, and a current passed in an opposite direction may orient the magnetization of memory cell layers to a high resistance state. Since bidirectional programming logic requires more complicated circuitry and more chip space, a method of generating electron currents with desired spin polarizations may reduce the complexity and size of memory cell area or other devices requiring currents of different polarities by facilitating unidirectional programming. The following discussion describes the systems and devices, and the operation of such systems and devices in accordance with the embodiments of the present technique.
FIG. 1 depicts a processor-based system, generally designated by reference numeral 10 . As is explained below, the system 10 may include various electronic devices manufactured in accordance with embodiments of the present technique. The system 10 may be any of a variety of types such as a computer, pager, cellular phone, personal organizer, control circuit, etc. In a typical processor-based system, one or more processors 12 , such as a microprocessor, control the processing of system functions and requests in the system 10 . As is explained below, the processor 12 and other subcomponents of the system 10 may include resistive memory devices manufactured in accordance with embodiments of the present technique.
The system 10 typically includes a power supply 14 . For instance, if the system 10 is a portable system, the power supply 14 may advantageously include a fuel cell, a power scavenging device, permanent batteries, replaceable batteries, and/or rechargeable batteries. The power supply 14 may also include an AC adapter, so the system 10 may be plugged into a wall outlet, for instance. The power supply 14 may also include a DC adapter such that the system 10 may be plugged into a vehicle cigarette lighter, for instance.
Various other devices may be coupled to the processor 12 depending on the functions that the system 10 performs. For instance, a user interface 16 may be coupled to the processor 12 . The user interface 16 may include buttons, switches, a keyboard, a light pen, a mouse, a digitizer and stylus, and/or a voice recognition system, for instance. A display 18 may also be coupled to the processor 12 . The display 18 may include an LCD, an SED display, a CRT display, a DLP display, a plasma display, an OLED display, LEDs, and/or an audio display, for example. Furthermore, an RF sub-system/baseband processor 20 may also be coupled to the processor 12 . The RF sub-system/baseband processor 20 may include an antenna that is coupled to an RF receiver and to an RF transmitter (not shown). One or more communication ports 22 may also be coupled to the processor 12 . The communication port 22 may be adapted to be coupled to one or more peripheral devices 24 such as a modem, a printer, a computer, or to a network, such as a local area network, remote area network, intranet, or the Internet, for instance.
The processor 12 generally controls the system 10 by implementing software programs stored in the memory. The software programs may include an operating system, database software, drafting software, word processing software, and/or video, photo, or sound editing software, for example. The memory is operably coupled to the processor 12 to store and facilitate execution of various programs. For instance, the processor 12 may be coupled to the system memory 26 , which may include spin torque transfer magnetic random access memory (STT-MRAM), magnetic random access memory (MRAM), dynamic random access memory (DRAM), and/or static random access memory (SRAM). The system memory 26 may include volatile memory, non-volatile memory, or a combination thereof. The system memory 26 is typically large so that it can store dynamically loaded applications and data. In some embodiments, the system memory 26 may include STT-MRAM devices, such as those discussed further below.
The processor 12 may also be coupled to non-volatile memory 28 , which is not to suggest that system memory 26 is necessarily volatile. The non-volatile memory 28 may include STT-MRAM, MRAM, read-only memory (ROM), such as an EPROM, resistive read-only memory (RROM), and/or flash memory to be used in conjunction with the system memory 26 . The size of the ROM is typically selected to be just large enough to store any necessary operating system, application programs, and fixed data. Additionally, the non-volatile memory 28 may include a high capacity memory such as a tape or disk drive memory, such as a hybrid-drive including resistive memory or other types of non-volatile solid-state memory, for instance. As is explained in greater detail below, the non-volatile memory 28 may include STT-MRAM devices manufactured in accordance with embodiments of the present technique.
Both the system memory 26 and the non-volatile memory 28 may include memory cells programmable by manipulation of electron spin or other spintronics components. For example, the memory cells may include MRAM cells, STT-MRAM cells, or memory cells that utilize the giant magnetoresistive (GMR) effect. The system memory 26 and the non-volatile memory 28 may further include a spin current generator to generate single-spin polarity current (i.e., a current that can be generated with a spin polarity in only one direction), bi-spin polarity current (i.e., a current that can be generated with a spin polarity in either direction), non-polarized current or arbitrary spin-polarized current to program the memory cells, as will be further described below.
FIG. 2 depicts an example of a portion of a spintronics device and a method by which a spin current generator 100 may be used to program the device in accordance with embodiments of the present technique. The portion of the spintronics device illustrated here includes an array 102 of memory cell components 104 with magnetic layers 106 and 108 . As will be appreciated, each memory cell component 104 may form the memory portion of a single memory cell in the array 102 . The memory cell components 104 may include magnetic tunnel junctions (MTJs), stacks of ferromagnetic and nonmagnetic layers, or any other structure in which magnetization may be manipulated to alter the structure's magnetoresistance state. Furthermore, the memory cell components 104 may be components of magnetic random access memory (MRAM) cells, spin torque transfer magnetic random access memory (STT-MRAM) cells, or any other device exploiting the manipulation of electron spin to program the cell.
In this example, the memory cell component 104 includes a pinned layer 106 and a free layer 108 . A memory cell may be “written” or “programmed” by switching the magnetization of the free layer 108 in the memory cell component 104 , and the cell may be read by determining the resistance across the free layer 108 and the pinned layer 106 . The layers 108 and 106 may comprise ferromagnetic materials, such as Co, Fe, Ni or its alloys, NiFe, CoFe, CoNiFe, or doped alloys CoX, CoFeX, CoNiFeX (X=B, Cu, Re, Ru, Rh, Hf, Pd, Pt, C), or other half-metallic ferromagnetic material such as Fe3O4, CrO2, NiMnSb and PtMnSb, and BiFeO, for instance. The pinned layer 106 is so named because it has a magnetization with a fixed or pinned preferred orientation, and this is represented by the unidirectional arrow illustrated in the pinned layer 106 . An additional layer of antiferromagnetic material may be deposited below the pinned ferromagnetic layer to achieve the pinning through exchange coupling. The bidirectional arrow illustrated in the free layer 108 represents that the free layer 108 may be magnetized either in a direction parallel to the pinned layer 106 , which gives a low resistance, or in a direction antiparallel to the pinned layer 106 , which gives a high resistance. The memory cell component 104 may also include a nonmagnetic layer between the free layer 108 and the pinned layer 106 to serve as an insulator between the two layers 108 and 106 , thereby forming a MTJ structure in this example. The nonmagnetic layer may include materials such as AlxOy, MgO, AN, SiN, CaOx, NiOx, HfO2, Ta2O5, ZrO2, NiMnOx, MgF2, SiC, SiO2, SiOxNy, for example.
The spin current generator 100 is connected to each memory cell in the array 102 through source lines 110 . In the presently illustrated embodiment, each of the memory cell components 104 is coupled in series to form a string, such that each of the memory cell components 104 is coupled to a common source line 110 . When a memory cell is selected to be programmed, the spin current generator 100 sends a spin polarized current through the source line 110 to the selected memory cell and memory cell component 104 . If the memory cell is to be programmed to a low resistance state (“write 1 operation”) 114 , the spin current generator 100 will generate a current polarized in one direction (e.g., to the left) 116 , and the left-polarized current will switch the magnetization of the free layer 108 to the left. Because the magnetization of the pinned layer 106 is also directed to the left, the magnetizations of the free layer 108 and the pinned layer 106 are parallel, and the memory cell is programmed to a low resistance state. Likewise, if the memory cell is to be programmed to a high resistance state (“write 0 operation”) 118 , the spin current generator 100 will generate a current polarized in an opposite direction (to the right) 120 , and the right-polarized current will switch the magnetization of the free layer 108 to the right. Because the magnetization of the pinned layer 106 is directed to the left, the magnetizations of the free layer 108 and the pinned layer 106 are antiparallel, and the memory cell is programmed to a high resistance state.
The method depicted in accordance with embodiments of the present technique thus enables the memory cells or other spintronics devices to be programmed by a unidirectional current, allowing for simpler unidirectional programming logic. As previously discussed, conventional spintronics devices, including STT-MRAM devices, typically use bidirectional programming logic, meaning the write current is driven in opposite directions through a device cell stack to switch the cell between different programmable states. For example, in a STT-MRAM cell, a write current may be driven from a transistor source to a transistor drain, and then through a MTJ to program the memory cell to a high resistant state. To program a memory cell to a low resistance state, a write current may be driven from a MTJ to a transistor drain to a transistor source. Unidirectional programming logic may be simpler and more efficient than bidirectional programming logic. Also, the array 102 may be fabricated without a separate transistor for each cell, which further decreases cell size and cost. By utilizing a spin current generator 100 which may generate a spin current polarized in either direction (a bi-spin polarity current), the memory cell component 104 may be programmed with a unidirectional current, as described further below. Further, in certain embodiments, a single-spin polarity current, or a non-polarized spin current may be utilized to program a memory cell component 104 , by adding certain features or layers to the memory cell component 104 , such that the memory cell component 104 is able to exploit the properties of the current to facilitate the changing of the magnetization of a free ferromagnetic layer, therein. For example, in FIG. 2 , if a non-polarized current is passed through the memory cell component 104 , the pinned layer 106 may reflect the current towards the free layer 108 and switch the magnetization direction of the free layer 108 to the opposite direction of the pinned layer 106 .
One embodiment of the present invention, a spin current generator configured to generate a unidirectional current to adjust polarization direction in a spintronics device, is illustrated in FIG. 3 , where a spin current generator 200 can generate a non-polarized current 212 or a single-spin polarized current 214 . The bidirectional arrows depicting the non-polarized current 212 represent that the current is not yet polarized in any direction. Conversely, the unidirectional arrow depicting the polarized current 214 represent that the current is polarized in one direction (single-spin polarized). The spin current generator 200 includes a spin-polarizing layer 202 , which may comprise ferromagnetic materials, such as Co, Fe, Ni or its alloys, NiFe, CoFe, CoNiFe, or doped alloys CoX, CoFeX, CoNiFeX (X=B, Cu, Re, Ru, Rh, Hf, Pd, Pt, C), or other half-metallic ferromagnetic material such as Fe3O4, CrO2, NiMnSb and PtMnSb, and BiFeO, for instance. The spin current generator 200 may also include a nonmagnetic layer 204 which may be nonconductive and include some combination of AlxOy, MgO, AN, SiN, CaOx, NiOx, HfO2, Ta2O5, ZrO2, NiMnOx, MgF2, SiC, SiO2, or SiOxNy, for example, or conductive and include some combination of Cu, Au, Ta, Ag, CuPt, CuMn or other nonmagnetic transition metal, for example. The spin-polarizing layer 202 and the nonmagnetic layer 204 may be isolated from a material 206 by an insulative material 208 . In some embodiments, the material 206 may generate heat (“heater material”), and in other embodiments, the material 206 may comprise piezoelectric materials (“piezoelectric material”).
In some embodiments, the material 206 may incorporate some combination of heat generating and piezoelectric materials, or the material 206 may comprise more than one heat generating and/or piezoelectric material. As used in the present specification, the term “layer” refers to materials formed in parallel, with one material disposed over another (e.g., layers 204 , 202 , and 210 of FIG. 3 ). In contrast other materials, not referred to as layers, may be formed perpendicular to a stack of parallel materials (e.g., layers 206 and 208 are perpendicular to layers 204 , 202 , and 210 of FIG. 3 ), as spacers other structures formed adjacent to the layers. As also used herein, it should be understood that when a layer is said to be “formed on” or “disposed on” another layer, the layers are understood to be parallel to one another, but there may be intervening layers formed or disposed between those layers. In contrast, “disposed directly on” or “formed directly on” refers to layers in direct contact with one another. Similarly, if materials are said to be “adjacent” to other materials, the materials are in the same cross-sectional plane (e.g., the layer 206 is adjacent to the layers 202 , 204 and 210 ). Further, if a material is said to be adjacent to another material or layer, there may be intervening materials therebetween, while “directly adjacent,” connotes no intervening materials therebetween.
Since heat decreases magnetization and spin-polarization efficiency in magnetic materials, a heater material 206 may apply heat to decrease or eliminate the magnetization or spin polarization of the spin-polarizing layer 202 , and the spin current generator 200 may output a non-polarized or less spin polarized current 212 . Specifically, when voltage is applied to the spin current generator 200 through the transistor 216 , the heater material 206 may heat up the spin-polarizing layer close to or above its curie temperature, which may be in a range of approximately 160° C. to 300° C. The spin-polarizing layer 202 would then substantially lose its magnetization, and current would be non-polarized or not highly polarized after it passes through the demagnetized spin-polarizing layer 202 . The spin-polarizing layer 202 may retain its magnetization through an exchange interaction with the antiferromagnetic layer 210 when the spin-polarizing layer 202 is cooled to approximately room temperature. Thus, the spin current generator 200 may produce a unidirectional non-polarized current to program a spintronics device. One example of how a unidirectional non-polarized current may program a spintronics device is to pass non-polarized current that becomes spin polarized by magnetic layers of fixed magnetization in a spintronics device. Further, magnetic layers may be switched by reflected currents polarized by other layers in a spintronics device.
Alternatively, the spin current generator 200 may produce polarized current 214 of various polarization degrees through a transient stress effect induced by the piezoelectric stress material 206 . The piezoelectric stress material 206 may apply varying stress to adjust the spin polarization of the spin-polarizing layer 202 . When voltage is applied to the piezoelectric stress material 206 through the transistor 216 , the piezoelectric stress material 206 may induce a stress that modulates the spin-polarization efficiency of the spin-polarizing layer 202 such that the current output of the spin current generator 200 may be polarized to a desired degree.
Specifically, the spin polarization degree of the output current is determined by the spin-polarization efficiency of the spin-polarizing layer 202 , which may be adjusted by either heat or stress to the spin-polarizing layer 202 . If the spin current generator 200 sends a polarized current 214 to a spintronics device, voltage may be applied to the spin current generator 200 , and the piezoelectric material 206 may generate a transient stress in the spin-polarizing layer 202 . The transient stress influences the spin-polarization efficiency of the spin-polarizing layer 202 , which affects the degree of polarization of the output current. Thus, embodiments in accordance with the present technique may produce unidirectional single-spin polarized current to switch the magnetization of a spintronics device. The direction of the spin current that may be output by the spin current generator 200 is dependent on the arrangement of the transistor 216 , as will be appreciated.
The heater material 206 may comprise refractory metals including, for example, nitride, carbide, and Boride, TiN, ZrN, HfN, VN, NbN, TaN, TiC, ZrC, HfC, VC, NbC, TaC, TiB2, ZrB2, HfB2, VB2, NbB2, TaB2, Cr3C2, Mo2C, WC, CrB2, Mo2B5, W2B5, or compounds such as TiAlN, TiSiN, TiW, TaSiN, TiCN, SiC, B4C, WSix, MoSi2, or elemental materials such as doped silicon, carbon, Pt, Niobium, Tungsten, molybdenum, or metal alloys such as NiCr, for example. In some embodiments, the piezoelectric material 206 may be composed of a conductive piezoelectric material, such as (TaSe4)2I, multi-layered AlxGa1−xAs/GaAs, BaTiO3/VGCF/CPE composites, or other piezoelectric/conductive material composites. In other embodiments, the piezoelectric material 206 may be an insulative material, such as berlinite (AlPO 4 ), quartz, gallium orthophosphate (GaPO 4 ), langasite (La 3 Ga 5 SiO 14 ), ceramics with perovskite or tungsten-bronze structures such as barium titanate (BaTiO 3 ), SrTiO3, bismuth ferrite (BiFeO 3 ), lead zirconate titanate (Pb[Zr x Ti 1−x ]O 3 0<x<1), Pb 2 KNb 5 O 15 , lead titanate (PbTiO 3 ), lithium tantalate (LiTaO 3 ), sodium tungstate (Na x WO 3 ), potassium niobate (KNbO 3 ), lithium niobate (LiNbO 3 ), Ba 2 NaNb 5 O 5 , and other materials such as ZnO, AlN, polyvinylidene fluoride (PVDF), lanthanum gallium silicate, potassium sodium tartrate, sodium potassium niobate (KNN). The nonmagnetic layer 204 may insulate the magnetic layers of the spin current generator 200 from other magnetic layers and may be either conductive or nonconductive. The conductive nonmagnetic layer 204 may comprise Cu, Au, Ta, Ag, CuPt, CuMn, or other nonmagnetic transition metals, or any combination of the above nonmagnetic conductive materials. The nonconductive nonmagnetic layer 204 may comprise Al x O y , MgO, AlN, SiN, CaO x , NiO x , HfO 2 , Ta 2 O 5 , ZrO 2 , NiMnO x , MgF 2 , SiC, SiO 2 , SiO x N y , or any combination of the above nonmagnetic nonconductive materials.
Another embodiment of the present invention is illustrated in FIG. 4 , where a spin current generator 300 can generate arbitrary spin current or spin current polarized in either direction (bi-spin polarity). As used in the present specification, arbitrary spin current refers to spin current polarized in either direction with any desired polarization degree. The spin current generator 300 uses two structures 302 and 304 of opposite magnetization. Each structure has a respective spin polarizing layer 306 and a nonmagnetic layer 308 . The spin-polarizing layer 306 in the structures 302 and 304 have opposite magnetizations, and this enables the spin current generator 300 to generate current spin-polarized in an arbitrary degree for a spintronics device, or in a specified direction based on the selection of the appropriate transistor 314 or 316 . The spin current generator 300 may be employed in applications and systems benefiting from a spin current generator capable of producing a bi-spin polarity current (i.e., a current with a spin-polarity in either direction), such as the memory cells of FIG. 1 .
For example, if a memory cell (as in FIG. 2 ) is selected to be programmed to a low resistance state, a current would pass through the structure 304 of the spin current generator 300 , via the transistor 316 , where the spin-polarizing layer 306 polarizes the spin of the electrons to the left. The spin current generator 300 then outputs a programming current spin polarized to the left 310 , and the left-polarized current 310 switches the magnetization of free layer 108 (of FIG. 2 ) to the left, parallel to the pinned layer 106 , writing the cell in a low resistance state. If a memory cell is selected to be programmed to a high resistance state, a current would pass through the structure 302 of the spin current generator 300 , via the transistor 314 , where the spin-polarizing layer 306 polarizes the spin of the electrons to the right. The programming current is spin polarized to the right 312 , and the right-polarized current 312 switches the magnetization of free layer 108 to the right, antiparallel to the pinned layer 106 , writing the cell in a high resistance state.
The spin-polarizing layer 306 may comprise ferromagnetic materials, such as Co, Fe, Ni or its alloys, NiFe, CoFe, CoNiFe, or doped alloys CoX, CoFeX, CoNiFeX (X=B, Cu, Re, Ru, Rh, Hf, Pd, Pt, C), or other half-metallic ferromagnetic material such as Fe3O4, CrO2, NiMnSb and PtMnSb, and BiFeO, for instance. The nonmagnetic layer 308 may insulate the magnetic layers of the spin current generator 300 from other magnetic layers and may be either conductive or nonconductive. The conductive nonmagnetic layer 308 may comprise Cu, Au, Ta, Ag, CuPt, CuMn, or other nonmagnetic transition metals, or any combination of the above nonmagnetic conductive materials. The nonconductive nonmagnetic layer 308 may comprise Al x O y , MgO, AlN, SiN, CaO x , NiO x , HfO 2 , Ta 2 O 5 , ZrO 2 , NiMnO x , MgF 2 , SiC, SiO 2 , SiO x N y , or any combination of the above nonmagnetic nonconductive materials.
This embodiment and other embodiments in accordance with the present technique may be used in spintronics applications, or in conjunction with or incorporated in any device using electron spin properties. As an example, STT-MRAM cells are programmed into low or high resistance states by switching the magnetization of a free ferromagnetic layer in the memory cell. As previously discussed, the memory cell is programmed to a low resistance state when a programming current switches the magnetization of the free layer to be parallel with the magnetization of a pinned layer in the STT-MRAM cell. The memory cell is programmed to a high resistance state when a programming current switches the magnetization of the free layer to be antiparallel with the magnetization of the pinned layer in the STT-MRAM cell. The typical STT-MRAM cell is structured with bidirectional programming logic, as the free layer requires programming current polarized in both directions, depending on the resistance state it will be switched to. In the embodiments of the present technique, a spin current generator capable of generating current polarized in either direction, or not polarized at all, may allow for simpler unidirectional programming logic in the STT-MRAM cell or other spintronics components.
While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. | Spin current generators and systems and methods for employing spin current generators. A spin current generator may be configured to generate a spin current polarized in one direction, or a spin current selectively polarized in two directions. The spin current generator may by employed in spintronics applications, wherein a spin current is desired. | 1 |
CROSS REFERENCE TO RELATED APPLICATOINS:
The following applications contain subject matter related to the present application:
U.S. Pat. No. 6,348,126 B1, issued Feb. 19, 2002 entitled, “EXTERNALLY EXCITED TORROIDAL PLASMA SOURCE,” By Hiroji Hanawa, et al.; U.S. patent application Ser. No.: 09/636,434, filed Aug. 11, 2000 entitled, “REACTOR CHAMBER FOR AN EXTERNALLY EXCITED TORROIDAL PLASMA SOURCE WITH A GAS DISTRIBUTION PLATE,” By Hiroji Hanawa, et al.; U.S. patent application Ser. No.: 09/636,435, filed Aug. 11, 2000 entitled, “EXTERNALLY EXCITED MULTIPLE TORROIDAL PLASMA SOURCE,” By Hirojji Hanawa, et al.; U.S. patent application Ser. No.: 09/636,436, filed Aug. 11, 2000 entitled, “A METHOD OF PROCESSING A WORKPIECE USING AN EXTERNALLY EXCITED TORROIDAL PLASMA SOURCE,” By Hiroji Hanawa, et at.; U.S. patent application Ser. No.: 09/637,174, filed Aug. 11, 2000 entitled, “EXTERNALLY EXCITED TORROIDAL PLASMA SOURCE WITH A GAS DISTRIBUTION PLATE,” By Hiroji Hanawa, et al.; U.S. patent application Ser. No.: 09/638,075, filed Aug. 11, 2000 entitled, “EXTERNALLY EXCITED TORROIDAL PLASMA SOURCE,” By Hiroji Hanawa, et al.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention concerns plasma reactors used in processing workpieces in the manufacturing of items such as microelectronic circuits, flat panel displays and the like, and in particular plasma sources therefor.
2. Background Art
The trend in microelectronic circuits toward ever increasing densities and smaller feature sizes continues to make plasma processing of such devices more difficult. For example, the diameter of contact holes has been reduced while the hole depth has increased. During plasma-enhanced etching of a dielectric film on a silicon wafer, for example, the etch selectivity of the dielectric material (e.g. silicon dioxide) to photoresist must be sufficient to allow the etch process to etch a contact hole whose diameter is ten to fifteen times its depth, without appreciably disturbing the photoresist mask defining the hole. This task is made even more difficult because the recent trend toward shorter wavelength light for finer photolithography requires a thinner photoresist layer, so that the dielectric-to-photoresist etch selectivity must be greater than ever. This requirement is more readily met using processes having relatively low etch rates, such as dielectric etch processes employing a capacitively coupled plasma. The plasma density of a capacitively coupled plasma is relatively less than that of an inductively coupled plasma, and the capacitively coupled plasma etch process exhibits good dielectric-to-photoresist etch selectivity. The problem with the capacitively coupled process is that it is slow and therefore relatively less productive. Another problem that arises in such etch processes is non-uniform plasma distribution.
In order to increase productivity or etch rate, higher density plasmas have been employed. Typically, the high density plasma is an inductively coupled plasma. However, the process precursor gases tend to dissociate more rapidly in such a high density plasma, creating a higher plasma content of free fluorine, a species which reduces the etch selectivity to photoresist. To reduce this tendency, fluoro-carbon process gases such as CF 2 are employed which dissociate in a plasma into fluorine-containing etchant species and one or more polymer species which tend to accumulate on-non-oxide containing surfaces such as photoresist. This tends to increase etch selectivity. The oxygen in the oxygen-containing dielectric material promotes the pyrolization of the polymer over the dielectric, so that the polymer is removed, allowing the dielectric material to be etched while the non-oxygen containing material (e.g., the photoresist) continues to be covered by the polymer and therefore protected from the etchant. The problem is that the increase in contact opening depth and decrease in photoresist thickness to accommodate more advanced device designs has rendered the high density plasma process more likely to harm the photoresist layer during dielectric etching. As the plasma density is increased to improve etch rate, a more polymer-rich plasma must be used to protect the non-oxygen containing material such as photoresist, so that the rate of polymer removal from the oxygen-containing dielectric surfaces slows appreciably, particularly in small confined regions such as the bottom of a narrow contact opening. The result is that, while the photoresist may be adequately protected, the possibility is increased for the etch process to be blocked by polymer accumulation once a contact opening reaches a certain depth. Typically, the etch stop depth is less than the required depth of the contact opening so that the device fails. The contact opening may provide connection between an upper polysilicon conductor layer and a lower polysilicon conductor layer through an intermediate insulating silicon dioxide layer. Device failure occurs, for example, where the etch stop depth is less than the distance between the upper and lower polysilicon layers. Alternatively, the possibility arises of the process window for achieving a high density plasma without etch stop becoming too narrow for practical or reliable application to the more advanced device designs such as those having contact openings with aspect ratios of 10:1 or 15:1.
What would-be desirable at present is a reactor that has the etch rate of an inductively coupled plasma reactor (having a high density plasma) with the selectivity of a capacitively coupled reactor. It has been difficult to realize the advantages of both types of reactors in a single machine led reactor.
One problem with high density inductively coupled plasma reactors, particularly of the type having an overhead coil antenna facing the wafer or workpiece, is that as the power applied to the coil antenna is increased to enhance the etch rate, the wafer-to-ceiling gap must be sufficiently large so that the power is absorbed in the plasma region well above the wafer. This avoids a risk of device damage on the wafer due to strong RF fields. Moreover, for high levels of RF power applied to the overhead coil antenna, the wafer-to-ceiling gap must be relatively large, and therefore the benefits of a small gap cannot be realized.
If the ceiling is a semiconductive window for the RF field of an inductively coupled reactor, or a conductive electrode of a capacitively coupled reactor, then one benefit of a small wafer-to-ceiling gap is an enhanced electric potential or ground reference that the ceiling could provide across the plane of the wafer at a relatively small gap distance (e.g., on the order of 1 or 2 inches).
Therefore, it would be desireable to have a reactor not only having the selectivity of a capacitively coupled reactor with the ion density and etch rate of an inductively coupled reactor, but further having none of the conventional limitations on the wafer-to-ceiling gap length other than a fundamental limit, such as the plasma sheath thickness, for example. It would further be desireable to have a reactor having the selectivity of a capacitively coupled reactor and the etch rate of an inductively coupled reactor in which the ion density and etch rate can be enhanced without necessarily increasing the applied RF plasma source power.
SUMMARY OF THE DISCLOSURE
A plasma chamber defining an evacuated interior environment for processing a substrate includes a substrate support, an apertured gas distribution plate in spaced facing relationship to the substrate support, and adapted to flow process gases into the chamber interior environment adjacent the substrate support, the gas distribution plate and substrate support defining a substrate processing region therebetween, a hollow reentrant-conduit having respective ends opening into the substrate processing region on opposite sides of the gas distribution plate, with the interior of said conduit sharing the interior environment. The conduit is adapted to accept irradiation of processing gases within the conduit to sustain a plasma in a path extending around the conduit interior and across the substrate processing region within the chamber interior environment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a first embodiment that maintains an overhead torroidal plasma current path.
FIG. 2 is a side view of an embodiment corresponding to the embodiment of FIG. 1 .
FIG. 3 is a graph illustrating the behavior of free fluorine concentration in the plasma with variations in wafer-to-ceiling gap distance.
FIG. 4 is a graph illustrating the behavior of free fluorine concentration in the plasma with variations in RF bias power applied to the workpiece.
FIG. 5 is a graph illustrating the behavior of free fluorine-concentration in the plasma with variations in RF source power applied to the coil antenna.
FIG. 6 is a graph illustrating the behavior of free fluorine concentration in the plasma with variations in reactor chamber pressure.
FIG. 7 is a graph illustrating the behavior of free fluorine concentration in the plasma with variations in partial pressure of an inert diluent gas such as Argon.
FIG. 8 is a graph illustrating the degree of dissociation of process gas as a function of source power for an inductively coupled reactor and for a reactor of the present invention.
FIG. 9 illustrates a variation of the embodiment of FIG. 1 .
FIGS. 10 and 11 illustrate a variation of the embodiment of FIG. 1 in which a closed magnetic core is employed.
FIG. 12 illustrates another embodiment of the invention in which a torroidal plasma current path passes beneath the reactor chamber.
FIG. 13 illustrates a variation of the embodiment of FIG. 10 in which plasma source power is applied to a coil wound around a distal portion the closed magnetic core.
FIG. 14 illustrates an embodiment that establishes two parallel torroidal plasma currents.
FIG. 15 illustrates an embodiment that establishes a plurality of individually controlled parallel torroidal plasma currents.
FIG. 16 illustrates a variation of the embodiment of FIG. 15 in which the parallel torroidal plasma currents enter and exit the plasma chamber through the vertical side wall rather than the ceiling.
FIG. 17A illustrates an embodiment that maintains a pair of mutually orthogonal torroidal plasma currents across the surface of the workpiece.
FIG. 17B illustrates the use of plural radial vanes in the embodiment of FIG. 17 A.
FIGS. 18 and 19 illustrate an embodiment of the invention in which the torroidal plasma current is a broad belt that extends across a wide path suitable for processing large wafers.
FIG. 20 illustrates a variation of the embodiment of FIG. 18 in which an external section of the torroidal plasma current path is constricted.
FIG. 21 illustrates a variation of the embodiment of FIG. 18 employing cylindrical magnetic cores whose axial positions may be adjusted to adjust ion density distribution across the wafer surface.
FIG. 22 illustrates a variation of FIG. 21 in which a pair of windings are wound around a pair of groups of cylindrical magnetic cores.
FIG. 23 illustrates a variation of FIG. 22 in which a single common winding is wound around both groups of cores.
FIGS. 24 and 25 illustrate an embodiment that maintains a pair of mutually orthogonal tbrroidal plasma currents which are wide belts suitable for processing large wafers.
FIG. 26 illustrates a variation of the embodiment of FIG. 25 in which magnetic cores are employed to enhance inductive coupling.
FIG. 27 illustrates a modification of the embodiment of FIG. 24 in which the orthogonal plasma belts enter and exit the reactor chamber through the vertical side wall rather than through the horizontal ceiling.
FIG. 28A illustrates an implementation of the embodiment of FIG. 24 which produces a rotating torroidal plasma current.
FIG. 28B illustrates a version of the embodiment of FIG. 28A that includes magnetic cores.
FIG. 29 illustrates a preferred embodiment of the invention in which a continuous circular plenum is provided to enclose the torroidal plasma current.
FIG. 30 is a top sectional view corresponding to FIG. 29 .
FIGS. 31A and 31B are front and side sectional views corresponding to FIG. 30 .
FIG. 32 illustrates a variation of the embodiment 29 employing three independently driven RF coils underneath the continuous plenum facing at 120 degree intervals.
FIG. 33 illustrates a variation of the embodiment of FIG. 32 in which the three RF coils are driven at 120 degree phase to provide an azimuthally rotating plasma.
FIG. 34 illustrates a variation of the embodiment of FIG. 33 in which RF drive coils are wound around vertical external ends of respective magnetic cores whose opposite ends extend horizontally under the plenum at symmetrically distributed angles.
FIG. 35 is an version of the embodiment of FIG. 17 in which the mutually transverse hollow conduits are narrowed as in the embodiment of FIG. 20 .
FIG. 36 is a version of the embodiment of FIG. 24 but employing a pair of magnetic cores 3610 , 3620 with respective windings 3630 , 3640 therearound for connection to respective RF power sources.
FIG. 37 is an embodiment corresponding to that of FIG. 35 but having three instead of two reentrant conduits with a total of six reentrant ports to the chamber.
FIG. 38 is an embodiment corresponding to that of FIG. 38 but having three instead of two reentrant conduits with a total of six reentrant ports to the chamber.
FIG. 39 is an embodiment corresponding to that of FIG. 35 in which the external conduits join together in a common plenum 3910 .
FIG. 40 is an embodiment corresponding to that of FIG. 36 in which the external conduits join together in a common plenum 4010 .
FIG. 41 is an embodiment corresponding to that of FIG. 37 in which the external conduits join together in a common plenum 4110 .
FIG. 42 is an embodiment corresponding to that of FIG. 38 in which the external conduits join together in a common plenum 4210 .
FIG. 43 is an embodiment corresponding to that of FIG. 17 in which the external conduits join together in a common plenum 4310 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Overview of the Plasma Reactor Chamber
Referring to FIG. 1, a plasma reactor chamber 100 enclosed by a cylindrical side wall 105 and a ceiling 110 houses a wafer pedestal 115 for supporting a semiconductor wafer or workpiece 120 . A process gas supply 125 furnishes process gas into the chamber 100 through gas inlet nozzles 130 a- 130 d extending through the side wall 105 . A vacuum pump 135 controls the pressure within the chamber 100 , typically holding the pressure below 0.5 milliTorr (mT). A half-torroidal hollow tube enclosure or conduit 150 extends above the ceiling 110 in a half circle. The conduit 150 , although extending externally outwardly from ceiling 110 , is nevertheless part of the reactor and forms a wall of the chamber. Internally it shares the same evacuated atmosphere as exists elsewhere in the reactor. In fact, the vacuum pump 135 , instead of being coupled to the bottom of the main part of the chamber as illustrated in FIG. 1, may instead be coupled to the conduit 150 , although this is not presently preferred. The conduit 150 has one open end 150 a sealed around a first opening 155 in the reactor ceiling 110 and its other end 150 b sealed around a second opening 160 in the reactor ceiling 110 . The two openings or ports 150 , 160 are located on generally opposite sides of the wafer support pedestal 115 . The hollow conduit 150 is reentrant in that it provides a flow path which exits the main portion of the chamber at one opening and re-enters at the other opening. In this specification, the conduit 150 may be described as being half-torroidal, in that the conduit is hollow and provides a portion of a closed path in which plasma may flow, the entire path being completed by flowing across the entire process region overlying the wafer support pedestal 115 . Notwithstanding the use of the term “torroidal”, the trajectory of the path as well as the cross-sectional shape of the path or conduit 150 may be circular or non-circular, and may be square, rectangular or any other shape either a regular shape or irregular.
The external conduit 150 may be formed of a relatively thin conductor such as sheet metal, but sufficiently strong to withstand the vacuum within the chamber. In order to suppress eddy currents in the sheet metal of the hollow conduit 150 (and thereby facilitate coupling of an RF inductive field into the interior of the conduit 150 ), an insulating gap 152 extends across and through the hollow conduit 150 so as to separate it into two tubular sections. The gap 152 is filled by a ring 154 of insulating material such as a ceramic in lieu of the sheet metal skin, so that the gap is vacuum tight. A second insulating gap 153 may be provided, so that one section of the conduit 150 is electrically floating. A bias RF generator 162 applies RF bias power to the wafer pedestal 115 and wafer 120 through an impedance match element 164 .
Alternatively, the hollow conduit 150 may be formed of a non-conductive material instead of the conductive sheet metal. The non-conductive material may be a ceramic, for example. In such an alternative embodiment, neither gap 152 or 153 is required.
An antenna 170 such as a winding or coil 165 disposed on one side of the hollow conduit 150 and wound around an axis parallel to the axis of symmetry of the half-torroidal tube is connected through an impedance match element 175 to an RF power source 180 . The antenna 170 may further include a second winding 185 disposed on the opposite side of the hollow conduit 150 and wound in the same direction as the first winding 165 so that the magnetic fields from both windings add constructively.
Process gases from the chamber 100 fill the hollow conduit 150 . In addition, a separate process gas supply 190 may supply process gases directly in to the hollow conduit 150 through a gas inlet 195 . The RF field in the external hollow conduit 150 ionizes the gases in the tube to produce a plasma. The RF field induced by the circular coil antenna 170 is such that the plasma formed in the tube 150 reaches through the region between the wafer 120 and the ceiling 110 to complete a torroidal path that includes the half-torroidal hollow conduit 150 . As employed herein, the term torroidall, refers to the closed and solid nature of the. path, but does not refer or limit its cross-sectional shape or trajectory, either of which may be circular or non-circular or square or otherwise. Plasma circulates through the complete torroidal path or region which may be thought of as a closed plasma circuit. The torroidal region extends across the diameter of the wafer 120 and, in certain embodiments, has a sufficient width in the plane of the wafer so that it overlies the entire wafer surface.
The RF inductive field from the coil antenna 170 includes a magnetic field which itself is closed (as are all magnetic fields), and therefore induces a plasma current along the closed torroidal path described here. It is believed that power from the RF inductive field is absorbed at generally every location along the closed path, so that plasma ions are generated all along the path. The RF power absorption and rate of plasma ion generation may vary among different locations along the closed path depending upon a number of factors. However, the current is generally uniform along the closed path length, although the current density may vary. This current alternates at the frequency of the RF signal applied to the antenna 170 . However, since the current induced by the RF magnetic field is closed, the current must be conserved around the circuit of the closed path, so that the amount of current flowing in any portion of the closed path is generally the same as in any other portion of the path. As will be described below, this fact is exploited in the invention to great advantage.
The closed torroidal path through which the plasma current flows is bounded by plasma sheaths formed at the various conductive surfaces bounding the path. These conductive surfaces include the sheet metal of the hollow conduit 150 , the wafer (and/or the wafer support pedestal) and the ceiling overlying the wafer. The plasma sheaths formed on these conductive surfaces are charge-depleted regions produced as the result of the charge imbalance due to the greater mobility of the low-mass negative electrons and the lesser mobility of the heavy-mass positive ions. Such a plasma sheath has an electric field perpendicular to the local surface underlying the sheath. Thus, the RF plasma current that passes through the process region overlying the wafer is constricted by and passes between the two electric fields perpendicular to the surface of the ceiling facing the wafer and the surface of the wafer facing the gas distribution plate. The thickness of the sheath (with RF bias applied to the workpiece or other electrode) is greater where the electric field is concentrated over a small area, such as the wafer, and is less in other locations such as the sheath covering the ceiling and the large adjoining chamber wall surfaces. Thus, the plasma sheath overlying the wafer is much thicker. The electric fields of the wafer and ceiling/gas distribution plate sheaths are generally parallel to each other and perpendicular to the direction of the RF plasma current flow in the process region.
When RF power is first applied to the coil antenna 170 , a discharge occurs across the gap 152 to ignite a capacitively coupled plasma from gases within the hollow conduit 150 . Thereafter, as the plasma current through the hollow conduit 150 increases, the inductive coupling of the RF field becomes more dominant so that the plasma becomes an inductively coupled plasma. Alternatively, plasma may be initiated by other means, such as by RF bias applied to the workpiece support or other electrode.
In order to avoid edge effects at the wafer periphery, the ports 150 , 160 are separated by a distance that exceeds the diameter of the wafer. For example, for a 12 inch diameter wafer, the ports 150 , 160 are about 16 to 22 inches apart. For an 8 inch diameter wafer, the ports 150 , 160 are about 10 to 16 inches apart.
Advantages of the Invention
A significant advantage is that power from the RF inductive field is absorbed throughout the relatively long closed torroidal path (i.e., long relative to the gap length between the wafer and the reactor ceiling), so that RF power absorption is distributed over a large area. As a result, the RF power in the vicinity of the wafer-to-ceiling gap (i.e., the process region 121 best shown in FIG. 2, not to be confused with the insulating gap 152 ) is relatively low, thus reducing the liklihood of device damage from RF fields. In constrast, in prior inductively coupled reactors, all of the RF power is absorbed within the narrow wafer-to-ceiling gap, so that it is greatly concentrated in that region. Moreover, this fact often limits the ability to narrow the wafer-to-ceiling gap (in the quest of other advantages) or, alternatively, requires greater concentration of RF power in the region of the wafer. Thus, the invention overcomes a limitation of long standing in the art. This aspect enhances process performance by reducing residency time of the reactive gases through a dramatic reduction in volume of the process region or process zone overlying the wafer, as discussed previously herein.
A related and even more important advantage is that the plasma density at the wafer surface can be dramatically increased without increasing the RF power applied to the coil antenna 170 (leading to greater efficiency). This is accomplished by reducing the cross-sectional area of the torroidal path in the vicinity of the pedestal surface and wafer 120 relative to the remainder of the torroidal path. By so constricting the torroidal path of the plasma current near the wafer only, the density of the plasma near the wafer surface is increased proportionately. This is because the torroidal path plasma current through the hollow conduit 150 must be at least nearly the same as the plasma current through the pedestal-to-ceiling (wafer-to-ceiling) gap.
A significant difference over the prior art is that not only is the RF field remote from the workpiece, and not only can ion density be increased at the wafer surface without increasing the applied RF field, but the plasma ion density and/or the applied RF field may be increased without increasing the minimum wafer-to-ceiling gap length. Formerly, such an increase in plasma density necessitated an increase in the wafer-to-ceiling gap to avoid strong fields at the wafer surface. In contrast, in the present invention the enhanced plasma density is realized without requiring any increase in the wafer-to-ceiling gap to avoid a concomitant increase in RF magnetic fields at the wafer surface. This is because the RF field is applied remotely from the wafer and moreover need not be increased to realize an increase in plasma density at the wafer surface. As a result, the wafer-to-ceiling gap can be reduced down to a fundamental limit to achieve numerous advantages. For example, if the ceiling surface above the wafer is conductive, then reducing the wafer-to-ceiling gap improves the electrical or ground reference provided by the conductive ceiling surface. A fundamental limit on the minimum wafer-to-ceiling gap length is the sum of the thicknesses of the plasma sheaths on the wafer surface and on the ceiling surface.
A further advantage of the invention is that because the RF inductive field is applied along the entire torroidal path of the RF plasma current (so that its absorption is distributed as discussed above), the chamber ceiling 110 , unlike with most other inductively powered reactors, need not function as a window to an inductive field and therefore may be formed of any desired material, such as a highly conductive and thick metal, and therefore may comprise a conductive gas distribution plate as will be described below, for example. As a result, the ceiling 110 readily provides a reliable electric potential or ground reference across the entire plane of the pedestal or wafer 120 .
Increasing the Plasma Ion Density
One way of realizing higher plasma density near the wafer surface by reducing plasma path cross-sectional area over the wafer is to reduce the wafer-to-ceiling gap length. This may be accomplished by simply reducing the ceiling height or by introducing a conductive gas distribution plate or showerhead over the wafer, as illustrated in FIG. 2 . The gas distribution showerhead 210 of FIG. 2 consists of a gas distribution plenum 220 connected to the gas supply 125 and communicating with the process region over the wafer 120 through plural gas nozzle openings 230 . The advantage of the conductive showerhead 210 is two-fold: First, by virtue of its close location to the wafer, it constricts the plasma path over the wafer surface and thereby increases the density of the plasma current in that vicinity. Second, it provides a uniform electrical potential reference or ground plane close to and across the entire wafer surface.
Preferably, in order to avoid arcing across the openings 230 , each opening 230 is relatively small, on the order of a millimeter (preferred hole diameter is approximately 0.5 mm). The spacing between adjacent openings may be on the order of a several millimeters.
The conductive showerhead 210 constricts the plasma current path rather than providing a short circuit through itself because a plasma sheath is formed around the portion of the showerhead surface immersed in the plasma. The sheath has a greater impedance to the plasma current than the space between the wafer 120 and the showerhead 210 , and therefore all the plasma current goes around the conductive showerhead 210 .
It is not necessary to employ a showerhead (e.g., the showerhead 210 ) in order to constrict the torroidal plasma current or path in the vicinity of the process region overlying the wafer. The path constriction and consequent increase in plasma ion density in the process region may be achieved without the showerhead 210 by similarly reducing the wafer-to-ceiling height. If the showerhead 210 is eliminated in this manner, then the process gases may be supplied into the chamber interior by means of conventional gas inlet nozzles (not shown).
One advantage of the showerhead 210 is that different mixtures of reactive and inert process gas ratios may be introduced through different orifices 230 at different radii, in order to finely adjust the uniformity of plasma effects on photoresist, for example. Thus, for example, a greater proportion of inert gas to reactive gas may be supplied to the orifices 230 lying outside a median radius while a greater proportion of reactive gas to inert gas may be supplied to the orifices 230 within that median radius.
As will be described below, another way in which the torroidal plasma current path may be constricted in the process region overlying the wafer (in order to increase plasma ion density over the wafer) is to increase the plasma sheath thickness on the wafer by increasing the RF bias power applied to the wafer support pedestal. Since as described previously the plasma current across the process region is confined between the plasma sheath at the wafer surface and the plasma sheath at the ceiling (or showerhead) surface, increasing the plasma sheath thickness at the wafer surface necessarily decreases the cross-section of the portion of the torroidal plasma current within process region, thereby increasing the plasma ion density in the process region. Thus, as will be described more fully later in this specification, as RF bias power on the wafer support pedestal is increased, plasma ion density near the wafer surface is increased accordingly.
High Etch Selectivity at High Etch Rates
The invention solves the problem of poor etch selectivity which sometimes occurs with a high density plasma. The reactor of FIGS. 1 and 2 has a silicon dioxideto-photoresist etch selectivity as high as that of a capacitively coupled plasma reactor (about 7:1) while providing high etch rates approaching that of a high density inductively coupled plasma reactor. It is believed that the reason for this success is that the reactor structure of FIGS. 1 and 2 reduces the degree of dissociation of the reactive process gas, typically a fluorocarbon gas, so as to reduce the incidence of free fluorine in the plasma region over the wafer 120 . Thus, the proportion of free fluorine in the plasma relative to other species dissociated from the fluorocarbon gas is desireably reduced. Such other species include the protective carbon-rich polymer precursor species formed in the plasma from the fluorocarbon process gas and deposited on the photoresist as a protective polymer coating. They further include less reactive etchant species such as CF and CF 2 formed in the plasma from the fluorocarbon process gas. Free fluorine tends to attack photoresist and the protective polymer coating formed thereover as vigorously as it attacks silicon dioxide, thus reducing oxide-to-photoresist etch selectivity. On the other hand, the less reactive etch species such as CF 2 or CF tend to attack photoresist and the protective polymer coating formed thereover more slowly and therefore provide superior etch selectivity.
It is believed the reduction in the dissociation of the plasma species to free fluorine is accomplished in the invention by reducing the residency time of the reactive gas in the plasma. This is because the more complex species initially dissociated in the plasma from the fluorocarbon process gas, such as CF 2 and CF are themselves ultimately dissociated into simpler species including free fluorine, the extent of this final step of dissociation depending upon the residency time of the gas in the plasma. The term “residency time” or “residence time” as employed in this specification corresponds generally to the average time that a process gas molecule and the species dissociated from the that molecule are present in the process region overlying the workpiece or wafer. This time or duration extends from the initial injection of the molecule into the process region until the molecule and/or its dissociated progeny are pass out of the process region along the closed torroidal path described above that extends through the processing zone.
As stated above, the invention enhances etch selectivity by reducing the residency time in the process region of the fluorocarbon process gas. The reduction in residency time is achieved by constricting the plasma volume between the wafer 120 and the ceiling 110 .
The reduction in the wafer-to-ceiling gap or volume has certain beneficial effects. First, it increases plasma density over the wafer, enhancing etch rate. Second, residency time falls as the volume is decreased. As referred to above, the small volume is made possible in the present invention because, unlike conventional inductively coupled reactors, the RF source power is not deposited within the confines of the process region overlying the wafer but rather power deposition is distributed along the entire closed torroidal path of the plasma current. Therefore, the wafer-to-ceiling gap can be less than a skin depth of the RF inductive field, and in fact can be so small as to significantly reduce the residency time of the reactive gases introduced into the process region, a significant advantage.
There are two ways of reducing the plasma path cross-section and therefore the volume over the wafer 120 . One is to reduce-the wafer-to-showerhead gap distance. The other is to increase the plasma sheath thickness over the wafer by increasing the bias RF power applied to the wafer pedestal 115 by the RF bias power generator 162 , as briefly mentioned above. Either method results in a reduction in free fluorine content of the plasma in the vicinity of the wafer 120 (and consequent increase in dielectric-to-photoresist etch selectivity) as observed using optical emission spectroscopy (OES) techniques.
There are three additional methods of the invention for reducing free fluorine content to improve etch selectivity. One method is to introduce a non-chemically reactive diluent gas such as argon into the plasma. Preferably, the argon gas is introduced outside and above the process region by injecting it directly into the hollow conduit 150 from the second process gas supply 190 , while the chemically reactive process gases (fluorocarbon gases) enter the chamber only through the showerhead 210 . With this advantageous arrangement, the argon ions, neutrals, and excited neutrals propagate within the torroidal path plasma current and through the process region across the wafer surface to dilute the newly introduced reactive (e.g., fluorocarbon) gases and thereby effectively reduce their residency time over the wafer. Another method of reducing plasma free fluorine content is to reduce the chamber pressure. A further method is to reduce the RF source power applied to the coil antenna 170 .
FIG. 3 is a graph illustrating a trend observed in the invention in which the free fluorine content of the plasma decreases as the wafer-to-showerhead gap distance is decreased. FIG. 4 is a graph illustrating that the free fluorine content of the plasma is decreased by decreasing the plasma bias power applied to the wafer pedestal 115 . FIG. 5 is a graph illustrating that plasma free fluorine content is reduced by reducing the RF source power applied to the coil antenna 170 . FIG. 6 is a graph illustrating that the free fluorine content is reduced by reducing chamber pressure. FIG. 7 is a graph illustrating that plasma free fluorine content is reduced by increasing the diluent (Argon gas) flow rate into the tubular enclosure 150 . The graphs of FIGS. 3-7 are merely illustrative of plasma behavioral trends inferred from numerous OES observations and do not depict actual data.
Wide Process Window of the Invention
Preferably, the chamber pressure is less than 0.5 T and can be as low as 1 mT. The process gas may be C 4 F 8 injected into the chamber 100 through the gas distribution showerhead at a flow rate of about 15 cc/m with 150 cc/m of Argon, with the chamber pressure being maintained at about 20 mT. Alternatively, the Argon gas flow rate may be increased to 650 cc/m and the chamber pressure to 60 mT. The antenna 170 may be excited with about 500 Watts of RF power at 13 MHz. The wafer-to-showerhead gap may be about 0.3 inches to 2 inches. The bias RF power applied to the wafer pedestal may be 13 MHz at 2000 Watts. Other selections of frequency may be made. The source power applied to the coil antenna 170 may be as low as 50 KHz or as high as several times 13 MHz or higher. The same is true of the bias power applied to the wafer pedestal.
The process window for the reactor of FIGS. 1 and 2 is far wider than the process window for a conventional inductively coupled reactor. This is illustrated in the graph of FIG. 8, showing the specific neutral flux of free fluorine as a function of RF source power for a conventional inductive reactor and for the reactor of FIGS. 1 and 2. For the conventional inductively coupled reactor, FIG. 8 shows that the free fluorine specific flux begins to rapidly increase as the source power exceeds between 50 and 100 Watts. In contrast, the reactor of FIGS. 1 and 2 can accept source power levels approaching 1000 Watts before the free fluorine specific flux begins to increase rapidly. Therefore, the source power process window in the invention is nearly an order of magnitude wider than that of a conventional inductively coupled reactor, a significant advantage.
Dual Advantages of the Invention
The constriction of the torroidal plasma current path in the vicinity of the wafer or workpiece produces two independent advantages without any significant tradeoffs of other performance criteria: (1) the plasma density over the wafer is increased without requiring any increase in plasma source power, and (2) the etch selectivity to photoresist or other materials is increased, as explained above. It is believed that in prior plasma reactors it has been impractical if not impossible to increase the plasma ion density by the same step that increases etch selectivity. Thus, the dual advantages realized with the torroidal plasma source of the present invention appear to be a revolutionary departure from the prior art.
Other Preferred Embodiments
FIG. 9 illustrates a modification of the embodiment of FIG. 1 in which the side antenna 170 is replaced by a smaller antenna 910 that fits inside the empty space between the ceiling 110 and the hollow conduit 150 . Preferably, the antenna 910 is a single coil winding centered with respect to the hollow conduit 150 .
FIGS. 10 and 11 illustrate how the embodiment of FIG. 1 may be enhanced by the addition of a closed magnetically permeable core 1015 that extends through the space between the ceiling 110 and the hollow conduit 150 . The core 1015 improves the inductive coupling from the antenna 170 to the plasma inside the hollow conduit 150 .
Impedance match may be achieved without the impedance match circuit 175 by using, instead, a secondary winding 1120 around the core 1015 connected across a tuning capacitor 1130 . The capacitance of the tuning capacitor 1130 is selected to resonate the secondary winding 1120 at the frequency of the RF power source 180 . For a fixed tuning capacitor 1130 , dynamic impedance matching may be provided by frequency tuning and/or by forward power servoing.
FIG. 12 illustrates an embodiment of the invention in which a hollow tube enclosure 1250 extends around the bottom of the reactor and communicates with the interior of the chamber through a pair of openings 1260 , 1265 in the bottom floor of the chamber. A coil antenna 1270 follows along side the torroidal path provided by the hollow tube enclosure 1250 in the manner of the embodiment of FIG. 1 . While FIG. 12 shows the vacuum pump 135 coupled to the bottom of the main chamber, it may just as well be coupled instead to the underlying conduit 1250 .
FIG. 13 illustrates a variation of the embodiment of FIGS. 10 and 11, in which the antenna 170 is replaced by an inductive winding 1320 surrounding an upper section of the core 1015 . Conveniently, the winding 1320 surrounds a section of the core 1015 that is above the conduit 150 (rather than below it). However, the winding 1320 can surround any section of the core 1015 .
FIG. 14 illustrates an extension of the concept of FIG. 13 in which a second hollow tube enclosure 1450 runs parallel to the first hollow conduit 150 and provides a parallel torroidal path for a second torroidal plasma current. The tube enclosure 1450 communicates with the chamber interior at each of its ends through respective openings in the ceiling 110 . A magnetic core 1470 extends under both tube enclosures 150 , 1450 and through the coil antenna 170 .
FIG. 15 illustrates an extension of the concept of FIG. 14 in which an array of parallel hollow tube enclosures 150 a, 150 b, 150 c, 150 d provide plural torroidal plasma current paths through the reactor chamber. In the embodiment of FIG. 15, the plasma ion density is controlled independently in each individual hollow conduit 150 a-d by an individual coil antenna 170 a-d, respectively, driven by an independent RF power source 180 a-d, respectively. Individual cylindrical open cores 1520 a- 1520 d may be separately inserted within the respective coil antennas 170 a-d. In this embodiment, the relative center-to-edge ion density distribution may be adjusted by separately adjusting the power levels of the individual RF power sources 180 a-d.
FIG. 16 illustrates a modification of the embodiment of FIG. 15 in which the array of tube enclosures 150 a-d extend through the side wall of the reactor rather than through the ceiling 110 . Another modification illustrated in FIG. 16 is the use of a single common magnetic core 1470 adjacent all of the tube enclosures 150 a-d and having the antenna 170 wrapped around it so that a single RF source excites the plasma in all of the tube enclosures 150 a-d.
FIG. 17A illustrates a pair of orthogonal tube enclosures 150 - 1 and 150 - 2 extending through respective ports in the ceiling 110 and excited by respective coil antennas 170 - 1 and 170 - 2 . Individual cores 1015 - 1 and 1015 - 2 are within the respective coil antennas 170 - 1 and 170 - 2 . This embodiment creates two mutually orthogonal torroidal plasma current paths over the wafer 120 for enhanced uniformity. The two orthogonal torroidal or closed paths are separate and independently powered as illustrated, but intersect in the process region overlying the wafer, and otherwise do not interact. In order to assure separate control of the plasma source power applied to each one of the orthogonal paths, the frequency of the respective RF generators 180 a, 180 b of FIG. 17 are different, so that the operation of the impedance match circuits 175 a, 175 b s decoupled. For example, the RF generator 180 a may produce an RF signal at 11 MHz while the RF generator 180 b may produce an RF signal at 12 MHz. Alternatively, independent operation may be achieved by offsetting the phases of the two RF generators 180 a, 180 b.
FIG. 17B illustrates how radial vanes 181 may be employed to guide the torroidal plasma currents of each of the two conduits 150 - 1 , 150 - 2 through the processing region overlying the wafer support. The radial vanes 181 extend between the openings of each conduit near the sides of the chamber up to the edge of the wafer support. The radial vanes 181 prevent diversion of plasma from one torroidal path to the other torroidal path, so that the two plasma currents only intersect within the processing region overlying the wafer support.
Embodiments Suitable for Large Diameter Wafers
In addition to the recent industry trends toward smaller device sizes and higher device densities, another trend is toward greater wafer diameters. For example, 12 inch diameter wafers are currently entering production, and perhaps larger diameter wafers will be in the future. The advantage is greater throughput because of the large number of integrated circuit die per wafer. The disadvantage is that in plasma processing it is more difficult to maintain a uniform plasma across a large diameter wafer. The following embodiments of the present invention are particularly adapted for providing a uniform plasma ion density distribution across the entire surface of a large diameter wafer, such as a 12 inch diameter wafer.
FIGS. 18 and 19 illustrate a hollow tube enclosure 1810 which is a wide flattened rectangular version 1850 of the hollow conduit 150 of FIG. 1 that includes an insulating gap 1852 . This version produces a wide “belt” of plasma that is better suited for uniformly covering a large diameter wafer such as a 12 inch diameter wafer or workpiece. The width W of the tube enclosure and of the pair of openings 1860 , 1862 in the ceiling 110 preferably exceeds the wafer by about 5% more. For example, if the wafer diameter is 10 inches, then the width W of the rectangular tube enclosure 1850 and of the openings 1860 , 1862 is about 11 inches. FIG. 20 illustrates a modified version 1850 ′ of the rectangular tube enclosure 1850 of FIGS. 18 and 19 in which a portion 1864 of the exterior tube enclosure 1850 is constricted. However, the unconstricted version of FIGS. 18 and 19 is preferred.
FIG. 20 further illustrates the optional use of focusing magnets 1870 at the transitions between the constricted and unconstricted portions of the enclosure 1850 . The focusing magnets 1870 promote a better movement of the plasma between the constricted and unconstricted portions of the enclosure 1850 , and specifically promote a more uniform spreading out of the plasma as it moves across the transition between the constricted portion 1864 and the unconstricted portion of the tube enclosure 1850 .
FIG. 21 illustrates how plural cylindrical magnetic cores 2110 may be inserted through the exterior region 2120 circumscribed by the tube enclosure 1850 . The cylindrical cores 2110 are generally parallel to the axis of symmetry of the tube enclosure 1850 . FIG. 22 illustrates a modification of the embodiment of FIG. 21 in which the cores 2110 extend completely through the exterior region 2120 surrounded by the tube enclosure 1850 are replaced by pairs of shortened cores 2210 , 2220 in respective halves of the exterior region 2120 . The side coils 165 , 186 are replaced by a pair of coil windings 2230 , 2240 surrounding the respective core pairs 2210 , 2220 . In this embodiment, the displacement D between the core pairs 2210 , 2220 may be changed to adjust the ion density near the wafer center relative to the ion density at the wafer circumference. A wider displacement D reduces the inductive coupling near the wafer center and therefore reduces the plasma ion density at the wafer center. Thus, an additional control element is provided for precisely adjusting ion density spatial distribution across the wafer surface. FIG. 23 illustrates a variation of the embodiment of FIG. 22 in which the separate windings 2230 , 2240 are replaced by a single center winding 2310 centered with respect to the core pairs 2210 , 2220 .
FIGS. 24 and 25 illustrate an embodiment providing even greater uniformity of plasma ion density distribution across the wafer surface. In the embodiment of FIGS. 24 and 25, two torroidal plasma current paths are established that are transverse to one another and preferably are mutually orthogonal. This is accomplished by providing a second wide rectangular hollow enclosure 2420 extending transversely and preferably orthogonally relative to the first tube enclosure 1850 . The second tube enclosure 2420 communicates with the chamber interior through a pair of openings 2430 , 2440 through the ceiling 110 and includes an insulating gap 2452 . A pair of side coil windings 2450 , 2460 along the sides of the second tube enclosure 2420 maintain a plasma therein and are driven by a second RF power supply 2470 through an impedance match circuit 2480 . As indicated in FIG. 24, the two orthogonal plasma currents coincide over the wafer surface and provide more uniform coverage of plasma over the wafer surface. This embodiment is expected to find particularly advantageous use for processing large wafers of diameters of 10 inches and greater.
As in the embodiment of FIG. 17, the embodiment of FIG. 24 creates two mutually orthogonal torroidal plasma current paths over the wafer 120 for enhanced uniformity. The two orthogonal torroidal or closed paths are separate and independently powered as illustrated, but intersect in the process region overlying the wafer, and otherwise do not interact or otherwise divert or diffuse one another. In order to assure separate control of the plasma source power applied to each one of the orthogonal paths, the frequency of the respective RF generators 180 , 2470 of FIG. 24 are different, so that the operation of the impedance match circuits 175 , 2480 is decoupled. For example, the RF generator 180 may produce an RF signal at 11 MHz while the RF generator 2470 may produce an RF signal at 12 MHz. Alternatively, independent operation may be achieved by offsetting the phases of the two RF generators 180 , 2470 .
FIG. 26 illustrates a variation of the embodiment of FIG. 18 in which a modified rectangular enclosure 2650 that includes an insulating gap 2658 communicates with the chamber interior through the chamber side wall 105 rather than through the ceiling 110 . For this purpose, the rectangular enclosure 2650 has a horizontal top section 2652 , a pair of downwardly extending legs 2654 at respective ends of the top section 2652 and a pair of horizontal inwardly extending legs 2656 each extending from the bottom end of a respective one of the downwardly extending legs 2654 to a respective opening 2670 , 2680 in the side wall 105 .
FIG. 27 illustrates how a second rectangular tube enclosure 2710 including an insulating gap 2752 may be added to the embodiment of FIG. 26, the second tube enclosure 2710 being identical to the rectangular tube enclosure 2650 of FIG. 26 except that the rectangular tube enclosures 2650 , 2710 are mutually orthogonal (or at least transverse to one another). The second rectangular tube enclosure communicates with the chamber interior through respective openings through the side wall 105 , including the opening 2720 . Like the embodiment of FIG. 25, the tube enclosures 2650 and 2710 produce mutually orthogonal torroidal plasma currents that coincide over the wafer surface to provide superior uniformity over a broader wafer diameter. Plasma source power is applied to the interior of the tube enclosures through the respective pairs of side coil windings 165 , 185 and 2450 , 2460 .
FIG. 28A illustrates how the side coils 16 S, 185 , 2450 , 2460 may be replaced (or supplemented) by a pair of mutually orthogonal interior coils 2820 , 2840 lying within the external region 2860 surrounded by the two rectangular tube enclosures 2650 , 2710 . Each one of the coils 2820 , 2840 produces the torroidal plasma-current in a corresponding one of the rectangular tube enclosures 2650 , 2710 . The coils 2820 , 2840 may be driven completely independently at different frequencies or at the same frequency with the same or a different phase. Or, they may be driven at the same frequency but with a phase difference (i.e., 90 degrees) that causes the combined torroidal plasma current to rotate at the source power frequency. In this case the coils 2820 , 2840 are driven with the sin and cosine components, respectively, of a common signal generator 2880 , as indicated in FIG. 28 A. The advantage is that the plasma current path rotates azimuthally across the wafer surface at a rotational frequency that exceeds the plasma ion frequency so that non-uniformities are better suppressed than in prior art methods such as MERIE reactors in which the rotation is at a much lower frequency.
Referring now to FIG. 28B, radial adjustment of plasma ion density may be generally provided by provision of a pair of magnetic cylindrical cores 2892 , 2894 that may be axially moved toward or away from one another within the coil 2820 and a pair of magnetic cylindrical cores 2896 , 2898 that may be axially moved toward or away from one another within the coil 2840 . As each pair of cores is moved toward one another, inductive coupling near the center of each of the orthogonal plasma currents is enhanced relative to the edge of the current, so that plasma density at the wafer center is generally enhanced. Thus, the center-to-edge plasma ion density may be controlled by moving the cores 2892 , 2894 , 2896 , 2898 .
FIG. 29 illustrates an alternative embodiment of the invention in which the two tube enclosures 2650 , 2710 are merged together into a single enclosure 2910 that extends 360 degrees around the center axis of the reactor that constitutes a single plenum. In the embodiment of FIG. 29, the plenum 2910 has a half-dome lower wall 2920 and a half-dome upper wall 2930 generally congruent with the lower wall 2920 . The plenum 2910 is therefore the space between the upper and lower half-dome walls 2920 , 2930 . An insulating gap 2921 may extend around the upper dome wall 2920 and/or an insulating gap 2931 may extend around the lower dome wall 2930 . The plenum 2910 communicates with the chamber interior through an annular opening 2925 in the ceiling 110 that extends 360 degrees around the axis of symmetry of the chamber.
The plenum 2910 completely encloses a region 2950 above the ceiling 110 . In the embodiment of FIG. 29, plasma source power is coupled into the interior of the plenum 2910 by a pair of mutually orthogonal coils 2960 , 2965 . Access to the coils 2960 , 2965 is provided through a vertical conduit 2980 passing through the center of the plenum 2910 . Preferably, the coils 2960 , 2965 are driven in quadrature as in the embodiment of FIG. 28 to achieve an azimuthally circulating torroidal plasma current (i.e., a plasma current circulating within the plane of the wafer. The rotation frequency is the frequency of the applied RF power. Alternatively, the coils 2960 , 2965 may be driven separately at different frequencies. FIG. 30 is a top sectional view of the embodiment of FIG. 29 . FIGS. 31A and 31B are front and side sectional views, respectively, corresponding to FIG. 30 .
The pair of mutually orthogonal coils 2960 , 2965 may be replaced by any number n of separately driven coils with their winding, axes disposed at 360/n degrees apart. For example, FIG. 32 illustrates the case where the two coils 2960 , 2965 are replace by three coils 3210 , 3220 , 3230 with winding axes placed at 120 degree intervals and driven by three respective RF supplies 3240 , 3250 , 3260 through respective impedance match circuits 3241 , 3251 , 3261 . In order to produce a rotating torroidal plasma current, the three windings 3210 , 3220 , 3230 are driven 120 degrees out of phase from a common power source 3310 as illustrated in FIG. 33 . The embodiments of FIGS. 32 and 33 are preferred over the embodiment of FIG. 29 having only two coils, since it is felt much of the mutual coupling between coils would be around rather than through the vertical conduit 2980 .
FIG. 34 illustrates an embodiment in which the three coils are outside of the enclosed region 2950 , while their inductances are coupled into the enclosed region 2950 by respective vertical magnetic cores 3410 extending through the conduit 2980 . Each core 3410 has one end extending above the conduit 2980 around which a respective one of the coils 3210 , 3220 , 3230 is wound. The bottom of each core 3410 is inside the enclosed region 2950 and has a horizontal leg. The horizontal legs of the three cores 3410 are oriented at 120 degree intervals to provide inductive coupling to the interior of the plenum 2910 similar to that provided by the three coils inside the enclosed region as in FIG. 32 .
The advantage of the flattened rectangular tube enclosures of the embodiments of FIGS. 18-28 is that the broad width and relatively low height of the tube enclosure forces the torroidal plasma current to be a wide thin belt of plasma that more readily covers the entire surface of a large diameter wafer. The entirety of the tube enclosure need not be of the maximum width. Instead the outer section of the tube enclosure farthest from the chamber interior may be necked down, as discussed above with reference to the embodiment of FIG. 20 . In this case, it is preferable to provide focusing magnets 1870 at the transition corners between the wide portion 1851 and the narrow section 1852 to force the plasma current exiting the narrow portion 1852 to spread entirely across the entire width of the wide section 1851 . If it is desired to maximize plasma ion density at the wafer surface, then it is preferred that the cross-sectional area of the narrow portion 1852 be at least nearly as great as the cross-sectional area of the wide portion 1851 . For example, the narrow portion 1852 may be a passageway whose height and width are about the same while the wide portion 1851 may have a height that is less than its width.
The various embodiments described herein with air-core coils (i.e., coils without a magnetic core) may instead employ magnetic-cores, which can be the open-magnetic-path type (“rod” type cores) or the closed-magnetic-core type illustrated in the accompanying drawings. Furthermore, the various embodiments described herein having two or more toroidal paths driven with different RF frequencies may instead be driven with same frequenct, and with the same or different phases.
FIG. 35 is a version of the embodiment of FIG. 17 in which the mutually transverse hollow conduits are narrowed as in the embodiment of FIG. 20 .
FIG. 36 is a version of the embodiment of FIG. 24 but employing a pair of magnetic cores 3610 , 3620 with respective windings 3630 , 3640 therearound for connection to respective RF power sources.
FIG. 37 is an embodiment corresponding to that of FIG. but having three instead of two reentrant conduits with a total of six reentrant ports to the chamber. Having a number of symmetrically disposed conduits and reentrant ports greater than two (as in the embodiment of FIG. 37) is believed to be particularly advantageous for processing wafers of diameter of 300 mm and greater.
FIG. 38 is an embodiment corresponding to that of FIG. 38 but having three instead of two reentrant conduits with a total of six reentrant ports to the chamber.
FIG. 39 is an embodiment corresponding to that of FIG. in which the external conduits join together in a common plenum 3910 .
FIG. 40 is an embodiment corresponding to that of FIG. 36 in which the external conduits join together in a common plenum 4010 .
FIG. 41 is an embodiment corresponding to that of FIG. 37 in which the external conduits join together in a common plenum 4110 .
FIG. 42 is an embodiment corresponding to that of FIG. 38 in which the external conduits join together in a common plenum 4210 .
FIG. 43 is an embodiment corresponding to that of FIG. 17 in which the external conduits join together in a common plenum 4310 .
Advantageous Features of the Invention
The reactor of the invention affords numerous opportunities for increasing etch selectivity without sacrificing other performance features such as etch rate. For example, constricting the torroidal plasma current in the vicinity of the wafer not only improves etch selectivity but at the same time increases the etch rate by increasing the plasma ion density. It is believed no prior reactor has increased etch selectivity by the same mechanism that increases etch rate or plasma ion density over the workpiece.
Improving etch selectivity by constricting the torroidal plasma current in the vicinity of the wafer or workpiece can be achieved in the invention in any one of several ways. One way is to reduce the pedestal-to-ceiling or wafer-to-ceiling height. Another is to introduce a gas distribution plate or showerhead over the wafer that constricts the path of the torroidal plasma ion current. Another way is to increase the RF bias power applied to the wafer or workpiece. Any one or any combination of the foregoing ways of improving etch selectivity may be chosen by the skilled worker in carrying out the invention.
Etch selectivity may be further improved in the invention by injecting the reactive process gases locally (i.e., near the wafer or workpiece) while injecting an inert diluent gas (e.g., Argon) remotely (i.e., into the conduit or plenum). This is preferably accomplished by providing a gas distribution plate or showerhead directly over and facing the workpiece support and introducing the reactive process gas exclusively (or at least predominantly) through the showerhead. Concurrently, the diluent gas is injected into the conduit well away from the process region overlying the wafer or workpiece. The torroidal plasma current thus becomes not only a source of plasma ions for reactive ion etching of materials on the wafer but, in addition, becomes an agent for sweeping away the reactive process gas species and their plasma-dissociated progeny before the plasma-induced dissociation process is carried out to the point of creating an undesirable amount of free fluorine. This reduction in the residence time of the reactive process gas species enhances the etch selectivity relative to photoresist and other materials, a significant advantage.
The invention provides great flexibility in the application of RF plasma source power to the torroidal plasma current. As discussed above, power is typically inductively coupled to the torroidal plasma current by an antenna. In many embodiments, the antenna predominantly is coupled to the external conduit or plenum by being close or next to it. For example, a coil antenna may extend alongside the conduit or plenum. However, in other embodiments the antenna is confined to the region enclosed between the conduit or plenum and the main reactor enclosure (e.g., the ceiling). In the latter case, the antenna may be considered to be “under” the conduit rather than alongside of it. Even greater flexibility is afford by embodiments having a magnetic core (or cores) extending through the enclosed region (between the conduit and the main chamber enclosure) and having an extension beyond the enclosed region, the antenna being wound around the core's extension. In this embodiment the antenna is inductively coupled via the magnetic core and therefore need not be adjacent the torroidal plasma current in the conduit. In one such embodiment, a closed magnetic core is employed and the antenna is wrapped around the section of the core that is furthest away from the torroidal plasma current or the conduit. Therefore, in effect, the antenna may be located almost anywhere, such as a location entirely remote from the plasma chamber, by remotely coupling it to the torroidal plasma current via a magnetic core.
Finally, the invention provides uniform coverage of the plasma over the surface of a very large diameter wafer or workpiece. This is accomplished in one embodiment by shaping the torroidal plasma current as a broad plasma belt having a width preferably exceeding that of the wafer. In another embodiment, uniformity of plasma ion density across the wafer surface is achieved by providing two or more mutually transverse or orthogonal torroidal plasma currents that intersect in the process region over the wafer. The torroidal plasma currents flow in directions mutually offset from one another by 360/n. Each of the torroidal plasma currents may be shaped as a broad belt of plasma to cover a very large diameter wafer. Each one of the torroidal plasma currents may be powered by a separate coil antenna aligned along the direction of the one torroidal plasma current. In one preferred embodiment, uniformity is enhanced by applying RF signals of different phases to the respective coil antennas so as to achieve a rotating torroidal plasma current in the process region overlying the wafer. In this preferred embodiment, the optimum structure is one in which the torroidal plasma current flows in a circularly continuous plenum communicating with the main chamber portion through a circularly continuous annular opening in the ceiling or side wall. This latter feature allows the entire torroidal plasma current to rotate azimuthally in a continuous manner.
While the invention has been described in detail by specific reference to preferred embodiments, it is understood that variations and modifications thereof may be made without departing from the true spirit and scope of the invention. | A plasma chamber defining an evacuated interior environment for processing a substrate includes a substrate support, an apertured gas distribution plate in spaced facing relationship to the substrate support, and adapted to flow process gases into the chamber interior environment adjacent the substrate support, the gas distribution plate and substrate support defining a substrate processing region therebetween, a hollow reentrant conduit having respective ends opening into the substrate processing region on opposite sides of the gas distribution plate, with the interior of said conduit sharing the interior environment. The conduit is adapted to accept irradiation of processing gases within the conduit to sustain a plasma in a path extending around the conduit interior and across the substrate processing region within the chamber interior environment. | 7 |
BACKGROUND
1. Technical Field
The present invention relates to a projector.
2. Related Art
Projectors are capable of displaying large screen images, and therefore, draw attention not only as display devices for presentation, but also as image display devices for displaying images required to have high quality, such as movies. Therefore, in the projectors, growth of resolution of light modulation elements is in progress, and there is a tendency of ever-growing sizes of the light modulation elements. The growth of the light modulation element sizes causes growth of sizes of overall optical systems, which incurs growth of the sizes of the projectors, and at the same time, increase in cost.
The lower limit of the pitches of the pixels constituting the light modulation elements is generally believed to be in a range of 8 through 9 μm. Therefore, in order for obtaining the resolution of, for example, 4K2K (assumed to be 4096 pixels in the lateral direction×2160 pixels in the vertical direction), the size (the diagonal length) of the area (referred to as an image display area) available for image display in the light modulation elements needs to be equal to or greater than 1.6 inch.
FIGS. 6A and 6B are diagrams showing a configuration of the light modulation element and the optical system in the periphery thereof in a typical projector in the related art. It should be noted that FIG. 6A is a perspective view, and FIG. 6B is a plan view corresponding to FIG. 6A , namely a diagram of the configuration shown in FIG. 6A viewed from a direction along the arrow a.
As shown in FIGS. 6A and 6B , in the typical projector, the light modulation elements 100 R, 100 G, and 100 B corresponding respectively to red (R), green (G), and blue (B) are each disposed so as to have the long side in the horizontal direction (the direction of the x-axis or the y-axis among the x, y, and z-axes shown in FIG. 6A ) and the short side in the vertical direction (the vertical direction in FIG. 6A , namely the direction of the z-axis among the x, y, and z axes). In other words, the light modulation elements 100 R, 100 G, and 100 B are arranged so that one of the short sides of the light modulation element 100 R and one of the short sides of the light modulation element 100 G are adjacent to each other, and further the other of the short sides of the light modulation element 100 G and one of the short sides of the light modulation element 100 B are adjacent to each other, in a similar manner. Further, in this case, in the positional relationship between the light modulation elements 100 R, 100 G, and 100 B, and a cross dichroic prism 110 as a combining optical system, each of the short sides of each of the light modulation elements 100 R, 100 G, and 100 B is disposed along a height direction (the z-axis direction) of four triangular prisms forming the cross dichroic prism 110 .
It should be noted that the light modulation elements 100 R, 100 G, and 100 B are arranged to modulate the R, G, and B colored light beams, respectively, based on image data, and the colored light beams modulated by the respective light modulation elements 100 R, 100 G, and 100 B are combined by the cross dichroic prism 110 to be output as image light. The image light emitted from the cross dichroic prism 110 is then projected by a projection optical system 120 on a projection screen, not shown, as a landscape image.
Further, to the light modulation elements 100 R, 100 G, and 100 B, there are respectively connected signal line cable substrates 130 R, 130 G, and 130 B each having various signal lines such as a data line for supplying the image data and a control line for supplying a control signal, printed thereon. It is general that these signal line cable substrates 130 R, 130 G, and 130 B are each formed of a flexible printed circuit board, and connected respectively to the long sides of the light modulation elements 100 R, 100 G, and 100 B. It should be noted that the signal line cable substrates 130 R, 130 G, and 130 B are hereinafter referred to as FPC boards 130 R, 130 G, and 130 B, respectively.
In the typical projector of the related art, the light modulation elements 100 R, 100 G, and 100 B, and the cross dichroic prism 110 have the configuration shown in FIGS. 6A and 6B . Therefore, assuming that each of the light modulation elements 100 R, 100 G, and 100 B has a resolution of, for example, 4K2K, the diagonal size of the image display area in each of the light modulation elements 100 R, 100 G, and 100 B is about 1.6 inch as described above. The size of the cross dichroic prism 110 in the case of using such light modulation elements needs to be about 60 mm (one side L 1 of the square composed of end surfaces of the respective four triangular prisms)×60 mm (the other side L 2 of the square composed of end surfaces of the respective four triangular prisms)×35 mm (the height H of the triangular prisms), and further, the lens diameter of the projection optical system 120 needs to be equal to or greater than 70 mm. It should be noted that, assuming that the lens diameter of the projection optical system is 70 mm, the F-value of 2.5 can be achieved in the design giving priority to the brightness of the lens of the projection optical system.
As described above, in the typical projector of the related art, the higher the resolution of the light modulation element is, the further the growth of the sizes of the cross dichroicprism 110 and the projection optical system 120 proceeds, which forms a factor causing decrease in the productivity of these optical elements and increase in the cost thereof.
To cope with the above, it is possible to arrange the light modulation elements 100 R, 100 G, and 100 B so that the long sides of the respective light modulation elements 100 R, 100 G, and 100 B are adjacent to each other while keeping the direction of the long sides of the respective light modulation elements 100 R, 100 G, and 100 B to be the horizontal direction (the lateral direction in FIG. 7A ) as shown in FIG. 7A . In this case, the light modulation elements 100 R, 100 G, and 100 B have the arrangement in which each of the long sides of each of the light modulation is disposed along the height direction (the x-axis direction) of the four triangular prisms constituting the cross dichroic prism 110 . It should be noted that FIG. 7A is a perspective view of the light modulation elements 100 R, 100 G, and 100 B arranged so that the long sides thereof are adjacent to each other, and FIG. 7B is a side view corresponding to FIG. 7A , namely the diagram of the light modulation elements viewed in a direction along the arrow b.
By arranging the light modulation elements 100 R, 100 G, and 100 B so that the long sides thereof are adjacent to each other as shown in FIGS. 7A and 7B , the size of the cross dichroic prism 110 becomes about 35 mm (one side L 1 of the square composed of end surfaces of the respective four triangular prisms)×35 mm (the other side L 2 of the square composed of end surfaces of the respective four triangular prisms)×60 mm (the height H of the triangular prisms) even in the case with the light modulation elements having the same resolution as that of the light modulation elements 100 R, 100 G, and 100 B shown in FIGS. 6A and 6B . Further, the lens diameter of the projection optical system becomes about 45 mm. Therefore, the volume of the cross dichroic prism 110 can be reduced to about 60% of that in the case shown in FIGS. 6A and 6B . Further, in this case, it is possible to achieve the F-value of 2.0 by designing the lens diameter of the projection optical system to be 50 mm, and therefore, downsizing is thought to be possible while keeping the same performance as in the case shown in FIGS. 6A and 6B .
However, if the light modulation elements 100 R, 100 G, and 100 B are arranged so that the long sides thereof are adjacent to each other, there arises a problem that at least one of the FPC boards 130 R, 130 G, and 130 B connected respectively to the light modulation elements 100 R, 100 G, and 100 B shields the light input from a light source to the respective light modulation elements 100 R, 100 G, and 100 B, thus the light from the light source is prevented from appropriately entering the light modulation elements 100 R, 100 G, and 100 B, respectively.
FIG. 8 is a diagram schematically showing a general configuration of the optical system of the projector in the case in which the light modulation elements 100 R, 100 G, and 100 B are arranged as shown in FIGS. 7A and 7B . As shown in FIG. 8 , the light from the light source 140 is separated by a first dichroic mirror 151 into the red light (R), the green light (G), and the blue light (B), and the blue light (B) thus separated is input by a mirror 161 to the light modulation element 100 B while the red light (R) and the green light (G) thus separated from the blue light (B) is separated by a second dichroic mirror 152 into the red light (R) and the green light (G). Further, the green light (G) separated by the second dichroic mirror 152 is input to the light modulation element 100 G while the red light (R) is input by mirrors 162 , 163 to the light modulation element 100 R.
In the optical system shown in FIG. 8 , when considering, for example, the light modulation element 100 G corresponding to the green light (G), the FPC board 130 G is coupled to the lower long side of the light modulation element 100 G as shown in the drawing in the light modulation element 100 G of the green light (G), and consequently, shields the blue light (B) separated by the dichroic mirror 151 .
It should be noted that although the FPC board can be curved or bent within an appropriate angle, if the FPC board is bent at an excessively acute angle or an excessive twist or the like is applied to the FPC board, a broken line or the like might be caused. Therefore, the FPC board needs to be connected to other devices in a manner not providing the FPC board with folding with an excessively acute angle or an excessive twist. Therefore, if the light modulation elements 100 R, 100 G, and 100 B are arranged so that the long sides thereof are adjacent to each other, at least one of the FPC boards 130 R, 130 G, and 130 B should exist on the light path as shown in FIG. 8 .
As a method for coping with this problem, it is possible to connect the FPC boards 130 R, 130 G, and 130 B to the short sides of the respective light modulation elements 100 R, 100 G, and 100 B. For example, JP-A-11-249070 (Document 1) shows a technology (hereinafter referred to as a related art technology) of arranging the light modulation elements so as to have the long sides adjacent to each other, and at the same time connecting the FPC boards to the short sides of the respective light modulation elements. By thus arranging the light modulation elements so as to have the long sides of the respective light modulation elements adjacent to each other, downsizing of the cross dichroic prism becomes possible, and further, by connecting the FPC boards to the short sides of the respective light modulation elements, it becomes possible to remove the FPC boards connected to the respective light modulation elements from the light paths of the respective colored light beams, thus an advantage of preventing the FPC boards from shielding the colored light beams can be obtained.
However, if it is arranged to connect the FPC boards simply to the short sides, there arises the following problem. The scanning direction for image data writing in the typical projector is set to be parallel to a direction (referred to as a long side direction) along the long side. Therefore, in the case of the light modulation element having a resolution of 4K2K, 4096 signal lines disposed along the long side are necessary for providing each of the pixels of the light modulation element. Therefore, if the FPC board is connected simply to the short side thereof while keeping the scanning direction for image data writing to the long side direction, a wiring space for leading the 4096 signal lines to the FPC board provided on the short side is required. This causes growth in overall size of the light modulation element.
FIGS. 9A and 9B are diagrams schematically showing the arrangement of the signal lines of the light modulation element. Although the light modulation element 100 G for the green light (G) is shown in FIGS. 9A and 9B , the light modulation elements 100 R and 100 B for the red light (R) and the blue light (B) have substantially the same configurations. It should be noted that FIG. 9A shows the typical light modulation element having the FPC board 130 coupled to the long side thereof, and in this case, there is adopted a configuration in which the 4096 signal lines from the FPC board 130 G are connected to a data line driver 102 disposed along the long side (the long side of the image display area 101 ) of the light modulation element 100 G. It should be noted that in the configuration, a gate line driver 103 is disposed on the short side (the short side of the image display area 101 ) of the light modulation element 100 G, and a few signal lines for control from the FPC board 130 G are connected to the gate line driver 103 .
FIG. 9B shows the case in which the FPC board 130 G is coupled to the short side of the light modulation element 100 G shown in FIG. 9A . In the case in which the FPC board 130 G is coupled to the short side of the light modulation element 100 G, the wiring space (the area A surrounded by the dotted frame in the drawing) for leading the 4096 signal lines connected to the data line driver 102 disposed on the long side to the FPC board 130 G coupled to the short side is required as shown in FIG. 9B . Since an area of at least 10 mm in size in the z-axis direction shown in the drawing is required as the wiring space, which causes the growth in the overall size of the light modulation element.
Therefore, if the FPC boards are simply coupled to the short side while keeping the long side direction of the light modulation elements 100 R, 100 G, and 100 B to the scanning direction for the image data writing, it is hardly possible to make the most use of the advantage obtained by disposing the light modulation elements 100 R, 100 G, and 100 B so as to have the long sides adjacent to each other, namely the advantage of making it possible to downsize the cross dichroic prism and the projection optical system.
SUMMARY
An advantage of some aspects of the invention is to provide a projector allowing downsizing of the combining optical system and the projection optical system even in the case of using a high resolution light modulation element.
A projector according to a first aspect of the invention includes a plurality of light modulation elements adapted to modulate a plurality of colored light beams with respective color components based on image data, a combining optical system adapted to combine the colored light beams, which are modulated by the respective light modulation elements, to emit the combined colored light beams as image light, and a projection optical system adapted to project the image light emitted from the combining optical system on a projection screen, and, the light modulation elements are disposed with respect to the combining optical system so that long sides of the respective light modulation elements are adjacent to each other, signal line cable boards adapted to provide the respective light modulation elements with signals, and coupled to short sides of the respective light modulation elements, and a scanning direction of writing the image data to the light modulation elements is set to be parallel to a direction of the short side of an image display area in each of the light modulation elements.
According to the projector of the first aspect of the invention, the light modulation elements are disposed with respect to the combining optical system so that the long sides of the respective light modulation elements are adjacent to each other. In this case, the relationship between the light modulation elements and the cross dichroicprism as the combining optical system corresponding to an arrangement in which the long sides of the light modulation elements are disposed along the height direction of the triangular prisms forming the cross dichroic prism. Thus, the volume of the combining optical system (the cross dichroic prism) can be reduced, thus achieving the downsizing of the combining optical system (the cross dichroic prism). Thus, the increase in productivity and the reduction in the cost of the optical elements such as the combining optical system (the cross dichroic prism) or the projection optical system can be achieved. Further, according to the present aspect of the invention, since the focal length of the projection optical system can be shortened, a higher luminance can easily be achieved using a bright lens with a rather large aperture.
Further, according to the projector in the first aspect of the invention, since the light modulation elements are disposed so that the long sides thereof are adjacent to each other, and the signal line cable boards (FPC boards) are coupled to the short sides of the respective light modulation elements, the problem that the FPC board shields the colored light beams input to the light modulation elements can be avoided.
Further, in the projector of the first aspect of the invention, the scanning direction of writing the image data to each of the light modulation elements is set to be parallel to the direction (referred to as a short side direction) along the short side of the image display area in each of the light modulation elements. Thus, in the case in which the FPC board is coupled to the short side of each of the light modulation elements, the wiring space for leading a number of data lines from the data line driver to the FPC board can be made smaller, thus the overall size of the light modulation element can be reduced to be a smaller size. Further, by setting the scanning direction for writing to be parallel to the short side direction, the number of data lines can also be reduced, thus the advantage of reducing the width of the FPC board can also be obtained.
Further, the projector according to the first aspect of the invention preferably includes an image data processing device including a first frame memory and a second frame memory each capable of holding the image data to be displayed corresponding to one frame, an address information generation section adapted to generate address information for executing writing and retrieving the image data on the first frame memory and the second frame memory, a frame memory control section adapted to control writing and retrieving of the image data on the first frame memory and the second frame memory based on the address information from the address information generation section, and alight modulation element drive section adapted to drive each of the light modulation elements based on the image data retrieved from either one of the first frame memory and the second frame memory, and the frame memory control section, while writing the image data corresponding to one frame in one of the first frame memory and the second frame memory, retrieves the image data corresponding to one frame previously written in the other of the first frame memory and the second frame memory, and converts the scanning direction of writing the image data into the direction of the short side of the image display area of each of the light modulation elements in one of writing and retrieving the image data.
By adopting the configuration of writing of the image data and retrieving of the image data are executed on the separate frame memories as described above, the scanning direction conversion process for setting the scanning direction for writing to be parallel to the short side direction can appropriately be executed. In other words, if it is attempted to execute the scanning direction conversion process with a single frame memory, when executing retrieving of the image data from the frame memory in order for setting the scanning direction for writing to be parallel to the short side direction, there might be caused a problem that, for example, the image data written as the image data for the subsequent frame exists in an area with the address for the data corresponding to a certain pixel on which the retrieving process is executed. In contrast, as in the case with the invention, by executing the writing and retrieving of the image data on the separate frame memories, such a problem can be solved, and the image data corresponding to the one frame can appropriately be retrieved with the scanning direction parallel to the short side direction.
Further, in the projector according to the first aspect of the invention, it is preferable that the frame memory control section controls executing writing and retrieving of the image data on the first frame memory and the second frame memory so that the writing of the image data corresponding to the one frame and the retrieving of the image data corresponding to one frame are executed in sync with each other.
As described above, by making the writing of the image data corresponding to one frame to one of the frame memories and the retrieving of the image data corresponding to one frame from the other of the frame memories are executed in sync with each other, the process of writing the image data corresponding to one frame and the process of retrieving the image data corresponding to one frame becomes possible continuously, and it becomes possible to output the retrieved image data to the light modulation element drive section as the image data with the continuous frames.
A projector according to a second aspect of the invention includes a plurality of light modulation elements adapted to modulate a plurality of colored light beams with respective color components based on image data, a combining optical system adapted to combine the colored light beams, which are modulated by the respective light modulation elements, to emit the combined colored light beams as image light, and a projection optical system adapted to project the image light emitted from the combining optical system on a projection screen, and a cooling device adapted to cool at least the light modulation elements, and, the light modulation elements are disposed with respect to the combining optical system so that long sides of the respective light modulation elements are adjacent to each other, and signal line cable boards adapted to provide the respective light modulation elements with signals are coupled to short sides of the respective light modulation elements, and the cooling device is disposed so as to flow the cooling air from the cooling device along a direction of the long side of each of the light modulation elements.
According to the projector of the second aspect of the invention, similarly to the projector of the first aspect of the invention, there can be obtained the advantage that the downsizing of the composing optical system (the cross dichroic prism) can be achieved, and the problem that the FPC board shields the colored light input to the light modulation element can be solved. Further, according to the projector in the second aspect of the invention, it is arranged that the cooling air from the cooling device is made to flow along the long side direction of the light modulation elements. This means that the cooling air is made to flow laterally, by flowing the cooling air in the lateral direction, there can be obtained an advantage of reducing the chances of stacking the dust on the light modulation elements and the cross dichroic prism. In other words, the dust generally falls in a direction of gravitational force, and by flowing the cooling air in a direction perpendicular to the gravitational direction, the chances of accumulating the dust on the light modulation elements or the cross dichroic prism and so on can be reduced.
It should be noted that also in the second projector according to this aspect, it is preferable to have the same feature as the projector of the first aspect of the invention.
Further, in the projector according to the second aspect of the invention, it is preferable that a scanning direction of writing the image data to the light modulation elements is set to be parallel to a direction of the short side of an image display area in each of the light modulation elements.
Thus, in the case in which the FPC board is coupled to the short side of each of the light modulation elements, the wiring space for leading a number of data lines from the data line driver to the FPC board can be made smaller, thus the overall size of the light modulation element can be reduced to be a smaller size in addition to the advantage that the chances of accumulating the dust on the light modulation elements and the cross dichroic prism can be reduced. Further, by setting the scanning direction for writing to be parallel to the short side direction, the number of data lines can also be reduced, thus the advantage of reducing the width of the FPC board can also be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
FIGS. 1A and 1B are diagrams showing a configuration of light modulation elements and an optical system in the periphery thereof in the projector according to a first embodiment.
FIG. 2 is a diagram schematically showing a general configuration of the optical system of the projector in the case in which the light modulation elements 100 R, 100 G, and 100 B are arranged as shown in FIGS. 1A and 1B .
FIG. 3 is a diagram schematically showing an arrangement of signal lines of the light modulation element of the projector according to the first embodiment.
FIG. 4 is a diagram showing a configuration of an image data processing device in the projector according to the first embodiment.
FIG. 5 is a diagram showing a configuration of light modulation elements and an optical system and so on in the periphery thereof in the projector according to a second embodiment.
FIGS. 6A and 6B are diagrams showing a configuration of the light modulation element and the optical system in the periphery thereof in a typical projector.
FIGS. 7A and 7B are diagrams showing a configuration of light modulation elements and an optical system in the periphery thereof in the case of arranging the light modulation elements so that the long sides thereof are adjacent to each other while keeping the respective long sides of the light modulation elements in a lateral direction (a horizontal direction).
FIG. 8 is a diagram schematically showing a general configuration of the optical system of the projector in the case in which the light modulation elements are arranged as shown in FIGS. 7A and 7B .
FIGS. 9A and 9B are diagrams schematically showing an arrangement of signal lines of a light modulation element.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Hereinafter, some embodiments of the invention will be explained.
First Embodiment
FIGS. 1A and 1B are diagrams showing a configuration of light modulation elements and an optical system in the periphery thereof in a projector according to a first embodiment, and in particular showing an image light forming optical system including a plurality of light modulation elements (assumed to be light modulation elements 100 R, 100 G, and 100 B corresponding respectively to R, G, and B) and a cross dichroic prism 110 as a combining optical system, and a projection optical system 120 . It should be noted that FIG. 1A is a perspective view, and FIG. 1B is a plan view corresponding to FIG. 1A , namely a diagram of the configuration shown in FIG. 1A viewed from a direction along the arrow b.
As shown in FIGS. 1A and 1B , in the projector according to the present embodiment of the invention, the light modulation elements 100 R, 100 G, and 100 B corresponding respectively to the red light (R), the green light (G), and the blue light (B) are arranged so that the long sides thereof are adjacent to each other. In other words, one of the long sides of the light modulation element 100 G and one of the long sides of the light modulation element 100 R are disposed adjacent to each other, and similarly, the other of the long sides of the light modulation element 100 G and one of the long sides of the light modulation element 100 B are disposed adjacent to each other. It should be noted that in FIGS. 1A and 1B , -z direction in the z-axis corresponds to the direction of the gravitational force. Therefore, it is assumed that the projector according to the first embodiment has a bottom section (the side provided with legs of the projector) of the projector on the -z direction side of the image light forming optical system. Further, it is also assumed that each of the light modulation elements 100 R, 100 G, and 100 B has a resolution of 4K2K (assumed to be 4096 pixels in the lateral direction×2160 pixels in the vertical direction).
Further, in this case, in the positional relationship between the light modulation elements 100 R, 100 G, and 100 B, and a cross dichroic prism 110 , the light modulation elements 100 R, 100 G, and 100 B are disposed so that each of the long sides of each of the light modulation elements 100 R, 100 G, and 100 B is disposed along a height direction (the x-axis direction) of four triangular prisms forming the cross dichroic prism 110 . Further, in the projector according to the first embodiment, there is adopted a configuration of coupling the FPC boards 130 R, 130 G, and 130 B respectively to the short side of the light modulation elements 100 R, 100 G, and 100 B.
FIG. 2 is a diagram schematically showing a general configuration of the optical system of the projector in the case in which the light modulation elements 100 R, 100 G, and 100 B are arranged as shown in FIGS. 1A and 1B . In the optical system shown in FIG. 2 , the arrangement of the optical constituents is substantially the same as the configuration shown in FIG. 8 , and the same sections are denoted with the same reference numerals. The configuration shown in FIG. 2 is different from the configuration shown in FIG. 8 in that the FPC boards 130 R, 130 G, and 130 B are coupled to the short sides of the respective light modulation elements 100 R, 100 G, and 100 B in the configuration shown in FIG. 2 , while the FPC boards 130 R, 130 G, and 130 B are coupled to the long sides of the respective light modulation elements 100 R, 100 G, and 100 B in the configuration shown in FIG. 8 .
As described above, in the configuration of the optical system of the projector according to the first embodiment, the light modulation elements 100 R, 100 G, and 100 B are disposed so that the long sides thereof are adjacent to each other, and at the same time, the FPC boards 130 R, 130 G, and 130 B are coupled to the short sides of the respective light modulation elements. Although the configuration described hereinabove is substantially the same as the related art (the technology disclosed in the Document 1) described above, in the projector according to the first embodiment, downsizing of the size of each of the light modulation elements 100 R, 100 G, and 100 B becomes possible by setting the scanning direction for the image data writing in each of the light modulation elements 100 R, 100 G, and 100 B to be parallel to the short side direction of the image display area in each of the light modulation elements.
It should be noted that in the present specification, “the scanning direction for writing” denotes the high-speed scanning out of the high-speed scanning (so-called “horizontal scanning”) and the low-speed scanning (so-called “vertical scanning”). In other words, in the embodiment of the invention, the real vertical direction (the z-axis direction in each of the drawings) and the high-speed scanning direction become substantially parallel to each other (the real vertical direction and the so-called horizontal scanning direction become substantially parallel to each other). Further, hereinafter, “the scanning direction for writing” is simply denoted as “the scanning direction.”
FIG. 3 is a diagram schematically showing an arrangement of signal lines of the light modulation element of the projector according to the first embodiment. Although the light modulation element 100 G for the green light (G) is shown in FIG. 3 , the light modulation elements 100 R and 100 B for the red light (R) and the blue light (B) have substantially the same configurations.
In the projector according to the first embodiment, the scanning direction of each of the light modulation elements 100 R, 100 G, and 100 B is set to be parallel to the short side direction. Therefore, as shown in FIG. 3 , in the configuration, the data line driver 102 is disposed on the short side of each of the light modulation elements ( FIG. 3 shows the light modulation element 100 G), and the data lines for supplying the image data from the FPC board 130 G are connected to the data line driver 102 . In this case, the light modulation element 100 G is a light modulation element of 4K2K, and therefore, has 2160 data lines corresponding to the number of pixels arranged in the short side direction. Meanwhile, on the long side of the light modulation element 100 G, there is disposed a gate line driver 103 . To the gate lined river 103 , there are connected a few signal lines such as a signal line for control.
By providing the structure shown in FIG. 3 to each of the light modulation elements 100 R, 100 G, and 100 B, the wiring space (the area A surrounded by the dotted line frame shown in FIG. 9B ) for leading the data lines to the short side as in the light modulation element shown in FIG. 9B , for example, can be eliminated, therefore, it is possible to downsize the overall light modulation element while keeping the resolution.
In order for making the configuration of the light modulation element shown in FIG. 3 possible, in the projector according to the first embodiment, the image data processing device shown in FIG. 4 is provided.
FIG. 4 is a diagram showing a configuration of the image data processing device in the projector according to the first embodiment. As shown in FIG. 4 , the image data processing device 500 has an image data input section 510 for inputting the image data to be displayed, a first frame memory 520 for storing the image data corresponding to one frame (one screen) of the image data input to the image data input section 510 , a second frame memory 530 similarly storing the image data corresponding to one frame (one screen) of the image data, a light modulation element drive section 540 for driving each of the light modulation elements 100 R, 100 G, and 100 B based on the image data retrieved from either one of the first frame memory 520 and the second frame memory 530 , an address information generation section 550 for generating the address information when executing writing and retrieving of the image data on the first frame memory 520 and the second frame memory 530 , and a frame memory control section 560 for controlling the writing and retrieving to and from the first and second frame memories 520 , 530 based on the address information from the address information generation section 550 .
It should be noted that in the projector according to the first embodiment, it is assumed that writing of the image data with the scanning direction along the long side direction is executed when writing the image data to the first and second frame memories 520 , 530 , and when retrieving the image data from the first and second frame memories 520 , 530 , a process of retrieving the image data with the scanning direction along the short side direction, namely a scanning direction conversion process is executed. Such a scanning direction conversion process is executed by the frame memory control section 560 based on the address information from the address information generation section 550 .
In the configuration described above, the writing and retrieving control of the image data to and from the first and second frame memories 520 , 530 by the frame memory control section 560 is executed in the following manner.
Now, it is assumed that the writing of the image data corresponding to a certain frame (assumed to be the nth frame) is completed in the first frame memory 520 , and subsequently the writing of the n+1th frame to the second frame memory 530 has been started. In sync with the writing of the n+1th frame to the second frame memory 530 , the image data corresponding to the nth frame, which has already been written, is retrieved from the first frame memory 520 , and subsequently, in sync with the writing of the image data corresponding to the n+2th frame to the first frame memory 520 , the image data corresponding to the n+1th frame, which has already been written, is retrieved from the second frame memory 530 . In other words, the writing process and the retrieving process of the image data corresponding to one frame are alternately executed on the first frame memory 520 and the second frame memory 530 .
The frame memory control section 560 executes the writing and retrieving control of the image data described above on the first and second frame memory 520 , 530 . In such a writing and retrieving control of the image data, when retrieving the image data from the first and second frame memories 520 , 530 , the scanning direction conversion process with the scanning direction parallel to the short side direction of the light modulation element. The scanning direction conversion process with the scanning direction parallel to the short side direction can be realized by obtaining the image data to each pixel based on the address information from the address information generation section 550 .
Since the writing and retrieving of the image data are executed in the separate frame memories in the image data processing device shown in FIG. 4 , the scanning direction conversion process for setting the scanning direction to be parallel to the short side direction can appropriately be executed. In other words, if it is attempted to execute the scanning direction conversion process with a single frame memory, when executing retrieving of the image data from the frame memory in order for setting the scanning direction to be parallel to the short side direction, there might be caused a problem that, for example, the image data written as the image data for the subsequent one frame exists in an area with the address for the image data corresponding to a certain pixel on which the retrieving process is executed. In contrast, as shown in FIG. 4 , by executing the writing and retrieving of the image data on the separate frame memories (the first and second frame memories 520 , 530 ) alternately, such a problem can be solved, and the image data corresponding to the one frame can appropriately be retrieved with the scanning direction parallel to the short side direction.
Further, when executing the writing and retrieving control of the image data described above on the first and second frame memories 520 , 530 , the frame memory control section 560 controls the writing and retrieving of the first frame memory 520 and the second frame memory 530 so that the writing of the image data corresponding to one frame and retrieving of the image data corresponding to one frame are in sync with each other. Thus, the writing and retrieving of the image data on the first frame memory 520 and the second frame memory 530 are finished simultaneously in each frame.
Since the frame memory control section 560 executes such writing and retrieving control, it becomes possible to continuously execute writing of the image data corresponding to one frame and retrieving of the image data corresponding to one frame, thus the image data thus retrieved can be output to the light modulation element drive section as the image data of the continuous frames.
As explained hereinabove, according to the projector related to the first embodiment, the light modulation elements 100 R, 100 G, and 100 B are disposed so that the long sides thereof are adjacent to each other with respect to the cross dichroic prism 110 . Thus, the volume of the cross dichroic prism 110 can be reduced, thus achieving the downsizing of the cross dichroic prism 110 . Thus, the increase in productivity and the reduction in the cost of the optical elements such as the cross dichroic prism or the projection optical system can be achieved. Further, according to the present embodiment of the invention, since the focal length of the projection optical system can be shortened, a higher luminance can easily be achieved using a bright lens with a rather large aperture.
Further, according to the projector related to the first embodiment, since the FPC boards 130 R, 130 G, and 130 B are coupled to the short sides of the respective light modulation elements 100 R, 100 G, and 100 B, the problem that the FPC board shields the colored light input from the light source to the light modulation elements can be avoided. Further, in the projector according to the first embodiment, the scanning direction of each of the light modulation elements 100 R, 100 G, and 100 B is set to be parallel to the short side direction of the light modulation elements. In this case, by executing the image data processing explained with reference to FIG. 4 , the image data with the scanning direction parallel to the short side direction can appropriately be provided to the light modulation elements 100 R, 100 G, and 100 B.
By setting the scanning direction to be parallel to the short side direction of the light modulation elements 100 R, 100 G, and 100 B, the wiring space for leading a number of data lines from the data line driver 102 to the FPC boards 130 R, 130 G, and 130 B can be reduced to an extremely small space in the case of coupling the FPC boards 130 R, 130 G, and 130 B to the short sides of the respective light modulation elements 100 R, 100 G and 100 B, thus the size of the overall light modulation element can be reduced to be a small size.
Further, by setting the scanning direction to be parallel to the short side direction, the number of data lines can also be reduced, thus the advantage of making it possible to reduce the width of the FPC boards 130 R, 130 G, and 130 B can also be obtained. For example, in the case in which the each of the light modulation elements 100 R, 100 G and 100 B has a resolution of 4K2K, the number of data lines on the short side becomes 2160, and therefore, in simple comparison on the number of data lines with the case of setting the scanning direction to be parallel to the long side direction in the light modulation element with the same resolution of 4K2K, the data lines roughly a half as many as the latter case are enough. Thus, the width of each of the FPC boards 130 R, 130 G, and 130 B coupled to the respective light modulation elements 100 R, 100 G and 100 B can be reduced.
It should be noted that although in the embodiment described above the scanning direction conversion process for setting the scanning direction to be parallel to the short side is arranged to be executed when retrieving the data from the first and second frame memories 520 , 530 , it is also possible to arrange that the scanning direction conversion process is executed when writing the data into the first and second frame memories 520 , 530 instead of retrieving.
Second Embodiment
FIG. 5 is a diagram showing a configuration of light modulation elements and an optical system and so on in the periphery thereof in the projector according to a second embodiment. The configuration of the light modulation elements and the optical system in the periphery thereof shown in FIG. 5 is substantially the same as that shown in FIGS. 1A and 1B , and what is different from that shown in FIGS. 1A and 1B is a cooling device 600 capable of cooling at least the light modulation elements 100 R, 100 G, and 100 B provided thereto. It should be noted that the same constituents as those shown in FIGS. 1A and 1B are denoted with the same reference numerals.
As shown in FIG. 5 , the projector according to the second embodiment has a structure in which the cooling air 610 from the cooling device 600 flows in a lateral direction, namely along the long side direction (the x-axis direction) of the light modulation elements 100 R, 100 G, and 100 B. By thus flowing the cooling air in the lateral direction, there can be obtained an advantage of reducing the chances of accumulating the dust on the light modulation elements 100 R, 100 G, and 100 B and the cross dichroic prism 110 . In other words, the dust generally falls in the direction of gravitational force (-z direction in the z-axis), and therefore, by flowing the cooling air along the direction (the x-axis direction) perpendicular to the direction of gravitational force, it becomes possible to reduce the chances of accumulating the dust on the light modulation elements 100 R, 100 G, and 100 B and the cross dichroic prism 110 .
Further, also in the projector according to the second embodiment, it is possible to set the scanning direction to be parallel to the short side direction similarly to the first embodiment by executing the image data processing explained with reference to FIG. 4 , thus the advantages described regarding the projector according to the first embodiment in addition to the advantage of reducing the chances of accumulating the dust on the light modulation elements 100 R, 100 G, and 100 B, and the cross dichroic prism 110 are obtained.
It should be noted that the invention is not limited to the embodiments described above, but can be put into practice with various modifications within the scope or spirits of the invention. For example, although in the embodiments described above, the transmissive liquid crystal panels are explained, the invention can be put into practice with reflective liquid crystal panels.
Further, although in the embodiments, the explanations are presented assuming that the resolution of the light modulation elements 100 R, 100 G, and 100 B is 4K2K, this is nothing more than an example, it is obvious that the resolution is not limited to the 4K2K.
The entire disclosure of Japanese Patent Application No. 2008-034116, filed Feb. 15, 2008 is expressly incorporated by reference herein. | A projector includes a plurality of light modulation elements adapted to modulate a plurality of colored light beams based on image data, a combining optical system adapted to combine the modulated colored light beams to emit image light, and a projection optical system adapted to project the image light emitted from the combining optical system on a projection screen. The light modulation elements are disposed with respect to the combining optical system so that long sides of the respective light modulation elements are adjacent to each other. Signal line cable boards adapted to provide the respective light modulation elements with signals, and coupled to short sides of the respective light modulation elements. A scanning direction of writing the image data to the light modulation elements is set to be parallel to a direction of the short side of an image display area in each of the light modulation elements. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of packaging. In particular, the present invention relates to a novel package that is constructed in such a manner that in an unfolded, or open condition, it is an attractive or novelty display, and in a folded condition, it is a secure package.
BACKGROUND OF THE INVENTION
[0002] The present invention is, in its most basic form, a foldable envelope with very little depth. An insert may be combined with the foldable envelope to provide a package with sufficient depth for packaging a jewellery item such as a pair of ear rings, or a locket and chain.
[0003] Envelopes for holding small items such as jewellery are well known in the art. Typically, the envelope will comprise a foldable blank having a central panel that is the back of the envelope. A front panel depends from the lower edge of the central panel, to be folded up onto it. Side panels depend from the side edges of the central panel, for adhesive or mechanical fixation to the front panel after it is folded over onto the central panel. A top flap depends from the top edge of the central panel, for adhesive or mechanical fixation to the front panel, to close the envelope. An example of such an envelope is shown in U.S. Pat. No. 2,326,390 dated Aug. 10 th , 1943 to Platt. Variants of this general design have proliferated over the years, directed primarily to structural modifications desirable for packaging specific items.
[0004] For example, U.S. Pat. No. 5,823,333 dated Oct. 20 th , 1998 to Mori shows a package of the sort described with bellows shaped side panels, for accommodating disk type recording media.
[0005] U.S. Pat. No. 5,255,785 dated Oct. 26 th , 1993 to Mackey shows a package of the sort described with top flaps depending from the front and central panels, for added security and strength.
[0006] U.S. Pat. No. 2,676,699 dated Apr. 27 th , 1954 to Friedman shows a carton with a front panel, a central panel that may be double thickness and a rear panel. The front panel is provided with apertures to view a pair of ear rings, whereby the carton is useful for display and packaging.
[0007] U.S. Pat. No. 6,053,399 dated Apr. 25 th , 2000 shows a double flap pocket mailer and envelope that opens to an attractive valentine shape when it is held on the diagonal. It is not, however, designed to display an object in the open position.
OBJECT OF THE INVENTION
[0008] The object of the present invention is to provide a package fabricated from a foldable blank that, in an open position presents an attractive display to catch the eye of the consumer.
[0009] The package of the present invention is composed of panels that fold together in a manner similar to that know in the prior art to provide a secure container, but which present an attractive appearance in an unfolded condition. In this way, a product, such as a pair of ear rings can be displayed in its packaging, and when it is sold, the retailer need only fold the packaging inwardly to create a container. Currently, products like ear rings or jewellery are displayed on cards or holders that have to be transferred to boxes when sold. Furthermore, since the cards on which jewellery items are currently displayed are usually quite small, they tend to be easy to steal, resulting in loss to the retailer. By using the present invention, which displays the same product in a large, unfolded container that doubles as an attractive display, the retailer will also be discouraging theft, since the large unfolded container will be more difficult to steal than a small card with a pair of ear rings on it.
[0010] Preferably, moreover, an appropriate jewellery mounting card is affixed to the central panel of the display and packaging device of the subject invention.
[0011] In a broad aspect, then, the present invention relates to a package for holding and displaying items for retail sale, comprising a central panel to which said items are affixed, left and right side panels extending from said central panel, a top panel extending from said central panel, and a bottom panel extending from said central panel, each of said left, right, top and bottom panels being foldable over said central panel to surround said item, wherein one or more of said left, right, top and bottom panels are shaped or ornamented to present a decorative design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In drawings that illustrate the present invention by way of example:
[0013] FIG. 1 is a plan view of a package blank according to the present invention;
[0014] FIG. 2 is a plan view of the blank of FIG. 1 with a jewellery mounting card attached thereto;
[0015] FIG. 3 is a front view of the blank of FIG. 2 with the side panels folded in;
[0016] FIG. 4 is a front view of the blank of FIG. 2 with the side and bottom panels folded in;
[0017] FIG. 5 is a front view of the blank of FIG. 2 with the side, bottom and top panels folded in;
[0018] FIGS. 6, 7 and 8 are plan view of package blanks similar to FIG. 1 , but cut to different shapes;
[0019] FIG. 9 is a plan view of an alternate embodiment of the present invention;
[0020] FIG. 10 is a folded and tied view of the embodiment of FIG. 9 ;
[0021] FIG. 11 is a plan view of a further alternate embodiment of the present invention.
DETAILED DESCRIPTION
[0022] Referring now to FIGS. 1 and 2 , a foldable blank is shown, shaped like a maple leaf. The blank includes a central panel 1 that will become the rear wall of the finished package. This central panel is rectangular, and preferably has a jewellery holding means, such as an ear ring card 11 , mounted in it. The card 11 , as shown in FIG. 2 , may be substantially congruent to the central panel 1 , adhesively affixed to the lower are thereof. This permits the card 11 to be easily flexed outwardly away from the central panel 11 , thereby to permit access to the jewellery, in this case ear rings, mounted on the card.
[0023] Typically, the earrings are mounted on the card with their pins extending through holes in the card, keepers affixed behind the card onto the pins, and the decorative portion of the ear rings visible on the front of the card.
[0024] It will be understood, however, that the device of the present invention may be made an appropriate size to package larger items like silk scarves. In such cases, appropriate mounting devices are affixed to central panel 1 .
[0025] Upper side panels 2 extend to the left and right of the central panel, joined to the central panel by fold lines 6 . Upper side panels 2 are decoratively cut, and will preferably (but not necessarily) be each at least half as wide (i.e., as wide in total) as the central panel 1 , so that when they are folded over onto the central panel, they overlap each other to securely hold the contents of the container against central panel 1 .
[0026] A lower bottom panel 3 is joined to the lower edge of central panel 1 , either directly, or by lower depth panel 12 . Lower depth panel 12 is joined to the central panel 1 and upper side panels 2 along fold lines 7 . Lower depth panel 12 is, moreover, joined to bottom panel 3 by fold line 8 . Lower side panels 4 extend from the left and right of bottom panel 3 , joined thereto along fold lines 6 .
[0027] Lower depth panel also separates upper 2 and lower 4 side panels, and is joined thereto by fold lines 7 , 8 respectively.
[0028] Bottom panel 3 may have a slot or slots 14 or other fastening opening in it. Slot 14 is adapted to receive a tab 15 in upper panel 5 . Upper panel 5 extends upwardly from central panel 1 , and may be separated from same by upper depth panel 13 . Upper depth panel 13 is joined to the upper 5 and central 1 panels by fold lines 10 , 9 respectively. It will be understood, moreover, that upper side panels, similar to lower side panels, may be provided, if the shape of the display requires it.
[0029] Moreover, upper panel 5 may be bent back from central panel 1 , while bottom panel 3 is bent back from central panel 1 , so that tab 15 engages slot 14 behind the central panel 1 . In this way, the device may be hung over a wire rod simply and effectively, by threading the wire rod between the upper panel 5 and the central panel 1 .
[0030] A hanging aperture is preferably provided at the upper end of upper panel 5 in the tab 15 portion of same.
[0031] As can be seen from FIGS. 3, 4 and 5 , the package of the present invention is used and assembled as follows:
i) The article for sale, e.g., ear rings, is displayed on the unfolded blank, attractively set, and provided with appropriate graphics on its face. It will be understood that the ear ring card shown may be substituted with any other appropriate, known carrier, such as a clip for holding a pendant, or chain. ii) The selected package then has the side panels 2 / 4 folded inwardly over central and lower panels 1 , 3 along fold lines 6 , as shown in FIG. 3 . iii): The lower panel 3 is then folded up along fold lines 7 , 8 so that it then lies parallel to central panel 1 , separated therefrom by lower depth panel 12 ( FIG. 4 ). The reason depth panel is provided is to allow for some product depth. While there will be some bulging of side panels 2 over the product, any such bulging is covered by the bottom and top panels, which will lie fairly flat, because of depth panels 12 , 13 . iv) Top panel 5 is then folded down along fold lines 9 , 10 to overlie bottom panel 3 , and tab 15 is inserted into slot 14 . It will be understood that other closure means may be provided. For instance, tab 15 may be provided with a wettable adhesive, or a pressure sensitive adhesive covered with a release sheet.
[0036] Referring now to FIGS. 6, 7 and 8 , other exemplary shapes are shown for the packaging and display device of the present invention.
[0037] Now, it will be understood that the blanks and packages shown in FIGS. 1-8 are preferably made from cardboard or other heavy paper, but may be made from foldable plastic, foil, or other suitable material.
[0038] In FIGS. 9, 10 and 11 , two embodiments that are preferably made from suede, leather or a heavy fabric like felt are shown. These embodiments are preferably, but not necessarily provided with slits 17 through which a cord, such as an elasticized fabric cord 18 may be looped, to extend from the back surface of the blank. When the blank is folded into a package, as shown in FIG. 10 , the cord can be quickly looped around the package twice, as shown, to achieve a secure, attractive package.
[0039] Moreover, as shown in FIG. 11 , holes 19 may be provided on each side of slits 17 , so that a cord may be threaded through the holes and slits, and jewellery pieces, such as earrings, being on the cord.
[0040] It is to be understood that the examples described above are not meant to limit the scope of the present invention. It is expected that the numerous variants will be obvious to a person skilled in the art of packaging design without any departure from the spirit of the invention. The appended claims, properly construed, form the only limitation upon the scope of the invention. | A package for holding and displaying items fo retail sale, comprises a central panel to which items may be affixed, left and right side panels extending from the central panel, a top panel extending from the central panel, and a bottom panel extending from the central panel. Each of the left, right, top and bottom panels are foldable over the central panel to surround an item, wherein one or more of the left, right, top and bottom panels are shaped or ornamented to present a decorative design. | 1 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/018,502, filed on Jun. 27, 2014, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Ground-moving, breaking and excavating equipment employs buckets, dragline buckets, shovels and other containers (hereafter collectively “buckets”) with which earth, gravel, rock formation and the like are excavated and moved around. Typically, such buckets carry a lip defining their digging edges, and the lips in turn mount consumable components which need periodic replacement, such as shrouds, adapters for digging teeth, digging teeth themselves and the like (hereinafter collectively “shrouds”).
[0003] The shrouds and their connections to the lips of the buckets are subject to the most wear and tear of the entire bucket because they are exposed to constant abrasion, shaking, impacts and the like encountered during ground moving operations. As a result, they require frequent replacement. Replacing shrouds in accordance with the prior art is relatively time-consuming and labor intensive because it typically requires a combination of wedges and clamp like structures which must be manually hammered into place or out of their locked positions. The excavating equipment must sit idle during that time, all of which is undesirable because it reduces profits.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to the manner in which the shrouds are secured to the lips of buckets, and replaced when worn or damaged, and concerns both a method and apparatus for rapidly and efficiently installing and removing shrouds from the lips.
[0005] The lips typically have forwardly converging upper and lower surfaces which are engaged by correspondingly rearwardly diverging legs of the shrouds that overly and are in contact with the lip surfaces. In many embodiments, a hole can be formed in the lip and an oblong-hole in the legs that is aligned with the hole and has axially extending, spaced-apart flat walls which define engagement ledges that face and overlap the hole. A connector for securing the shroud to the lip can be placed in the oblong-bore and the hole and has shaped exterior surfaces for positioning between the walls so that the connector is axially movable along the walls and past the engagement ledges while relative rotations between the connector and the oblong-bore in the leg are prevented. In another embodiment the exterior of the connector pin and the hole in the lip and the bore in the shroud leg can be cylindrical.
[0006] In many embodiments, the connector can have a base for insertion into the hole in the lip and a housing that extends from the bore into the hole. The housing is split in the axial direction and defines opposing housing halves which surround the base to keep the base and the housing in axial alignment with each other. The base can have flat wall sections in alignment with the flat walls on the exterior of the housing and the housing and base are further prevented from rotationally moving relative to each other.
[0007] A first, lateral projection inside the bore can extend from the housing to an enlarged portion of the bore and laterally past the hole to limit how far the housing can move axially into the bore. A second, lateral projection can extend from the base in lateral alignment with the first projection from the hole and into a space between the first projection and the lip. Retractable locking arms can be embedded in recesses formed in surfaces of the base opposite the wall. Portions of the arms, e.g. their ends facing the bore in the housing, can be resiliently urged, laterally and outwardly, towards the walls.
[0008] The shroud can be secured to the lip by aligning the respective bore and hole and axially sliding the connector, connector base first, into the bore and from there into the hole. During this motion of the connector the outwardly biased locking arm ends are forced and retracted into the associated recesses in the base. As soon as the locking arm ends clear the engagement ledges during the downward movement of the connector pin the arm ends are automatically moved laterally and outwardly to contact the engagement ledges that overlap hole, thereby automatically locking the base and the housing to the shroud and to the lip.
[0009] In many embodiments, the housing and the base of the connector are secured to each other with an axially extending bolt that engages a threaded hole in the base. Upon tightening the bolt the housing and the base are drawn together to set an axial distance between the end of the locking arms facing the bore in the housing and the engagement ledges formed by the housing which allows minimal play between the locking arms and the engagement ledges, just sufficient to permit the arms to pivot inwardly when their free ends clear the ledges. To install the shroud on the lip the connector is simply dropped, base first, into the bore and, to the extent necessary, urged, e.g. manually pushed into the bore until the locking arms can laterally expand into engagement with the engagement ledges, which secures and locks the shroud to the lip.
[0010] Following the lateral release of the locking arms they are in lose engagement with the engagement surfaces which alone secures the connector to the lip. Moreover the bolt can be tightened to firmly press the locking arms into contact with the engagement ledges of the connector housing.
[0011] The parting lines between the components of the configured to form narrow gaps, typically in the order of no more than about 1/64″ to ⅛″, into which fine granular material such as fine sand or powder, for example, will migrate during operational use of the bucket. With use this granular material becomes compacted in the gaps and thereby further rigidifies the installed connector.
[0012] The shroud is securely attached to the lip with a connector pin between the top surface of the lip and the upper shroud leg that engages the top surface of the lip. The connector pin resists downward forces acting on the shroud because it acts as a rigid upright post. The shroud becomes attached to the lip because the legs of the shroud are in snug contact with the converging surfaces of the lip and the post formed by the connector pin prevents movements of the shroud relative to the lip. In some embodiments, the shroud can only be replaced by first unthreading the bolt while it is still in the hole and the bore and then individually sliding the components of the connector out of the bore and the hole.
[0013] To speed up the replacement of shrouds it is preferred to provide the bolt with a head that can be power rotated, for example with an electric drill fitted with suitable rotating implements such as screw drivers or sockets, for example. Activation of the electric drill rapidly unthreads the bolt, releases it from the base and raises the bolt and the housing upwardly in the bore where the connector pin can be grasped, pulled out or the bore and the fresh shroud can be installed. Rotation of the bolt raises both the bolt and the housing in the bore since the base of the connector remains locked to the lip.
[0014] In this manner, a worn shroud can typically be removed in less than one minute, much less time than is needed to remove worn shrouds in accordance with past practices. This leads to significant cost savings because of the relatively large number of shrouds on industrial buckets and the frequency with which they must be replaced.
[0015] A further advantage provided by this invention is that removal of the worn shroud with an electric drill or the like automatically provides access to the bolt even when, as is frequently the case, the bolt head inside the bore in the shroud becomes embedded in hardened particulate matter, and even hardened concrete, that accumulate during operational use. In the past this required that the hardened material be tediously removed with chisels and the like.
[0016] In contrast thereto, the activated drill bit is pushed against the embedded material which causes it to shatter, thereby freeing and providing access to the bolt head so that continued activation of the electric drill will unthread the bolt from the base as earlier described.
[0017] In the other embodiment mentioned earlier, the pivoting arms are replaced by reciprocating pawls that are moved over the locking surface to secure and lock the connector pin in place.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a plan view and shows a shroud demountably attached to a lip of a bucket in accordance with the invention;
[0019] FIG. 2 is a cross-section taken along line A-A of FIG. 1 , and shows the shroud in its installed condition securing the shroud to the lip;
[0020] FIG. 3 is a cross-section taken along line B-B of FIG. 2 and also shows the shroud in its installed condition;
[0021] FIGS. 4 and 5 are cross-sections also taken along lines A-A and B-B of FIGS. 1 and 2 , respectively, but show the connector pin in its separated condition and ready for removal;
[0022] FIG. 6 shows an assembled connector pin constructed according with the invention;
[0023] FIG. 7 is an exploded view of the connector pin shown in FIG. 6 ;
[0024] FIG. 8 shows the components of the connector pin shown in FIGS. 6 and 7 separated from each other to better illustrate their individual constructions;
[0025] FIG. 9 is a plan view similar to FIG. 1 and shows another embodiment of a connector pin constructed according to the invention;
[0026] FIG. 10 is an upright cross-section taken along line A-A of FIG. 9 ; and
[0027] FIG. 11 is an enlarged cross-sectional view of the connector pin shown in FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring to FIGS. 1-6 , a lip 2 of a bucket (not separately shown) of earthmoving equipment (not separately shown) has forwardly converging upper and lower surfaces 4 , 6 that terminate at a forward end 8 of the lip 2 . A shroud 10 (as mentioned the term also encompasses consumable components such as adapters for teeth, teeth alone and other attachment demountably secured to the lip) has rearwardly diverging legs 12 that overly and engage the lip surfaces 4 , 6 .
[0029] The terms “forward”, “aft”, “up” and “down” as used herein to simplify the description and they refer to the typically horizontal orientation of the lip during installation and removal of the shroud and connector pin.
[0030] The lip 2 has a cylindrical hole 16 that communicates with an enlarged, oblong bore 18 in at least one of the legs of the shroud 10 . The hole 16 and bore 18 are vertically oriented and to secure the shroud 10 to the lip 2 all that is required that the connector pin of this invention be manually dropped into the upwardly open end of the bore and be pushed down as needed until it has arrived in its locked position as is further explained below.
[0031] Connector pin 20 has a base 22 that is principally disposed in and substantially immovable fixed to the lip 2 in lip hole 16 . A housing 24 extends from bore 18 in the upper shroud leg into hole 16 in the lip 2 and a threaded bolt 26 secures the housing 24 and the base to each other.
[0032] As described in more detail below, installed base 22 is locked to the lip 2 so that it cannot move into the hole past a preset, fully inserted locked position. In that position the base cannot be moved out of the hole. As a result, the entire connector is locked and fixed to the lip as well. When the shroud needs replacement bolt 26 is backed up, that is unthreaded from the base into its released position shown in FIGS. 4 and 5 .
[0033] Referring to FIGS. 5-7 and addressing the construction of connector pin 20 in greater detail, its base 22 , disposed in lip hole 16 , has a generally cylindrical center section 28 with pivotally mounted, laterally projecting locking arms 30 and a stop nose 32 formed by a projection 33 that extends outward and upward from the center section and is located circumferentially midway between the locking arms. A curved outer surface 40 of the projection has a diameter that corresponds to the diameter of hole 16 in the lip and permits snug movements of the base in the hole.
[0034] Diametrically opposite pivot pockets 34 at the lower end of the center section each have an upwardly open recess which forms cooperating pivot surfaces 36 at the lower ends of the locking arms and their opposing interior pivot pocket surfaces. A resilient member 38 , such as a spring or a compressible foam pad, for example, is placed between the inside of the locking arms and the center section and resiliently urges the upper ends of the arms outwardly.
[0035] Stop nose 32 at the upper end of projection 33 is located inside shroud bore 18 . An underside 42 of the stop nose faces downwardly and is dimensioned so that when it engages upper lip surface 4 as best seen in FIG. 2 the upper end 43 of the center section is positioned slightly below the upper lip surface.
[0036] Housing 24 is longitudinally split along a vertical parting line 50 into first and second housing halves 44 , 48 which leaves the earlier mentioned small gaps between opposing surfaces of the halves. Together the two halves form a tubular structure which, on its outside, movably engages both lip hole 16 and shroud hole 18 and is slidable along them. On the inside of the housing is threaded bolt 26 . The bolt is placed inside one of the housing halves and thereafter the halves are placed over each other and over the bolt in a cavity between them. When assembled the cavity inside the housing forms the insides of both housing halves form an upper aperture section 52 , where bolt head 78 is located, an intermediate, reduced diameter middle aperture section 54 , which houses a section of the shaft between the bolt head and the upper end of the threads on the shaft, and a lower aperture section 55 which surrounds the base. The thickness of the middle aperture section is selected so that the lower end 62 of the intermediate aperture section 54 engages the upper end 43 of the center section when bolt 26 is tightened and the free ends of the locking arms 30 are moved into contact with engagement ledges 86 formed by the shroud legs as further described below.
[0037] The bolt has a ring flange 56 at the lower end of the head the underside 58 of which rests on a ring-shaped ledge formed by the upper end 60 of middle aperture section 54 . The bolt further has a groove 64 between the underside 58 of ring flange 56 and the beginning of threads 66 on the shaft of the bolt. The groove is sufficiently wide to accommodate and straddle middle aperture section 54 and allows the bolt rotate in the cavity of the housing.
[0038] The connector pin is assembled prior to its installation and use by separating the housing halves 44 , 48 and initially placing a bolt 26 in one of them so that its ring flange 56 rests on the upper end 60 of middle aperture section 54 and its groove 64 straddles the middle aperture section. The other housing half is then placed over the bolt and the bolt is threaded into the center section. This moves the housing halves 44 , 48 and the base from the initial assembly position, as generally illustrated in FIGS. 4 and 5 , into the fully assembled position, as illustrated in FIGS. 2 and 3 . A gasket, such as an O-ring 68 is placed between the underside 58 of ring flange 56 on the bolt and upper end 43 of center section 28 to shield the threads from contamination during use.
[0039] First housing half 44 extends over substantially the full length of the connector pin. Its exterior is semi-circular and conforms to the diameter of hole 16 and the shape of bore 18 in the shroud leg so that the housing is axially slidable in the hole.
[0040] Second housing half 48 has the same axial length as the first housing. A lower part 69 of this housing has the same diameter as the exterior of the first housing and includes an axially extending, elongated cut-out 70 that is dimensioned to accommodate projection 33 extending upwardly from the center section 28 of the base and positioned midway between the respective locking arms 30
[0041] An upper part 72 of the second housing half 48 has an enlarged cross-section relative to the diameter of lip hole 16 in the lip that is oblong and forms opposing, parallel, flat surfaces 74 which are spaced apart by less than the diameter of hole 16 . As a result portions of the shroud leg 12 overly hole 16 in the lip and form a pair of opposite, downwardly facing engagement ledges 86 . The upper part of the housing further defines another vertically projection 71 that is aligned with and overlies stop nose 32 at the end of projection 33 .
[0042] The exterior configuration of bore 18 in shroud leg 12 corresponds to that of the upper housing part 72 so that the housing and therewith the entire connector pin are non-rotatable relative to shroud leg 12 . This enables the tightening and loosening of the bolt into and out of the base. On the lower part of the housing corresponding flat surfaces are aligned with flat surfaces 74 on the upper part of the housing. These flat surfaces are formed by outer surfaces of the pivot pockets 34 and by outer surface portions of the lower housing half adjacent the pivot pockets.
[0043] To facilitate the assembly of the connector bolt head 78 includes a power-drive coupling, such as a screw driver slot 80 , a socket-head 82 or the like for electrically turning the bolt, as with an electric drill.
[0044] Prior to its installation, e.g. at the time of its manufacture, bolt 26 of the connector pin is tightened to secure the parts to each other. The connector pin is installed by manually compressing the arms locking arms inwardly so they fit into open bore 18 . The connector pin is next dropped or pushed into the bore where it can slide gravitationally downwardly, if needed assisted by manually pushing. Once the biasing force exerted by resilient member 38 has moved the upper ends of the locking arms 30 to beneath engagement ledges 86 overlying hole 16 in the lip, the laterally expanded locking arms lock and fix the connector pin in place on the lip and ready for use. To protect the inside of bore 18 from contaminants a cap 84 , preferably made of a resiliently deformable material such as rubber or plastic, is placed into the bore and over bolt head 78 in the bore after the installation is complete.
[0045] To replace a worn shroud, cap 84 is first removed and connector pin 20 is disassembled while in place inside hole 16 and bore 18 by backing up bolt 26 , preferable with an electric drive to save time and shatter any compacted solid material that may have accumulated in the bore during use. The unthreaded bolt and the housing halves 44 , 48 are then slidably removed from the bore and base 22 is slidably removed from the hole.
[0046] FIGS. 9-11 illustrate another embodiment of the invention for securing a shroud 10 to a lip 2 of a bucket. Legs 12 of the shroud engage upwardly and downwardly facing surfaces 4 , 6 of the lip as was previously described. In this embodiment the upper leg of the shroud has a round through bore 90 which communicates with an upwardly open depression 92 in upper surface 4 of the lip. The depression includes an upwardly open chamber 94 that extends laterally away from bore 90 in the leg. A connector pin 96 extends from bore 90 into the portion of depression 92 disposed directly beneath the bore. A connector pin locking device 98 is located in chamber 94 .
[0047] Similar to connector pin 20 shown and described earlier, connector pin 96 has a base 100 , a housing 102 partially surrounding the base, and a threaded bolt 104 which releasably secures the housing to the base.
[0048] Base 100 includes a cylindrical center section 106 with a threaded, upwardly open hole, and an enlarged diameter lower end 108 . Along a portion of one side, e.g. its aft side as seen in FIG. 10 , lower end 108 has a downwardly facing, upwardly diverging first contact surface 111 that intersects a horizontally oriented locking surface 114 formed in turn by a recess 107 on the exterior of the housing. A second, upwardly diverging contact surface 112 extends from the locking surface upwardly at an inclined angle as is illustrated in FIGS. 10 and 11 .
[0049] Housing 102 , like the housing of connector pin 20 described above, is longitudinally split into two housing halves. Its exterior is cylindrical and shaped so that it can be slidably inserted into and withdrawn from bore 90 in shroud leg 12 and depression 92 in lip 2 . Schematically illustrated dowel pins 128 extend across the opposing surfaces of the halves and align them in the vertical direction.
[0050] To assure proper rotational alignment of the locking surface 114 with locking device 98 , the housing and the base are rotationally fixed relative to each other, for example by providing a cooperating radially oriented groove and a groove-engaging projection interlock (not shown) between opposing, surfaces of the base and the housing.
[0051] To prevent rotation of housing 102 relative to lip bore 90 and fix the orientation of the connector pin 96 in the bore, the upper part of the housing includes a laterally projecting, vertically oriented projection 116 . The lower end 118 of the projection engages upper lip surface 4 which limits the downward movement of the connector pin. The position of projection 116 is selected so that when it engages its mating vertically oriented groove (not separately shown) in bore 90 , the recess 107 and contact surfaces 111 , 112 face towards aft chamber 94 .
[0052] Locking device 98 has a body 121 that snugly but slidably fits into recess chamber 94 . A forward side 120 of the body snugly but slidably faces the outside of connector pin 9 over an arc of less than 180 degrees and helps stabilize the fully inserted connector pin. A locking pawl 122 is slidably arranged in a forwardly open passage in body 121 and includes an engagement surface 124 which, in use, overlaps locking surface 114 on base 100 and thereby restrains the connector pin to lip 2 . An actuator 126 , such as a resilient foam pad, or magnetic, electric, hydraulic or pneumatic device, for example, resiliently urge pawl 122 in a forward direction toward the housing so that the underside 124 of the pawl contacts locking surface 114 .
[0053] Connector pin 96 is installed by first assembling its parts and tightening bolt 104 to secure all components of the connector pin to each other. Locking device 98 is placed into recess chamber 94 so that its pawl 122 extends into the portion of depression 92 which overlies bore 90 in leg 12 . Projection 116 of the connector pin is aligned with its associated groove and inserted into the bore. As the connector moves downwardly lower contact surface 111 of base 100 engages the upwardly inclined nose end 130 of the pawl and pushes the pawl out of the downward path of the connector pin so that it can be fully inserted into the depression.
[0054] After engagement surface 124 of the pawl has moved past locking surface 114 on base 100 , actuator 126 pushes the pawl into space 107 above locking surface. This locks the base and therewith the housing and entire connector pins to lip 2 . The connector pin remains fixed relative to the lip because the overlying shroud leg does not permit the locking device to move out of its chamber.
[0055] The connector pin is removed in essentially the same manner in which connector 20 is removed as earlier described, i.e. by first unthreading bolt 104 and then, following the removal of the shroud from the lip, manually withdrawing all parts of the connector and locking device from lip bore 90 an depression 92 .
[0056] Other variations are within the spirit and scope of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
[0057] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0058] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto 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 contradicted by context. | A method and apparatus for installing and removing shrouds from the lips of an earth moving bucket. The lips have forwardly converging upper and lower surfaces which are engaged by correspondingly rearwardly diverging legs of the shrouds that overly and are in contact with the lip surfaces. A hole is provided in the lip and an oblong hole in one of the legs that is aligned with the hole and has axially extending, spaced-apart flat walls which define engagement ledges that face and overlap the bore. A connector for securing the shroud to the lip is placed in the bore and the hole and has shaped exterior surfaces for positioning between the walls so that the connector is axially movable along the walls and past the engagement ledges while relative rotations between the connector and the hole in the leg are prevented. | 4 |
BACKGROUND OF THE INVENTION
It is generally recognized that bisphenols are important starting monomers for the synthesis of a variety of high performance thermoplastic polymers and resins. Bisphenol-A or 4,4'-isopropylidene diphenol of the formula, ##STR1## is generally synthesized from phenol and acetone using an acid catalyst. In addition to bisphenol-A of formula (1), 2,2-(2,4'-dihydroxydiphenol)propane or the "ortho" isomer of the formula ##STR2## is also formed as a comonomer with bisphenol-A when the acetone process is employed, as taught, for example by Schlichting et al, U.S. Pat. No. 3,359,281.
An alternative procedure for making isopropylidene bisphenols which substantially eliminates any possibility of side reactions, as shown by the above described acetone process, is by the acid condensation of phenol with either the corresponding para-hydroxy-α,α-methylbenzyl alcohol, as shown by the following equation, ##STR3## or by employing phenol with the corresponding isopropenyl phenol which is shown as follows: ##STR4##
Experience has shown that the corresponding ortho-isomer of formula 2 cannot be made directly using either of the above alternative procedures. A self condensation of the corresponding ortho-hydroxybenzyl alcohol, or ortho-isopropenyl phenol, proceeds at a faster rate than the intercondensation with phenol.
SUMMARY OF THE INVENTION
The present invention is based on the discovery that meta,para-isopropylidene bisphenol-A of the formula, ##STR5## can be successfully made by an acid catalyzed condensation of phenol with either meta-isopropenyl phenol or meta-hydroxy-α,α-dimethylbenzyl alcohol. In addition, meta,para-isopropylidene bisphenol-A of the formula, ##STR6## can be made by employing a substituted phenol in an acid catalyzed condensation with either meta-isopropenyl phenol, or metahydroxy-α,α-dimethylbenzyl alcohol as shown by the following equation, ##STR7## where R is a monovalent radical selected from C.sub.(1-8) alkyl radicals, C.sub.(1-4) alkoxy radicals, X is a halogen radical selected from chloro and bromo, a is a whole number having a value of from 0-3 inclusive and b is a whole number having a value of from 0-2 inclusive and the sum of a and b has a value of from 1-4 inclusive.
As shown in copending application Ser. No. 966,896, filed concurrently herewith and assigned to the same assignee as the present invention and now U.S. Pat. No. 4,237,259, the meta,para-isopropylidene bisphenol of formula (3) or analogs of formula (4) can be homopolymerized or copolymerized with other bisphenols or difunctional reactants to produce a variety of high performance thermoplastic organic polymers, such as polycarbonates, polyesters, polyester carbonates, polyformals, polyetherimides, polysulfones, epoxy resins and polycarbonate-polydiorganosiloxane block polymers.
DESCRIPTION OF THE INVENTION
There is provided by the present invention, a method for making a bisphenol of the formula, ##STR8## which comprises,
(A) effecting reaction between a phenol of the formula, ##STR9## and a meta-substituted phenol selected from the class consisting of ##STR10## in the presence of an acid catalyst and at a temperature of from 0° C. to 100° C., and
(B) recovering the bisphenol from the mixture of (1), where R and X are as previously defined, c is a whole number equal to 0 to 3 inclusive, d is a whole number equal to 0 to 2 inclusive and the sum of c and d is equal to 0 to 4 inclusive.
Bisphenols included by formulas (4) and (5) are, for example, ##STR11##
A method for making meta-isopropenyl phenol is shown by K. Auwers, Ann., 413, 253 (1917). Another procedure is shown by B. B. Corson et al, Preparation of Vinylphenol, Journal of Organic Chemistry, 23 544, (1958). Procedures for making meta-hydroxy-α,α-dimethylbenzyl alcohol is shown by Gilman et al Journal of Organic Chemistry, 19, p. 1057 (1954) based on the use of a methyl Grignard reagent with methyl m-hydroxy benzoate.
DETAILED DESCRIPTION OF THE INVENTION
In the practice of the invention, the condensation is effected between "phenol", which hereinafter includes phenol and substituted phenols as previously described, and the "meta-substituted phenol", which hereinafter includes meta-isopropenyl phenol, and meta-dimethylcarbinol hydroxy benzene or meta-hydroxy-α,α-dimethylbenzyl alcohol. Reaction can be effected at ambient temperatures in the presence of suitable organic solvent, or it can be effected in the absence of an organic solvent at temperatures above the melting point of phenol, such as 50° C. to 100° C., which can serve as both a reactant and solvent for the aforementioned meta-isopropenyl phenol or meta-dimethylcarbinol hydroxy benzene. In addition, the reaction can be conducted in the presence of an acid catalyst.
A more ratio of 1.0 to 10 moles of phenol, per mole of meta-substituted phenol can be used and preferably 1 to 3 moles of phenol, per mole of meta-substituted phenol.
Suitable organic solvents which can be employed under ambient conditions are, for example, toluene, chlorobenzene, etc. Suitable acid catalysts which can be used as sulfuric acid, hydrochloric acid, hydrogen chloride gas which can be employed under pressure, boron trifluoride, hydrogen fluoride, trifluoroacetic acid, acidified clays, acid ion exchange resin beds for the passage of phenol and meta-substituted phenol. Agitation of the reactants to facilitate reaction can be accomplished with standard means such as stirrer, etc. Reaction can be achieved over a period of from 1 to 30 minutes, depending upon the nature of the reactants, and such factors as the degree of agitation, whether a solvent is used, temperature, etc.
The meta,para-isopropylidene bisphenol can be recovered as a crude product from the reaction mixture or it can be recrystallized in accordance with a standard technique from solvents such as water, hydrocarbons, alcohols, water alcohol mixtures, etc.
In order that those skilled in the art will be better able to to practice the present invention, the following examples are given by way of illustration and not by way of limitation. All parts are by weight.
EXAMPLE 1
A mixture of 5 parts of phenol and 1 part of meta-isopropenyl phenol in 21 parts of toluene was added dropwise to about 5 parts of 75% aqueous sulfuric acid solution. When the addition was completed, the reaction mixture was stirred an additional 5 minutes and diluted with 35 parts of diethylether to produce a two phase mixture. The organic layer was separated and washed with 25 parts of a saturated aqueous sodium bicarbonate solution, dried over magnesium sulfate and concentrated under reduced pressure to produce a brown oil. The oil was recrystallized from chloroform. There was obtained about an 80% yield of a white powder having a melting point of 97°-98° C. Based on method of preparation and its NMR spectrum, the product was meta,para-isopropylidene bisphenol having the formula, ##STR12##
The above bisphenol is blended with a polyvinyl chloride resin along with sufficient dioctylphthalate and a dry base lead stabilizer EXL of the National Lead Company, on a roll mill to produce a plasticized blend having 1/2% by weight of the bisphenol and about 3% by weight of lead stabilizer. Several 41/2 inch by 41/2 inch by 75 mil test slabs are prepared. Additional test slabs free of the bisphenol are prepared by the same procedure. The test slabs are then placed in a circulating air oven at 121° C. for a period of 4 weeks. It is found that the test slabs free of the bisphenol have darkened considerably and have generally changed in physical characteristics based on a failure to resist the effect of heat-aging. This shows that the bisphenol exhibits valuable stabilizing characteristics for polyvinyl chloride resins.
It is further found that the meta,para-bisphenol-A is a white crystalline solid and is soluble in several solvents such as methylene chloride, chloroform and toluene in which the corresponding para,para-bisphenol-A of formula (1) is only slightly soluble. As a result of this improved showing of solubility, it is found that the meta,para-bisphenol-A is capable of being converted to a polycarbonate in a highly efficient manner as compared to the para,para-bisphenol-A as shown by the following:
A mixture of 2 parts of meta,para-bisphenol-A, 13.5 parts of methylene chloride, 7 parts of water, about 0.04 part of triethylamine and 0.016 part of phenol is phosgenated over a 20 minute period. There is added to the mixture during the phosgenation 1.9 part of phosgene and enough 20% by weight of aqueous sodium hydroxide solution to maintain the mixture at a pH at 10-12. After the phosgenation the mixture is flushed with nitrogen and washed with about 25 parts of 10% hydrochloric acid. The polycarbonate is precipitated in a blender with about 80 parts of methanol and collected by suction filtration and dried under vacuum at 65° C. for 18 hours. There is obtained a polycarbonate having an average molecular weight of about 70,000, a number average molecular weight of about 17,000 and a glass transition temperature of 112° C.
EXAMPLE 2
A mixture of 5 parts of phenol, 1.14 part of meta-hydroxy-α,α-dimethylbenzyl alcohol in 20 parts of toluene was added dropwise to about 5 parts of 75% aqueous sulfuric acid. When the addition was completed, the reaction mixture was then stirred an additional 5 minutes, diluted with 35 parts of diethyl ether and the layers separated. The organic layer was washed with about 25 parts of a saturated aqueous sodium bicarbonate solution, dried over magnesium sulfate, and concentrated under reduced pressure to provide a brown oil. The oil was crystallized from chloroform. There was obtained an 81% yield of white powder having a melting point of 97°-98° C. Based on method of preparation the product was meta,para-bisphenol-A. Its identity was further identified by its IR spectrum.
EXAMPLE 3
There was added a solution of 0.1 part of meta-hydroxy-α,α-dimethylbenzyl alcohol, 0.5 part of 2,6-xylenol and about 4 parts of toluene to about 5 parts of a 75% aqueous solution of sulfuric acid. The addition was completed dropwise and the mixture was stirred constantly during the addition. After the addition was completed, separation of the organic phase and the aqueous phase was allowed to occur. The aqueous phase was extracted with about 35 parts of diethylether. The organic layers were then combined and dried with anhydrous magnesium sulfate. The resulting dried mixture was then concentrated by stripping the mixture of solvent under reduced pressure. The resulting material was then eluted in the form of a methylene chloride solution using silica gel chromatography resulting in a 79% yield of product having a melting point of 126°-127° C. Based on method of preparation and its infrared spectrum, the product was a bisphenol of the formula, ##STR13##
The above compound is roll milled with polyvinyl chloride resin and a lead stabilizer in accordance with the procedure of Example 1 to produce test slabs. It is found that the above bisphenol imparts improved stability to polyvinyl chloride resin. In addition, the above bisphenol is used to make high molecular weight polycarbonate by phosgenating a methylene chloride solution in the presence of triethylamine as described in Example 1.
EXAMPLE 4
A solution of 0.1 part meta-hydroxy-α,α-dimethylbenzyl alcohol and 0.5 part of 2,6-dimethoxyphenol in about 4 parts of toluene is added dropwise with stirring to about 5 parts of a 75% aqueous sulfuric acid solution. After the addition was completed, the layers were allowed to separate and the aqueous layer was extracted with about 35 parts of diethylether. The combined organic layers were then dried with magnesium sulfate and dried under reduced pressure. After the crude product was crystallized from hexane there was obtained a tan solid having a melting point of 138°-140° C. having the formula, ##STR14##
The above bisphenol is roll milled with polyvinyl chloride, plasticizer and lead stabilizer in accordance with the procedure of Example 1 to produce test slabs. After heat-aging in accordance with the procedure of Example 1, it is found that the bisphenol is a valuable stabilizer for polyvinyl chloride resins. The bisphenol is also used to make a polycarbonate polymer following the procedure of Example 1.
Although the above examples are directed to only a few of the very many variables within the scope of the present invention, it should be understood that the present invention is directed to a much broader class of meta,para-isopropylidene bisphenols as shown by the description preceding these examples. | Meta,para-substituted isopropylidene bisphenols are provided and methods for making such materials. Phenol, or substituted phenol is condensed with a meta-substituted isopropenyl phenol or a meta-hydroxy-α,α-dimethylbenzyl alcohol in the presence of an acid catalyst. The resulting meta,para-substituted isopropylidene bisphenols can be used as stabilizers for polyvinyl chloride resins and as intermediates for making high performance thermoplastics having chemically combined meta,para-isopropylidene diphenoxy units. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority from U.S. provisional patent application No. 60/692,112, which was filed on Jun. 20, 2005, and which is incorporated herein by reference in its entirety. This application is a continuation-in-part application of, and claims priority to, U.S. application Ser. No. 11/471,276, filed Jun. 20, 2006, and now allowed, and which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the use of radiofrequency energy to heat heavy crude oil or both heavy crude oil and subsurface water in situ, thereby enhancing the recovery and handling of such oil. The present invention further relates to methods for applying radiofrequency energy to heavy oils in the reservoir to promote in situ upgrading to facilitate recovery. This invention also relates to systems to apply radiofrequency energy to heavy oils in situ.
BACKGROUND OF THE INVENTION
[0003] Heavy crude oil presents problems in oil recovery and production. Crude oils of low API gravity and crude oils having a high pour point present production problems both in and out of the reservoir. Extracting and refining such oils is difficult and expensive. In particular, it is difficult to pump heavy crude oil or move it via pipelines.
[0004] Recovery of heavy crude oils may be enhanced by heating the oil in situ to reduce its viscosity and assist in its movement. The most commonly used process today for enhanced oil recovery is steam injection, where the steam condensation increases the oil temperature and reduces its viscosity. Steam in the temperature range of 150 to 300 degrees Fahrenheit may decrease the heavy oil viscosity by several orders of magnitude. Cyclic steam simulation (CCS) is a method that consists of injecting steam into a well for a period of time and then returning the well to production. A recently developed commercial process for heavy oil recovery is steam assisted gravity drainage (SAGD), which finds its use in high permeability reservoirs such as those encountered in the oil sands of Western Canada. SAGD has resulted recovery of up to 65% of the original oil in places, but requires water processing. All such methods tend to be expensive and require the use of external water sources.
[0005] Other methods in current use do not require the use of water or steam. For example, processes such as the Vapex process, which uses propane gas, and naphtha assisted gravity drainage (NAGD) use solvents to assist in the recovery of heavy crude oils. The drawback to these processes is that the solvents—propane or naphtha—are high value products and must be fully recovered at the end of the process for it to be economical.
[0006] Yet another potential method to enhance the recovery of heavy crude oils is the Toe-To-Heel Injection (THAI) process proposed by the University of Bath. THAI involves both vertical wells and a pair of horizontal wells similar to that used in the SAGD configuration, and uses combustion as the thermal source. Thermal cracking of heavy oil in the porous media is realized, and the high temperature in the mobile oil zone provides efficient thermal sweeping of the lighter oil to the production well.
[0007] Even when they are recovered, heavy crude oils present problems in refinement. Heavy and light crude oil processing will give the same range of refined products but in very different proportions and quantities. Heavy oils give much more vacuum residues than lighter oils. These residues have an API between one and five and very high sulfur and metals content, which makes treatment difficult. Several processes exist to convert vacuum residues. They are thermal, catalytic, chemical, or combinations of these methods. Thermal processes include visbreaking, aquathermolysis and coking.
[0008] Solvent deasphalting (SDA) is a proven process which separates vacuum residues into low metal/carbon deasphalted oil and a heavy pitch containing most of the contaminants, especially metals. Various types of hydrotreating processes have been developed as well. The principle is to lower the carbon to hydrogen ratio by adding hydrogen, catalysis such as tetralin. The goal is to desulfurize and remove nitrogen and heavy metals. These processes may require temperature control, pressure control, and some form of reactor technology such as fixed bed, ebullated bed, or slurry reactor.
[0009] Recent concepts associate different processes to optimize the heavy crude conversion. For example, the combination of hydrotreating and solvent deasphalting in refineries or on site for partial upgrading of heavy crude may be used.
[0010] Finally, the process of gasification for upgrading heavy oil is used. It consists of conversion by partial oxidation of feed, liquid, or solid into synthesis gas in which the major components are hydrogen and carbon monoxide.
[0011] There is a need for an apparatus and method to enhance the recovery of heavy crude oils that does not suffer from the drawbacks associated with current methods. In particular, there is a need for a method that does not use steam or water from external sources, solvents that must be recovered, or combustion. Ideally, such an apparatus and method would at the same time assist in the in situ refinement of the heavy oil.
[0012] The present invention provides just such a method and apparatus. It utilizes radiofrequency energy to combine enhanced oil recovery with physical upgrading of the heavy oil.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention provides a system and method to apply radiofrequency energy to in-situ heavy crude oil to heat the oil and other materials in its vicinity. This system and method enhance the recovery of the heavy crude oil. At the same time, it may be used to upgrade the heavy crude oil in situ.
[0014] This system enhances the recovery of oil through a thermal method. Heavy crude oils have high viscosities and pour points, making them difficult to recover and transport. Heating the oil, however, lowers the viscosity, pour point, and specific gravity of the oil, rendering it easier to recover and handle. Thus, in the present invention, directed radiofrequency radiation and absorption are used to heat heavy oil and reduce its viscosity, thus enhancing recovery. This dielectric heating also tends to generate fissures and controlled fracture zones in the formation for enhanced permeability and improved flow recovery of fluids and gases.
[0015] The system of the present invention is an in-situ radiofrequency reactor (RFR) to apply radiofrequency energy to heavy crude oil in situ. The RFR incorporates an in-situ configuration of horizontal and vertical wells in a heavy crude oil field. Using these wells, the RFR creates a subterranean reactor for the optimum production and surface recovery of the heavy crude oil. The RFR will provide an oil/hydrocarbon vapor front that will optimize recovery of the oil.
[0016] In it simplest form, the RFR may consist of two wells in the oil field, one a radiofrequency well and the second an oil/gas producing well. At least a portion of both wells are horizontal in the oil field, and the horizontal portion of the radiofrequency well is above the horizontal portion of the oil/gas producing well. A radiofrequency transmission line and antenna are placed in the horizontal radiofrequency well and used to apply radiofrequency energy to the oil, thereby heating it. The resulting reduction in the viscosity of the oil and mild cracking of the oil causes the oil to drain due to gravity. It is then recovered through the horizontal oil/gas producing well. Naturally, any number of radiofrequency and oil/gas producing wells can be used to create an RFR for the recovery of heavy crude oils.
[0017] The invention also has the capability of further enhancing recovery through the directed upgrading of the heavy oil in situ. The horizontal radiofrequency well may be strongly electromagnetically coupled to the horizontal oil/gas producing well so that the temperature of the horizontal oil/gas producing well may be precisely controlled, thereby allowing for upgrading of the heavy oil in the producing well over a wide range of temperatures. The oil/gas producing well may be embedded in a fixed bed of material, such as a catalyst bed, selected to provide upgrading of the crude oil draining from above. The upgrading can be based on several different known technologies, such as visbreaking, coking, aquathermolysis, or catalytic bed reactor technology.
[0018] The present invention has several promising advantages over present methods used to enhance recovery of heavy oil. In particular, the RFR does not require the use of water from external sources. This reduces expense and makes the recovery more economical and efficient. Furthermore, the present invention does not require the use of expensive solvents. Through the use of the present invention, enhanced recovery of heavy crude oil can be achieved more efficiently and cost-effectively.
[0019] Furthermore, in situ processing of crude oil has several advantages over conventional oil surface upgrading technology. First, in situ upgrading can be applied on a well to well basis, so that large volumes of production needed for surface processes are not required. Large, costly pressure vessels are not required since the reservoir formation serves as a reactor vessel. It can be applied in remote locations where a surface refinery would be inappropriate. Some of the required gases and possibly water can be generated in situ by the radiofrequency energy absorption. Finally, full range whole crude oils are treated by RFR and not specific boiling range fractions as is commonly done in refineries. This is made possible by the ability of radiofrequency absorption to provide precise temperature control throughout the reactor volume. The proposed reactor provides large quantities of heat through radiofrequency absorption close to the production well where the catalyst bed is placed. No heat carrying fluids are necessary with radiofrequency heating.
[0020] In one embodiment of the invention, an in situ radiofrequency reactor for use in thermally recovering oil and related materials may be provided. The reactor may comprise at least one radiofrequency heating well in an area in which crude oil exists in the ground, a radiofrequency antenna positioned within each radiofrequency heating well in the vicinity of the crude oil, a cable attached to each radiofrequency antenna to supply radiofrequency energy to such radiofrequency antenna, a radiofrequency generator attached to the cables to generate radiofrequency energy to be supplied to each radiofrequency antenna, and at least one production well in proximity to and below the radiofrequency wells for the collection and recovery of crude oil.
[0021] In another embodiment of the invention, an in situ radiofrequency reactor for use in thermally recovering oil and related materials and refining heavy crude oil in situ may be provided. The reactor may comprise at least one radiofrequency heating well in an area in which crude oil exists in the ground, a radiofrequency antenna positioned within each radiofrequency heating well in the vicinity of the crude oil, a cable attached to each radiofrequency antenna to supply radiofrequency energy to such radiofrequency antenna, a radiofrequency generator attached to the cables to generate radiofrequency energy to be supplied to each radiofrequency antenna, at least one production well in proximity to and below the radiofrequency wells and coupled magnetically to the radiofrequency wells for the collection and recovery of crude oil, and at least one catalytic bed in which the production well is embedded.
[0022] In yet another embodiment of the invention, a method for recovering heavy crude oil is provided. The method comprises the steps of positioning a radiofrequency antenna in a well in the vicinity of heavy crude oil, generating radiofrequency energy, applying the radiofrequency energy to the heavy crude oil with the radiofrequency antenna to heat the oil, and recovering the heavy crude oil through production well.
[0023] In one aspect, in general, a radiofrequency reactor for use in thermally recovering oil and related materials. The radiofrequency reactor includes a radiofrequency antenna configured to be positioned within a well, where the well is provided within an area in which crude oil exists in the ground. The radiofrequency antenna includes a cylindrically-shaped radiating element for radiating radiofrequency energy into the area in which crude oil exists. The cylindrically-shaped radiating element is configured to allow passage of fluids there through. The radiofrequency reactor also includes a radiofrequency generator electrically coupled to the radiofrequency antenna. The radiofrequency reactor is operable to control the radiofrequency energy generated.
[0024] Aspects may include one or more of the following.
[0025] The cylindrically-shaped radiating element in the radiofrequency reactor includes a plurality of apertures for allowing passage of the fluids. In some examples, the plurality of apertures have dimensions selected on the basis of the frequency of the radiofrequency energy.
[0026] The radiofrequency reactor includes a coaxial cable for coupling the radiofrequency antenna to the radiofrequency generator.
[0027] The radiofrequency reactor includes a choke assembly positioned between the radiofrequency antenna and radiofrequency generator to maximize transmission of the radiofrequency energy to the radiofrequency antenna. In some examples, the choke assembly includes an inner conductive casing surrounded by a dielectric portion, the assembly running at least one-quarter of a maximal frequency to be emitted, and the inner casing is connected to a cable for coupling the radiofrequency antenna to the radiofrequency generator.
[0028] The radiofrequency reactor may be one of a plurality of reactors. In such a situation, the radiofrequency generator of each reactor is operable to control the radiofrequency energy generated and is configured to work in conjunction with the radiofrequency generators of the plurality of reactors.
[0029] The radiofrequency generator operable to control the radiofrequency energy generated is configured to control the phase of the radiofrequency energy emitted.
[0030] In another aspect, in general, a method of retrofitting an oil well for extracting crude oil. The method includes electrically coupling a radiofrequency generator to a radiofrequency antenna, where the radiofrequency antenna includes a cylindrically-shaped radiating element for radiating radiofrequency energy into the crude oil. The method also includes controlling the radiofrequency generator to provide radiofrequency energy to the radiofrequency antenna.
[0031] Aspects may include one or more of the following.
[0032] Positioning the radiofrequency generator proximally to the well surface and electrically coupling the radiofrequency generator to the cylindrically-shaped radiating element via a coaxial cable.
[0033] Connecting a choke assembly between the radiofrequency generator and the cylindrically-shaped radiating element.
[0034] Controlling the radiofrequency generator to provide radiofrequency energy to the radiofrequency antenna, including controlling the phasing of the radiofrequency energy emitted.
[0035] While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a perspective view of a basic in situ radiofrequency reactor.
[0037] FIG. 2 is a perspective view of an alternative arrangement of an in situ radiofrequency reactor.
[0038] FIG. 3 is a top view of an arrangement for an in situ radiofrequency reactor for use in large oil fields.
[0039] FIG. 4 is a perspective view of a single borehole radiation type applicator that may be used in the radiofrequency reactor of the present invention.
[0040] FIG. 5 is a diagram of a prior art steam assisted gravity drainage (SAGD) system.
[0041] FIG. 6 is a diagram of a well retrofitted as an in situ radiofrequency reactor.
[0042] FIG. 7 is a diagram of a slotted liner protruding from a well shaft.
DETAILED DESCRIPTION
[0043] A variety of different arrangements of wells and antennae may be employed to apply radiofrequency energy to heavy crude oil in situ, thereby enhancing oil recovery and achieving in situ upgrading of the oil. The proper structure and arrangement for any particular application depends on a variety of factors, including size of field, depth, uniformity, and nature and amount of water and gases in the field.
[0044] FIG. 1 is a perspective view of a basic in situ radiofrequency reactor. Heavy oil is present in oil field 10 . Oil/gas production well 20 is drilled into the oil field for recovery of heavy oil and other materials. At least a portion of oil/gas production well 20 is drilled horizontally through the oil field. Horizontal oil/gas production well 21 is positioned to receive oil and other gas that are moved or generated by the action of the radiofrequency reactor. A second well, radiofrequency well 30 , is drilled into the oil field in proximity to oil/gas production well 20 . At least a portion of radiofrequency well 30 is drilled horizontally through the oil field in proximity to and above horizontal oil/gas production well 21 . Horizontal radiofrequency well 31 is used to apply radiofrequency energy to the surrounding heavy crude oil field, thereby heating the oil and reducing its viscosity. Due to gravity, the reduced heated heavy crude oil drains, where it may be captured by and pumped out through oil/gas production well 20 to storage or processing equipment.
[0045] Radiofrequency energy is generated by a radiofrequency generator. It is transmitted via radiofrequency transmission line 40 through radiofrequency well 30 and horizontal radiofrequency well 31 to radiofrequency antenna 41 . Radiofrequency antenna 41 applies radiofrequency energy to the surrounding heavy crude oil, thereby heating it and reducing its viscosity so that it may be collected by and recovered through oil/gas production well 20 . The oil/gas production well 20 may also act as a parasitic antenna to redirect radiation in an upward direction toward the formation to be heated by the radiofrequency energy, thereby increasing efficiency.
[0046] For purposes of in situ processing and upgrading of the heavy crude oil, horizontal oil/gas production well 21 may be embedded in catalytic bed 50 . Horizontal radiofrequency well 31 may be strongly electromagnetically coupled to horizontal oil/gas producing well 21 so that the temperature of horizontal oil/gas producing well 21 may be precisely controlled, thereby allowing for upgrading of the heavy oil in horizontal oil/gas production well 21 over a wide range of temperatures. The upgrading can be based on several different known technologies, such as visbreaking, coking, aquathermolysis, or catalytic bed reactor technology.
[0047] Radiofrequency antennae may be placed in an oil field in numerous configurations to maximize oil recovery and efficiency. FIG. 2 shows a perspective view of an alternative arrangement of an in situ radiofrequency reactor. Radiofrequency antennae 41 may be placed in proximity to one another in oil field 10 . Radiofrequency energy is supplied to the antennae 41 by a radiofrequency generator and then applied to the oil field 10 . The resulting heating reduces the viscosity of the oil, which drains due to gravity. Horizontal oil/gas production well 21 is positioned below the antennae 41 to collect and recover the heated oil.
[0048] As with the RFR in FIG. 1 , this arrangement may also be used to process the heavy oil in situ. A horizontal radiofrequency well 31 with horizontal radiofrequency antenna 42 may be placed in proximity to horizontal oil/gas producing well 21 below antennae 41 to control the temperature of the oil. Horizontal oil/gas production well 21 may be embedded in catalytic bed reactor 50 . The oil may thereby be upgraded in situ.
[0049] FIG. 3 shows a top view of another arrangement for an in situ radiofrequency reactor for use in large oil fields. In this radial configuration, one central and vertical radiofrequency heating well 32 with radiofrequency antenna 41 is used for larger volumes of oil. Radiofrequency antenna 41 applies radiofrequency energy to area 11 , thereby heating the oil in that area. The heated oil drains to horizontal oil/gas production wells 21 for collection and recovery. Parallel horizontal radiofrequency wells 31 may also be used to heat the oil. In addition, radiofrequency antennae 43 may be placed in vertical radiofrequency wells 33 to assist with in situ upgrading of the heavy crude oil.
[0050] The radiofrequency antennae used in the RFR system of the present invention may be any of those known in the art. FIG. 4 shows a perspective view of a radiofrequency applicator that may be used with the RFR of the invention. Applicator system 45 is positioned within radiofrequency well 30 . Applicator system 45 is then used to apply electromagnetic energy to heavy crude oil in the vicinity of radiofrequency well 30 .
[0051] Applicator structure 46 is a transmission line retort. Radiofrequency energy is supplied to applicator 46 by an RF generator (not shown). The radiofrequency generator is connected to applicator 46 via radiofrequency transmission line 40 . The radiofrequency transmission line 40 may or may not be supported by ceramic beads, which are desirable at higher temperatures. By this means, the radiofrequency generator supplies radiofrequency energy to applicator 46 , which in turn applies radiofrequency energy to the target volume of oil.
[0052] Although one specific examples of an applicator structure is given, it is understood that other arrangements known in the art could be used as well. Uniform heating may be achieved using antenna array techniques, such as those disclosed in U.S. Pat. No. 5,065,819.
[0053] The present invention also has application in oil shale fields, such as those present in the Western United States. Large oil molecules that exist in such oil shale have been heated in a series of experiments to evaluate the dielectric frequency response with temperature. The response at low temperatures is always dictated by the connate water until this water is removed as a vapor. Following the water vapor state, the minerals control the degree of energy absorption until temperatures of about 300-350 degrees centigrade are reached. In this temperature range, the radiofrequency energy begins to be preferentially absorbed by the heavy oil. The onset of this selective absorption is rapid and requires power control to insure that excessive temperatures with attendant coking do not occur.
[0054] Because of the high temperature selective energy absorption capability of heavy oil, it is therefore possible to very carefully control the bulk temperature of crude oil heated by radiofrequency energy. The energy requirement is minimized once the connate water is removed by steaming. It takes much less energy to reach mild cracking temperatures with radiofrequency energy than any other thermal means.
[0055] Kasevich has published a molecular theory that relates to the specific heating of heavy of oil molecules. He found that by comparing cable insulating oils with kerogen (oil) from oil shale, a statistical distribution of relaxation times in the kerogen dielectric gave the best theoretical description of how radiofrequency energy is absorbed in oil through dielectric properties. With higher temperatures and lowering of potential energy barriers within the molecular complex a rapid rise in selective energy absorption occurs.
[0056] In use, a user of an embodiment of the present invention would drill oil/gas production wells and radiofrequency wells into a heavy crude oil field. At least a portion of the wells would be horizontal. The radiofrequency wells would be placed in proximity to and above the oil/gas production wells. The user would install a radiofrequency antenna in each radiofrequency well and supply such antennae with radiofrequency energy from a radiofrequency generator via a radiofrequency transmission cable. The user would then apply radiofrequency energy using the radiofrequency generator to the antenna, thereby applying the radiofrequency energy to the heavy crude oil in situ. The radiofrequency energy would be controlled to minimize coking and achieve the desired cracking and upgrading of the heavy crude oil. The resulting products would then be recovered via the oil/gas production well and transferred to a storage or processing facility.
[0057] Referring again to FIG. 4 , the applicator structure 46 is a vertical monopole antenna within a non-metallic production pipe (shown as a radiofrequency well 30 ). The production pipe extension below the applicator or antenna may be used to enhance the radiation efficiency by adjusting the length of the pipe. The pipe may extend into or below the subterranean oil or gas.
[0058] As described in the above background section, steam assisted gravity drainage (SAGD), is an existing commercial process for heavy oil recovery, used especially in high permeability reservoirs such as those encountered in the oil sands of Western Canada. Referring to FIG. 5 , in the SAGD process, two parallel horizontal oil wells 520 & 550 are drilled in the formation, one above the other (in some examples, roughly 10 meters apart). The upper well acts as a steam injector 520 and typically includes a slotted liner 522 (in some examples, roughly 300 meters long) for allowing steam to be released through the slots 530 . The steam increases the temperature of the crude oil in the oil sand formation 512 , reducing the crude oil's viscosity and allowing it to be collected by gravity drainage via the lower well, referred to as an oil producer 550 . The slotted liner 522 is typically made of conductive materials.
[0059] Referring to FIG. 6 , in some embodiments, the SAGD configuration is retrofitted to use one or both wells (or portions thereof, e.g., the liners) as an antenna for emitting RF energy into the oil sand formation. The RF energy increases the temperature of the crude oil, reducing its viscosity and allowing it to be collected. In some embodiments the oil is collected using a pipe (not shown) within the same well as the well 600 configured to host an antenna.
[0060] A coaxial cable 630 connects a power source (not shown), for example, a radiofrequency generator stationed on the surface, to the slotted liner 622 . The coaxial cable 630 has a central conductor 632 surrounded by a dielectric insulating portion and an outer conductive shield 634 . In some embodiments, the outer conductor 634 is also wrapped in an external insulating layer.
[0061] At the distal end of the well, the coaxial cable's central conductor 632 is electrically connected to the well's slotted liner 622 . In some embodiments, the connection to the liner 622 is achieved using a metal contact ring 660 to which the central conductor 632 is electrically connected 664 (e.g., welded). The contact ring 660 is mated with the liner 622 .
[0062] In some embodiments, an insulating section 650 is used, for example, to separate the slotted liner 622 from the well wall 620 . The insulating section 650 is a hollow cylinder that allows the coaxial cable 630 and any other cables or pipes (e.g., an oil collection pipe) to pass through it. In some examples, the insulating section 650 is ceramic.
[0063] As shown if FIG. 6 , the well 600 is supported in the earth 616 by a cement casing 614 . The cement 614 is susceptible to cracking if subjected to excessive heat. In such embodiments, it may be desirable to restrict the level of RF energy returning up the well 600 , for example, to reduce the risk of the cement 614 cracking. Therefore, a high impedance block is created.
[0064] In the embodiment shown in FIG. 6 , the outer conductor 634 of the coaxial cable 630 is electrically connected 648 to a quarter-wave choke assembly 640 . The optimal length of the choke assembly is an odd multiple of quarter-wavelengths (¼, ¾, 5/4, etc.). That is, the choke assembly 640 extends back from the insulator 650 at least one quarter of the maximum wavelength for the energy to be emitted from the antenna. The choke assembly 640 may extend further back, in some examples, extending all of the way back to the surface.
[0065] The quarter-wave choke assembly 640 includes an inner conductor 642 , which is separated from either the well wall 620 or an outer assembly casing 644 by either air or a dielectric layer 646 . The outer conductor 634 of the coaxial cable 630 is electrically connected 648 to the inner conductor 642 of the choke assembly 640 . The inner conductor 642 is shorted 654 to the inner side of the well wall 620 at the proximal end of the choke assembly 640 .
[0066] The quarter-wave choke assembly 640 creates a high impedance block restricting the flow of energy back up the well 600 . Alternatively, in some embodiments, the outer conductor 634 is electrically connected directly to the inside of the well wall 620 .
[0067] Referring again to FIG. 5 , in certain embodiments, multiple wells (e.g., both the steam injector 520 and the oil producer 550 ) are retrofitted as RF antennas. In such embodiments, the multiple antennas are powered in a manner to boost the RF energy, for example, by emitting energy in phase. In other embodiments, the phase of the energy emitted by each of the multiple antennas can be tuned to control the energy levels within the oil sand formation by controlling the antennas to emit out of phase.
[0068] In certain applications, the slots in the slotted liner are sized in a manner to increase the efficacy of subsequent RF retrofit. Referring to FIG. 7 , in some embodiments, a well 700 is configured with two slotted liners—an inner liner 710 and an outer liner 720 . Each liner includes slots 730 . At least one liner, e.g., the inner liner 710 , is configured to be adjusted, acting as a telescoping sleeve. By telescoping the liner, the size of the slots 730 are adjusted. The liner overlap 740 therefore creates variably sized slots. Using this approach, the slots in the slotted liner are dynamically sized as needed.
[0069] In some embodiments, the presence of the RF retrofit does not preclude the contemporary use of steam or other oil recovery methods. For example, the RF energy is used to initiate the process of oil recovery by alternative means.
[0070] Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | The present invention relates generally to a radiofrequency reactor for use in thermally recovering oil and related materials. The radiofrequency reactor includes a radiofrequency antenna configured to be positioned within a well, where the well is provided within an area in which crude oil exists in the ground. The radiofrequency antenna includes a cylindrically-shaped radiating element for radiating radiofrequency energy into the area in which crude oil exists. The cylindrically-shaped radiating element is configured to allow passage of fluids there through. The radiofrequency reactor also includes a radiofrequency generator electrically coupled to the radiofrequency antenna. The radiofrequency reactor is operable to control the radiofrequency energy generated. | 4 |
This application is a division of Ser. No. 09/262,962, filed May 4, 1999, now U.S. Pat. No. 6,236,633.
BACKGROUND OF THE INVENTION
The present invention relates to a bifocal optical pickup head, and more particularly to an optical pickup apparatus used with a single objective lens for accessing a compact disc (CD) and a digital versatile disc (DVD), which are different in thickness
A technique of accessing data recorded on a surface of an optical disc such as CD or DVD by an optical pickup head has been known. In reading, a laser beam is focused on a data storage surface of the optical disc and the beam reflected from the optical disc is converted to an electric signal by a photo detector. In writing, the above procedures are inverted. The specifications of CD and DVD are shown in Table 1.
TABLE 1
Thickness
Track pitch
Wavelength
NA (numerical
(mm)
(μm)
(nm)
aperture)
CD
1.2
1.6
780
0.45
DVD
0.6 *2
0.74
635-650
0.6
As know from Table 1, in comparison with CD, DVD has a higher storage density. The differences in dimension (especially the storage density difference) result in various reading requirements for an optical pickup apparatus. To access data on a data storage surface of a CD or a DVD, an optical pickup head is a key component in the optical pickup apparatus, and optics is most critical in the optical pickup head.
Therefore, to access both CD and DVD by an optical pickup apparatus having a single objective lens, it is necessary to design an optics in which beam spot size is changed on the basis of two different numerical apertures.
To meet compatible requirement for CD and DVD, it is necessary to access both CD and DVD with a single optical pickup head, and how to obtain a bifocal optics is a critical technique.
Conventional techniques of accessing both CD and DVD with a bifocal optical pickup head are listed as follows:
1. Two objective lenses having different focal lengths corresponding to CD and DVD respectively are used, and a driving mechanism is utilized to select one of the objective lenses. Such a design has disadvantages of increased weight of an optical pickup head and increased manufacturing cost.
2. A diffraction element is used to achieve bifocal effect.
3. A holographic optical element is used for bifocus. However, it suffers from manufacturing difficulty and high manufacturing cost.
4. A NA controller is constructed by a liquid crystal display (LCD) shutter such that an objective lens has two NA values, thereby achieving bifocus. However, the orientation of the polarization of a laser source needs to be accurately aligned, and the LCD should be continuously powered.
5. An annular objective lens is used in which beams passing through center of the lens are for CD while beams passing though inner and outer rings thereof are for DVD. A similar technique is disclosed in U.S. Pat. No. 5,665,957 in which a hologram lens having a pattern thereon is used for bifocus. However, its manufacturing cost is high and mounting tolerance is low.
6. Two light sources and two lens are used. For example, according to U.S. Pat. No. 5,777,970, two laser sources of different wavelengths correspond to respective lenses to provide respective focal lengths and spots of respective diameters. It has disadvantages of high manufacturing cost and complicated structure.
7. A zooming aperture is utilized in association with a movable objective lens, as shown in U.S. Pat. No. 5,659,533 and U.S. Pat. No. 5,281,797.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a bifocal optical pickup head having advantages of simple structure, low cost, easy assembly and high tolerance.
According to a bifocal optical pickup head of the present invention, to access both CD and DVD, an optical element is used in association with a conventional optical pickup head comprising a laser diode, a beam splitter (or holographic optical element (HOE)), a collimator lens, an objective lens and a photo detector, without adding any other optical elements such as zooming aperture, movable objective lens or dual objective lenses.
Another object of the present invention is to provide an optical element adapted to a conventional optical pickup head, holographic optical pickup head or two-source optical pickup head. The optical element splits a single laser beam into two laser beams of different optical paths, which are collimated by a collimator lens and then focused by an objective lens to achieve two focuses.
According to the present invention, an optical element disposed in a light path is disclosed. When a beam passes through the optical element, numerical aperture is controlled and spherical aberration is reduced by the optical element due to variations in optical path and radius. Therefore, after beams having different numerical apertures are focused by an objective lens, various focuses can be obtained.
When a monochrome beam undergoes two different optical paths, two focuses can be obtained. According to the present invention, a cylinder or a circular recess is provided at center of a prior art optical element, such as three-beam grating or holographic optical element, to split a laser beam into two. An optical path difference is caused by the cylinder or circular recess, and NA of the optical element is controlled, such that the beam completely passing through the optical element is used for DVD and the beam passing through the cylinder or circular recess is used for CD.
These and other objects, features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an optical element of a first embodiment;
FIG. 2 shows a bifocal optical pickup head of the first embodiment of the present invention;
FIG. 3 is a partially enlarged view showing a beam focused on a DVD;
FIG. 4 is a partially enlarged view showing a beam focused on a CD;
FIG. 5 shows an optical element of a second embodiment;
FIG. 6 shows a bifocal optical pickup head of the second embodiment of the present invention in which the optical element is used with a conventional optical pickup head;
FIG. 7 shows an optical element of a third embodiment in which the optical element is provided in a three-beam grating;
FIG. 8 shows a bifocal optical pickup head of the third embodiment of the present invention in which the optical element is used with a holographic optical pickup head;
FIG. 9 shows a bifocal optical pickup head of a fourth embodiment of the present invention in which the combination of an optical element and a three-beam grating is used with a two-source optical pickup head; and
FIG. 10 shows a bifocal optical pickup head of a fifth embodiment of the present invention in which an optical element, a three-beam grating and a holographic optical element are used with a two-source optical pickup head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an optical element 10 having a first refraction surface 11 and a second refraction surface 12 perpendicular to axis of a laser beam in an optical pickup head. The refraction surfaces 11 and 12 are located at different places corresponding to different optical paths and different radiuses of the laser beam. For example, a protruded cylinder 130 is formed at a side of a flat transparent body 13 such as glass plate or quartz plate having a high transmittance. Surface A of the transparent body 13 at the same side with the cylinder 130 is formed as the first refraction surface 11 , while axial end surface B of the cylinder 130 is formed as the second refraction surface 12 . The surface A and the axial end surface B are concentric such that a laser beam will be split into two beams of different optical paths when it passes through the refraction surfaces 11 and 12 . Then the beams are collimated and pass through an objective lens to form two spots of different focuses.
Preferably, the radial section of the cylinder 130 has a shape depending on sectional shape of the laser beam to enhance the efficiency thereof. The optical element 10 is manufactured by photolithography to perform pattern transfer, followed by etching wherein a desired etched depth can be obtained by controlling the etching time. Of course, injection molding or the likes can be employed instead.
FIG. 2 shows a bifocal optical pickup head of a first embodiment of the present invention. The bifocal optical pickup head comprises: a laser diode 20 for generating a laser beam for accessing an optical disc 8 (CD or DVD); an optical element 10 for splitting the laser beam emitted from the laser diode 20 into two beams of different optical paths; a beam splitter cube 30 for separating the two laser beams of different optical paths from a reflection beam from the optical disc 8 (CD or DVD); a collimator lens 40 for collimating the beams as a parallel beam; an objective lens 50 for focusing the parallel beam including the two laser beams of different optical paths on a data storage surface of the optical disc 8 (CD or DVD); a photo detector 61 for converting the reflection beam from the optical disc 8 (CD or DVD) into an electric signal; and a condensing lens 60 for focusing the reflection beam from the beam splitter cube 30 on the photo detector 61 .
As clear from FIG. 2, the laser beam for accessing the optical disc 8 (CD or DVD) is emitted from the laser diode 20 through optical element 10 where it is split into two laser beams of different optical paths. Then, these two beams pass through the collimator lens 40 and the objective lens 50 , and are focused on the data storage surface of the optical disc. These two beams passes through the first refraction surface 11 and the second refraction surface 12 , respectively. One of the beams having higher efficiency is used for DVD 81 (referring to FIG. 3 ), while the other which passes through only the cylinder 130 is used for CD 82 (referring to FIG. 4 ). Therefore, by the aid of the optical element 10 of the present invention, to access both CD 82 and DVD 81 , the collimator lens 40 and the objective lens 50 are employed and no other optical devices such as zooming aperture, movable objective lens or dual objective lenses are necessary.
To align center of the cylinder 130 with the laser beam center can easily assemble the optical element 10 . Further, since the beam reflected from the optical disc surface passes through the condensing lens 60 to the photo detector 61 via the beam splitter cube 30 and does not returned to the optical element 10 , the assembly tolerance is higher.
FIG. 5 shows another preferred embodiment of an optical element 10 a wherein a cylindrical recess 131 is formed on surface of a flat transparent body 13 . Axial end surface C of the cylindrical recess 131 acts as second refraction surface 12 like axial end surface B in FIG. 1 .
FIG. 6 shows a bifocal optical pickup head of a second embodiment of the present invention in which how to use an optical element 10 of the present invention with a conventional optical pickup head is disclosed. The bifocal optical pickup head comprises: a laser diode 20 for emitting a laser beam for accessing an optical disc 8 (CD or DVD); a three-beam grating 70 ; an optical element 10 ; a beam splitter 30 ; a collimator lens 40 ; an objective lens 50 ; a condensing lens 60 ; and a photo detector 61 .
In this embodiment, the optical element 10 can be formed as shown in FIG. 1 or FIG. 5, and can be directly integrated on back of a three-beam grating 70 or the like.
A holographic optical pickup head shown in FIG. 8 comprises: a laser diode 20 for emitting a laser beam for accessing an optical disc 8 (CD or DVD); an optical element 10 as shown in FIG. 1 or 5 for splitting the laser beam emitted from the laser diode 20 into two beams of different optical paths; a holographic optical element (HOE) 80 for separating the two laser beams of different optical paths from a reflection beam from the optical disc 8 (CD or DVD); a collimator lens 40 for collimating the laser beams passing through the holographic optical element 80 as a parallel beam; an objective lens 50 for focusing the parallel beam including the two laser beams of different optical paths on a data storage surface of CD 82 or DVD 81 ; and a photo detector 61 for converting the reflection beam from the holographic optical element 80 into an electric signal.
In FIG. 9, a two-source optical pickup head is shown in which an optical element 10 is integrated with a three-beam grating 70 (as shown in FIG. 7 ). As shown, two laser diodes, i.e., first laser diode 20 a and second laser diode 20 b, which generate laser beams of different wavelengths, are used to access different optical discs 8 (CD or DVD) respectively. The laser beam emitted from the first laser diode 20 a passes through the combination of the optical element 10 and the three-beam grating 70 , a collimator lens 40 and an objective lens 50 , and then is focused on a data storage surface of the optical disc 8 . The laser beam emitted from the second laser diode 20 b passes through a first beam splitter cube 30 a, the collimator lens 40 and the objective lens 50 , and then is focused on the data storage surface of the optical disc 8 . The laser beam reflected from the data storage surface of the optical disc 8 passes through a second beam splitter cube 30 b and a condensing lens 60 , and then is focused on a photo detector 61 where the laser beam representing a photo signal is converted into an electric signal.
In the example shown in FIG. 9, if the first laser diode 20 a emits a laser beam having wavelength of 780 nm, the inner portion of the laser beam is used to access CD, and another laser beam having wavelength of 650 nm from the second laser diode 20 b is used to access DVD. Therefore, an optical pickup head capable of selectively accessing CD or DVD by the objective lens 50 is formed. If the first laser diode 20 a is a SHG laser with wavelength of 820 nm, the inner portion of the laser beam accesses CD while the laser beam of second harmonic with wavelength of 41 nm accesses DVD.
FIG. 10 shows a preferred embodiment in which a three-beam grating 70 , an optical element 10 and a holographic optical element 80 are combined together to form an integrated optical element 90 , which is used with a two-source optical pickup head. In this embodiment, a first laser diode 20 a with wavelength of 780 mn and a second laser diode 20 b with wavelength of 650 nm are for CD and DVD, respectively.
A laser beam emitted from the first laser diode 20 a passes through the integrated optical element 90 , a collimator lens 40 and an objective lens 50 , and then is focused on a data storage surface of an optical disc 8 . The laser beam reflected from the data storage surface of the optical disc 8 follows the opposite optical path, and is focused by the holographic optical element (HOE) 80 in the integrated optical element 90 on a photo detector 61 where the laser beam representing a photo signal is converted into an electric signal. A laser beam emitted from the second laser diode 20 b passes through a beam splitter cube 30 a, the collimator lens 40 and the objective lens 50 , and then is focused on the data storage surface of the optical disc 8 . The laser beam reflected from the data storage surface of the optical disc 8 follows the opposite optical path, and is focused by a holographic optical element (HOE) 80 a on another photo detector 61 a where the laser beam representing a photo signal is converted into an electric signal.
According to the present invention, to access both CD and DVD, it is unnecessary to add any other optical elements such as zooming aperture, movable objective lens or dual objective lenses. The present invention provides advantages of simple structure, low cost, easy assembly and high tolerance. Besides, the optical element of the present invention is adapted to a conventional optical pickup head, holographic optical pickup head or two-source optical pickup head.
While the present invention has been described in conjunction with preferred embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and scope thereof as set forth in the appended claims.
INDEX
10
optical element
10a
optical element
11
first refraction surface
12
second refraction surface
13
transparent body
130
cylinder
131
cylindrical recess
20
laser diode
20a
first laser diode
20b
second laser diode
30
beam splitter cube
30a
first beam splitter cube
30b
second beam splitter cube
40
collimator lens
50
objective lens
60
condensing lens
61
photo detector
61a
photo detector
70
three-beam grating
8
optical disc
80
holographic optical element
80a
holographic optical element
81
DVD
82
CD
90
integrated optical element | A bifocal optical pickup head is disclosed for use in a optical pickup apparatus having a single objective lens, for generating two different focuses (bifocus) to access a compact disc (CD) and a digital versatile disc (DVD), which the thickness is different. When a beam passes through an optical element disclosed in the present invention, numerical aperture is controlled and spherical aberration is reduced by the optical element due to variations in optical path and radius. Therefore, after beams having different numerical apertures are focused by an objective lens, various focuses can be obtained. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation in part of application Ser. No. 11/561,393, Filed Dec. 10, 2006, now U.S. Pat. No. 7,980,080, granted Jul. 12, 2011, within which we include by reference the flat ceramic plates with geometrical cavities designed to hold all components enclosed and pipes within structure construction.
FEDERALLY SPONSORED RESEARCH
None
SEQUENCE LISTING
None
BACKGROUND OF INVENTION
The original patent application 11561393 was filed with the copper Heat-Anvil, performing the import and temporary holding of caloric energy. After the application was filed the inventors became aware of new developments in ceramics that afforded heat exchangers to be created almost entirely from ceramics. The main inventor Mr. Pickette assumed the task of creating a lighter more robust performing Heat-Anvil equivalent in the form of multiple homogeneous ceramic components contained within a shell outwardly a physical form identical with that of the original Heat Anvil.
The inventor was aware that oil had been utilized in electrical Power Company transformers for years. It seemed logical to embrace this mode of a utility media to manage caloric energy. After another short search, a biologically compatible oil was found. A biological harmonious oil is necessary to avoid toxic environmental contamination in any case of a spill.
The original homogeneous ceramic is a poor conductor of caloric energy, making it ideal for the construction of a device that should not steal energy from the contents it encounters. Further searching found another ceramic that, while not the best conductor of caloric energy, was nearly one-half as conductive as the optimum conductor copper. This ceramic is utilized to construct caloric energy exchanging parts.
Other embodiments of this device may include embedding or other styles of embodiments without departing from the spirit of the device.
SUMMARY
The concept developed to design a universal part of the homogeneous material defined as the Quill. This quill could be constructed of both caloric conducting or caloric conduction resistant ceramic. Hereinafter the quill when combined with ferrite shall be named a Cerfite.
Other effects of the homogeneous ceramic material are its ability to seal securely under slight compression and where necessary, while components are light weight, precisely formed and slide nearly without effort, requiring minuscule, if any, lubrication.
The Cerfite may be constructed of either ceramic material which may be molded into any shape embedding extremely fine detail, ease of sliding, and of the stable dimensionality.
The Cerfite, when filled with soft-ferrite material, becomes a part that responds to magnetic energy, and may be molded in nearly any form necessary.
The Cerfite, when filled with hard-ferrite material, becomes a permanent magnet, which is protected from acids, corrosion, moderate impact, and may be molded into nearly any shape.
In accordance with one embodiment, the above effects combined with the geometrical cavity plates and pipes in structure provide means to compact at reduced manufacturing cost, great complexity and miniaturization, which may also be expounded to larger assemblies without modification. These features then allow for more compact and reliable larger assemblies of the same and other functional orders with the same savings in manufacturing costs. All this shall become apparent by a study of this application.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a Cerfite hot-spot.
FIG. 2 illustrates a Cerfite shuttle.
FIG. 3 illustrates a Cerfite heat exchange quill.
FIG. 4 illustrates one embodiment of the Cerfite quills on a surface.
FIG. 5 illustrates an alternate embodiment of the Cerfite quills on a surface.
FIG. 6 illustrates Cerfite quills on a tube assembly.
FIG. 7 illustrates bias magnets.
FIG. 8 illustrates an exploded view of the caloric energy manger.
FIGS. 9 , 9 A, and 9 B illustrate various perspectives of the Case.
FIGS. 10 , 10 A, 10 B, and 10 C illustrate various perspectives of the Plate E.
FIGS. 11 , 11 A, 11 B, and 11 C illustrate various perspectives of the Plate D.
FIGS. 12 , 12 A, 12 B, and 12 C illustrate various perspectives of the Plate C.
FIGS. 13 , 13 A, and 13 B illustrate various perspectives of the Plate S 1 .
FIGS. 14 , 14 A, and 14 B illustrate various perspectives of the Plate S 2 .
FIGS. 15 , 15 A, and 15 B illustrate various perspectives of the Plate S 3 .
FIGS. 16 , 16 A, and 16 B illustrate various perspectives of the Plate S 4 .
FIGS. 17 , 17 A, and 17 B illustrate various perspectives of the Plate S 5 .
FIGS. 18 , 18 A, and 18 B illustrate various perspectives of the Plate S 6 .
FIGS. 19 , 19 A, and 19 B illustrate various perspectives of the Plate S 7 .
FIGS. 20 , 20 A, and 20 B illustrate various perspectives of the Plate S 8 .
FIGS. 21 , 21 A, and 21 B illustrate various perspectives of the Plate S 9 .
FIGS. 22 , 22 A, and 22 B illustrate various perspectives of the Caloric Induction Ring.
FIGS. 23 , 23 B, and 23 B illustrate various perspectives of the Shuttle.
FIGS. 24 and 24A illustrate various perspectives of the Shuttle ferrite element.
FIGS. 25 , 25 A, and 25 B illustrate various perspectives of the Caloric Conductor.
FIGS. 26 , 26 A, and 26 B illustrate various perspectives of the Plate S 9 A.
FIGS. 27 , 27 A, and 27 B illustrate various perspectives of the electric heating element.
FIGS. 28 , 28 A, and 28 B illustrate various perspectives of the Cerfite Ball.
FIGS. 29 , 29 A, and 29 B illustrate various perspectives of the Switch Magnet A.
FIGS. 30 , 30 A and 30 B illustrate various perspectives of the Switch Magnet B.
FIGS. 31 , 31 A, and 31 B illustrate various perspectives of the Bias Magnet.
FIGS. 32 , 32 A, and 32 B illustrate various perspectives of the Lock Magnet.
FIG. 33 illustrates the assembly mixer.
FIGS. 34 , 34 A, and 34 B illustrate various perspectives of the CEM Plate S 2 Track.
FIGS. 35 , 35 A, and 35 B illustrate various perspectives of the CEM Plate S 3 Track.
FIGS. 36 , 36 A, and 36 B illustrate various perspectives of the pump rotor.
FIG. 37 illustrates the quill employed by intersecting a surface in the cutaway depiction of a Porcupine heat exchanger.
DRAWINGS
FIG. 1 : It illustrates the Cerfite Hot-Spot, which contains on its bottom rounded Cerfite extrusions to aid caloric energy transfer, the entire assembly is constructed of the caloric energy conducting ceramic.
FIG. 2 : It illustrates the Cerfite Shuttle, which oscillates inside a track, where it drives a gear in stroke then continues around the end of the track to return to the start point for another stroke. The entire part is constructed of non-caloric energy conducting ceramic embedded with soft-ferrite material.
FIG. 3 : It illustrates the solid round Cerfite Exchange quill constructed in a solid-bodied part, when interspersed on a tube or other type of carrier to form a caloric energy exchange function or likewise function, the part is constructed entirely of caloric energy conducting ceramic.
FIG. 4 : It illustrates the solid round Cerfite quill dispersed as an array on a surface to exchange caloric energy from a vapor with a magnetically activated Cerfite flapper fan. The entire body of the caloric energy exchanger is constructed of caloric energy conducting ceramic, while the Cerfite flapper fan is constructed of non-caloric energy conducting ceramic embedded with soft-ferrite material at the top.
FIG. 5 : It illustrates the solid round Cerfite pin dispersed along a curved surface to aid in exchange of caloric energy, in this case the entire component is constructed of caloric energy conducting ceramic.
FIG. 6 : It illustrates the solid round Cerfite quill dispersed around a sinusoidal exchange tube assembly to enhance the transfer of caloric energy from vapors contained within the outer tube. While the outer tube is constructed of none caloric energy conducting ceramic, the entire inner tube and quill construction is created from caloric energy conducting ceramic.
FIG. 7 : It illustrates the bias magnets that are formed by combining non-caloric conducting ceramic, enclosing hard-ferrite material to form a permanent magnet that is thermally protected, resistant to acid and alkaline effluents, while being lightweight, precise, stable and may be molded into any shape.
FIG. 8 : It illustrates the caloric energy transfer ring that is constructed entirely of caloric energy conduction ceramic.
a Case 1 b Electrical Heating Element 1 c Plate S 9 A 1 d Plate S 9 1 e Plate S 8 1 f Plate S 7 1 g Plate S 6 h Plate S 5 1 i Plate S 4 1 j Plate S 3 k Shuttle lower Guide Plate 1 l Pump Rotor m Shuttle 1 n Shuttle Ferrite 1 o Shuttle upper Guide Plate 1 p Plate S 2 1 q Plate S 1 1 r Turret Plate C 1 s Turret Plate D 1 t turret Plate E 1 u Caloric Conductor (hot spot) 4 v Caloric Induction Ring 1 w Bias Magnet 1 x Reset (Look) Magnet 1 y Switch Magnet A 1 z Switch Magnet B 1 % Switch Ball 2
DRAWINGS
Reference Numerals
Exploded Drawing CEM FIG. 8 : (a-z, %).
Case FIG. 9 : ( 1 - 2 ); a( 3 ); b( 4 ).
Plate E FIG. 10 : a( 5 ); b( 7 - 9 ); c( 6 ).
Plate D FIG. 11 : ( 21 ); a( 12 - 13 , 22 ); b( 18 - 20 ); c( 16 ).
Plate C FIG. 12 : a( 23 ); b( 24 - 27 ); c( 28 - 29 ).
Plate S 1 FIG. 13 : a( 30 - 34 ); b( 37 - 39 ).
Plate S 2 FIG. 14 : a( 40 - 46 ); b( 48 - 55 ).
Plate S 3 FIG. 15 : a( 60 - 69 ); b( 70 - 74 ).
Plate S 4 FIG. 16 : a( 81 - 82 ); b( 85 - 87 ).
Plate S 5 FIG. 17 : a( 90 - 92 ); b( 95 - 97 ).
Plate S 6 FIG. 18 : a( 100 - 104 ); b( 106 - 109 ).
Plate S 7 FIG. 19 : a( 112 , 114 , 116 ); b( 118 - 119 , 121 ).
Plate S 8 FIG. 20 : a( 125 , 127 - 128 ); b( 129 ).
Plate S 9 FIG. 21 : a( 130 ); b( 131 ).
Caloric-Induction-Ring FIG. 22 : a( 141 , 143 ); b( 145 ).
Shuttle FIG. 23 : a( 151 , 153 , 155 ); b( 157 , 159 ).
Shuttle Ferrite element FIG. 24 : a( 160 ).
Caloric-Conductor(s) FIG. 25 : a( 165 ).
Plate S 9 A FIG. 26 : a( 170 ); b( 172 ).
Electrical Heat Element FIG. 27 : a( 180 ); b( 182 ).
Cerfite Ball FIG. 28 : a( 190 ).
Switch Magnet A FIG. 29 : a( 200 ); b( 204 ).
Switch Magnet B FIG. 30 : a( 210 ); b( 212 ).
Bias Magnet FIG. 31 : a( 220 ); b( 224 ).
Lock Magnet FIG. 32 : a( 230 ); b( 232 ).
Assembly Mixer in 3D FIG. 33 : ( 235 ).
CEM Plate S 2 Track FIG. 34 : a( 240 ); b( 244 , 246 ).
CEM Plate S 3 Track FIG. 35 : a( 250 ); b( 252 ).
Pump_Rotor FIG. 36 : a( 260 , 262 ); b( 264 , 266 ).
REFERENCES
Caloric energy storage spiral diameter 0.020 inch.
Total length 17.722408 in per layer includes inlet. Total of 3 layers storage one layer active. area 1.159551 in(2), 0.008052 ft., vol 0.058 cu. in.per layer.
Total oil in device volume of storage area 0.01627 oz., total volume in the entire machine 0.02146+−0.004 oz., rate of flow 0.0002 to 0.0007 oz per second, storage volume 0.174 cu in total volume 0.232 cu in.
The mathematical description of temperature in the storage is presented by a parabolic differential equation in partial derivatives:
C *(dU/dl)^2=dU/dt (1)
Where U (t, l) is the function of the temperature in the caloric storage. We utilized here for the simplicity L, as the finite rod of the given length, C, as the constant of heat transformation of cotton seed oil (the oil is utilized in the device), which can be easily calculated numerically with the help of well-developed already technique of calculation of this value through viscosity of cotton seed oil under different temperatures. It is easy to understand that, in reality, X, Y, Z coordinates of the device can be presented as continuous without any irregularity's functions of L. For example, X=F (L), Y=G (L) and Z=Q (L). The full analytical (and numerical) presentation of these functions could be derived from the FIGS. 17 , 18 , 19 of the device's illustrations. Once again, because these functions are continuous and have reverse continuous functions for the entire while of our consideration, the consideration of this problem can be presented, as a one-dimensional corresponding equation (1) for the search of analytical solution by traditional methods (see, for example, “The Course of High Mathematics”, volume IV, by V. I. Smirnoff), this solution can be obtained as the traditional Green function for the one-dimensional case for a rod of given length and then transformed into U′ (X, Y, Z) through substitution of their analytical values from L=F′(X), where F′ is the reverse function of F(L), and through similarly constructed G′(Y) and Z′(Z).
Thus, the entire problem of mathematical calculations of problems, pertinent to caloric storage, would be presented by already well-developed techniques with the already existing proven theorems of existence and uniqueness of solutions.
DETAILED DESCRIPTION
First Embodiment
Now referring to FIG. 8 . Within the Caloric Energy Manager the Quill is utilized in four different configurations: one on the hot-spots to aid the importing of caloric energy to those components; two in the Caloric Importing Ring to aid the transfer of caloric energy available outside the unit to the energy carrier media within the unit; three the Quill is utilized to form the Shuttle, which is a magnetically activated part, which, in its turn, rotates the pump rotor as it passes on each stroke, re-tracing on the return channel to next begin another stroke of the rotor in the next pass; four in CEM Plate S 8 , where Quills are interspersed along the spiral curve to eddy and convulse the media to enhance the transfer o caloric energy from the plate to the caloric energy transport media.
The Porcupine Quill is employed in the Caloric Energy Manager (CEM), an assembly of dual sided flat ceramic plates incorporating the spiral cavities in structure, magnetic, electromagnetic and electronic components designed to store and to manage the import of caloric energy into a FCHTMC engine. Contained within the Caloric Energy Manager Case is a stack of thirteen ceramic plates of various functions that also incorporate components of the Porcupine Quill, as further described, within this specification. The Caloric Energy Manager, as the caloric energy transfer and storage, use an oil as the caloric energy transfer media.
The oil when maintained in an evacuated atmosphere is allowed to achieve high temperatures without carbonation. The caloric energy sources cannot contact the oil directly as it is fully protecting the oil from boiling. The oil is circulated throughout the device by an electromagnetically controlled (Cerfite) rotary pump to transport and store caloric energy safely and securely. The caloric storage capabilities move from temporary with the Heat-Anvil to be semi-permanent with the CEM.
The media is guided through three circuits within the CEM, Loop 1 guides media from the pump up to the hot-spots (Caloric Conductors). An alternate: if switch ball A is open media from Caloric Storage is mixed with the Loop 3 media to increase caloric energy density. CEM, Loop 2 guides media up to the Caloric Induction Ring circuit, which encircles the upper outside edge of the turret relative to plates' E, D, and C, where the circular portion of the loop follows the one and a half-circle spiral, originating at the E plate then terminating at the C plate. The heated media may all be returned to the Storage Loop, which is the third loop. CEM, Loop 3 is composed of a half plate S 4 , which terminates the storage loop, and three plates (S 5 -S 7 ) that have mirror matched spiral cavities to form spiral tubes between the plates with alternating entrances and exits to form a continuous tube, which cumulatively includes half of a fifth plate S 8 , which, in its turn, doubles as storage and caloric energy import transfer unit. Due to the angular material depth, the caloric energy is held secure as for caloric energy to leak it must have a path. The linear material between any possible caloric energy leak is guaranteed by the construction of the device. Each individual plate except plate S 8 and S 9 A are made of minimally caloric energy conducting ceramic.
FIG. 8 : It illustrates the Caloric Energy Manager (CEM) Exploded View and is an illustration for an assembly of ceramic; magnetic; electromagnetic and electronic components designed to manage the import of caloric energy into the FCHTMC engine. Contained within the Caloric Energy Manager Case (a) is a stack of thirteen ceramic plates and other components. The other 12 components are: Electrical Heating Element (b); Square Plate S 9 A (c); Square Plate S 9 (d); Square Plate S 8 (e); Square Plate S 7 (f); Square Plate S 6 (g); Square Plate S 5 (h); Square Plate S 4 (i); Square Plate S 3 (j); Shuttle lower Guide Plate (k); Pump Rotor ( 1 ); Shuttle (m); Shuttle Ferrite (n); Shuttle upper Guide Plate (o); Square Plate S 2 (p); Square Plate S 1 (q); Turret Plate C (r); Turret Plate D (s); Turret Plate E (t); Caloric Conductors (u); Caloric Induction Ring (v); Bias Magnet (w); Reset (Lock) Magnet (x); Switching Magnet A (y); Switching Magnet B (z); Switch Balls (%).
The Caloric Energy Manager as the caloric energy transfer utilizes a media as the storage and energy transfer media. The media maintained in an evacuated atmosphere that allows it to achieve higher temperatures without carbonation. The caloric energy sources cannot contact the media directly in full, due to the fact that the ceramic surrounding is protecting the media from boiling. The media is circulated throughout the device by a rotary pump (I) to transport and store caloric energy under the control of the two switch magnets, the ball valves and outside electromagnetic forces.
FIG. 9 : It illustrates the Caloric Energy Manager Case, that encloses the caloric manager components. At the top, cavity ( 1 ) provides clearance for the hot-spots (Caloric Conductors, ( FIG. 25 )) to interface with the FCHTMC rotary expansion controls. Just below the edge of the turret on the outer surface is a geometrical partial cavity ( 2 ) with symmetrical through cavity holes at varying angles who provide access for the Cerfite Caloric Induction Ring ( FIG. 22 ) that is mounted during the molding of the Case. FIG. 9 a : The top of the turret has a reduced diameter cavity ( 3 ) to provide an upward seating edge for the CEM Plate E ( FIG. 10 ). FIG. 9 b : At the bottom of the case is a key extrusion ( 4 ), which proceeds up the inner square portion of the case to provide a position locking and seating edge to match the square cutout on each square plate, assuring that the plates may only be oriented and inserted facing upward towards the inside of the case.
FIG. 10 : It illustrates the CEM Plate E. FIG. 10 a : It serves as the mounting manifold ( 5 ) for the four hot-spots, ( FIG. 25 ). FIG. 10 b : In addition, plate E serves as the starting point of the Caloric Induction Loop ( 7 ), that encircles the edge face of each turret plate. FIG. 10 c : The half-circle cavity ( 6 ) progresses downward towards CEM Plate D ( FIG. 11 ) to terminate on CEM Plate_C ( FIG. 12 ). The Caloric Induction Loop works in concert with the Caloric Induction Ring ( FIG. 22 ) that imports caloric energy into the caloric transfer media, surrounding the external outside surface of the turret of the CEM_Case ( FIG. 9 , 2 ). FIG. 10 b : It illustrates the CEM Plate E lower surface, which is used to form the top half of the caloric energy embedding spiral ( 8 ) for the hot-spots ( FIG. 25 ), whose bases protrude through the manifold. FIG. 10 b : The curves of the hot-spots match the spiral ( 8 ) of the caloric energy embedding loop, while the Cerfite Quill round extrusions ( 9 ) assist to import caloric energy into the hot-spots from energy laden caloric energy transport media, flowing along the caloric energy embedding spiral.
FIG. 11 : It illustrates the CEM Plate D. FIG. 11 a : On its top surface is the beginning of a spiral caloric energy embedding flow pattern ( 12 ), which is fed by the vertical circular through cavity ( 12 ) that ends at this surface. This cavity originates on CEM Plate S 3 ( FIG. 15 ). It guides energy laden caloric energy transfer media from the CEM Switch A default position. The caloric embedding spiral exits at the center of the plate ( 13 ), where the media exits by a large circular through cavity to CEM Plate C ( FIG. 12 ). FIG. 11 b : The circular through cavity ( 18 ) conveys caloric energy transport media to the hot-spot embedding spiral. The circular through cavity ( 19 ) conveys the caloric transport media to the Caloric Induction Loop origin ( FIG. 10 b ), ( 7 ). The large circular through cavity ( 20 ) conveys the depleted caloric energy transfer media to the open cavity on CEM Plate C ( FIG. 12 a ), ( 23 ). FIG. 11 c : It circumscribes all along the edge of the CEM Plate E, progresses towards the outer edge spiral half circular cavity Caloric Induction Ring loop ( 16 ), which progresses, in its turn, around the plate edge face. FIG. 11 : The half-circle cavity ( 21 ) progresses downward to CEM Plate C ( FIG. 12 ). The circular through cavity ( 14 ) provides a source route for caloric energy transfer media destined to the Caloric Induction Ring loop, progressing up to CEM Plate E ( FIG. 10 b ), ( 7 ).
FIG. 12 : It illustrates the CEM Plate C. FIG. 12 a : It shows the geometrical circular entities that collect depleted caloric energy transport media into an open cavity then direct the media along a rectangular cavity to a circular through cavity ( 23 ). FIG. 12 b : The depleted media is further directed through circular cavity ( 27 ) to the CEM Plate S 1 ( FIG. 13 ). The Caloric Induction Loop half-circle cavity ( 28 ) progresses from the CEM Plate D, spiraling downward to the circular cavity ( 29 ). FIG. 12 c : The edge face routing terminates the media into a circular cavity ( 29 ) that then continues to CEM Plate S 1 . FIG. 12 b : The circular cavity ( 24 ) conveys media to CEM Plate S 1 ( FIG. 13 ). The circular through cavity ( 25 ) supplies caloric energy transport media to the top of the CEM Plate D, where it then enters the hot-spot caloric embedding spiral ( FIG. 11 a ), ( 12 ). The circular through cavity ( 26 ) supplies caloric energy transport media to the Caloric Induction Ring loop, which originates on the CEM Plate E ( FIG. 10 b ), ( 7 ).
FIG. 13 : It illustrates the CEM Plate S 1 . It has a primary function to house the caloric transport media pump rotor ( FIG. 24 ), a secondary function is to provide circular through cavity extensions for the circular cavities progressing to and from the CEM Plate C. FIG. 12 a : Circular through cavities ( 24 - 27 ) are the through cavities previously mentioned. The circular through cavity ( 30 ) transports the Caloric Induction Ring output to the CEM Plate S 2 . The circular through cavity ( 31 ) transports the caloric energy laden media towards the corresponding cavity in CEM Plate C ( FIG. 12 ). The circular through cavity ( FIG. 13 a ), ( 32 ) transports the caloric transport media from the CEM Plate S 2 ( FIG. 14 ) towards the corresponding cavity in CEM Plate C ( FIG. 12 ). The circular through cavity ( 33 ) transports depleted caloric energy media from the CEM Plate C ( FIG. 12 ) to the inner pump chamber. FIG. 13 b : It illustrates the circular through cavity ( 37 ), which is the inlet for depleted media to the pump chamber. The inside wall of the CEM Plate S 1 pump chamber provides a splash guide ( 38 ) to assist the capture of the centrifugal output of the pump as well as the impeller output directing media towards the exit cavity for the caloric energy transport media ( 39 ). The standard alignment key on all CEM Plate S series assures the proper orientation of the plates ( FIG. 13 a , 34 ).
FIG. 14 : It illustrates the CEM Plate S 2 , which is the top partner of a two plate assembly with geometrical cavities, ceramic and Cerfite components contained within. The plates may be simply referred to as the caloric energy transfer media switch and driver of media, as these plates contain components within and perform all the variable functions of the system.
FIG. 14 a : The circular through cavity ( 40 ) is the origin of the caloric energy transport media return to Storage Loop path from the Switch B default cavity formed between CEM Plate S 2 ( FIG. 14 ) and CEM Plate S 3 ( FIG. 15 ). The circular through cavity ( 41 ) transfers the collected caloric energy transport media pushed by the pump to the CEM Plate S 2 Mixer cavity ( FIG. 14 b ), ( 51 ), ( FIG. 33 ), ( 235 ). The circular through cavity ( 42 ) receives Caloric Induction Loop output from CEM Plate S 1 ( FIG. 13 ), routing the media into the Switch B cavity that is created between CEM Plate S 2 ( FIG. 14 ) and CEM Plate S 3 ( FIG. 15 ). The circular though cavity ( 43 ) carries caloric energy transport media from the Switch A cavity to the CEM Plate S 1 , the destination is the Caloric Embed Loop, originating on the CEM Plate E ( FIG. 15 ). The circular through cavity ( 44 ) forms the mating surface to the media pump ( FIG. 24 ) hub to circulate within. The circular through cavity ( 45 ) transports caloric energy transport media from the Switch B hot cavity to CEM Plate 51 ( FIG. 13 ), and the destination is the Caloric Induction Loop that originates on CEM Plate E ( FIG. 10 ). The circular cavity ( 46 ) is the support cavity for the caloric energy transport media pump rotor ( FIG. 24 ), which circulates within.
FIG. 14 b : It presents the Switch A default geometrical cavity ( 48 ), which routes to the Mixer ( FIG. 33 ), ( 235 ) output to the storage loop bottom level. The Switch A hot geometrical cavity ( 49 ) routes to mixer ( FIG. 33 ), ( 235 ) output to the CEM Plate S 1 destination-the hot-spot embedding loop, which originates on CEM Plate E ( FIG. 10 ). The geometrical cavity ( 50 ) routes the Caloric Induction Loop output to the Switch B. The geometrical cavities ( 51 ), which construct the caloric energy transport media Mixer. The geometrical cavity ( 52 ) routes the output from the Switch B default conduit to the CEM Plate S 1 destination cavity ( FIG. 14 a ), ( 45 ), which feeds the circular cavity, while proceeding to the Caloric Induction Loop, which, in its turn, originates on CEM plate E ( FIG. 10 ). The Cerfite Lock Magnet is a permanent magnet that captures the Shuttle ( FIG. 33 ) then locks it into a safe state. The Cerfite shuttle track ( 54 ) is a construction that provides a power channel and a retrace channel, both linked by restricted movement areas designed to keep the shuttle properly oriented, while under modifying position, due to magnetic forces. The Cerfite Bias Magnet ( 55 ), which causes the shuttle to park lightly against the side of the area once electromagnetic forces recede. The weak magnetic force of the Bias Magnet is soon overcome by the stronger force of the Lock Magnet, which is barely intense enough to pull the shuttle back to lock position on the return channel. The geometrical cavity ( 52 ) routes the output from Switch B default to the CEM Plate S 1 , destination of the Caloric Induction Loop input, which is originated on CEM Plate E ( FIG. 10 ).
FIG. 15 : It illustrates the CEM Plate S 3 . FIG. 15 a : It is 80% of a mirror implementation of the geometrical cavities of the CEM Plate S 2 bottom side ( FIG. 14 b ). The differences are the central cavity is not a through cavity but a shallow cavity ½ the depth of the plate. The geometrical cavity ( 60 ) is the mirror half of the Switch A default cavity, which is defined by ( FIG. 14 b ), ( 48 ). The geometrical cavity ( 61 ) is the mirror half of Caloric Induction Ring output defined, as ( FIG. 14 b ), ( 50 ). The geometrical cavity ( 62 ) is the mirror half of the Switch A hot output cavity to CEM Plate S 1 circular cavity ( 13 a ), ( 31 ), where the destination to be is the hot-spot embedding spiral. The geometrical cavity ( 63 ) is to transport caloric energy transfer media to bypass from the Mixer, when pressure from the pump causes back-flow from the Storage Loop. The geometrical cavity ( 64 ) is a mirror cavity route for the Switch B magnet. The geometrical cavity ( 65 ) allows the Pump-Rotor ( FIG. 24 ) hub to seat, while allowing the hub to rotate freely on center. The geometrical cavity ( 66 ) is the mirror cavity for the Lock Magnet ( FIG. 32 ). The geometrical cavity ( 67 ) is the designated cavity for the CEM Plate S 3 track ( FIG. 36 ). The geometrical cavity ( 68 ) is the mirror cavity for the Bias Magnet. The geometrical cavity ( 69 ) is the mirror half of the cavity of Switch B default destination, the Caloric Induction Ring Loop fed by the circular cavity ( FIG. 13 a ), ( 32 ).
FIG. 15 b : The circular through cavity ( 70 ) continues to the Return to Storage Loop and proceeds from the Switch A default cavity ( FIG. 15 a ), ( 60 ). The rectangular geometrical cavity with the circular through cavity ( 71 ) is the Caloric Induction Ring Loop output from the CEM Plate S 1 ( FIG. 13 a ), ( 30 ). The circular cavity ( 72 ) is the CEM Caloric Embedding Loop to CEM Plate S 1 ( FIG. 13 a ), ( 31 ). The circular through cavity ( 73 ) conveys the Mixer fed from Storage Loop output ( FIG. 16 a ), ( 81 ). The circular through cavity ( 74 ) conveys media to the Caloric Induction Ring to CEM Plate E ( FIG. 10 ).
FIG. 16 : It illustrates the CEM Plate S 4 . FIG. 16 a : It shows the top surface to interface with CEM Plate S 3 , while on its bottom surface, it is the last spiral cavity of the Storage Loop component. The circular through cavity ( 80 ) is the continued conveyance of the depleted energy transport media to the initial point of the Storage Loop on CEM Plate S 8 ( FIG. 20 ). The rectangular geometrical cavity ( 81 ) conveys the energy transport media into the Caloric Embedding spiral ( FIG. 15 b ), ( 72 ). The circular through cavity ( 82 ) exits from the Storage Loop into the Mixer that is located between CEM Plate S 2 ( FIG. 14 b ), ( 51 ) and CEM Plate S 3 ( FIG. 15 b ), ( 73 ).
FIG. 16 b : The circular through cavity ( 85 ) conveys the depleted caloric energy transfer media to the next level towards the origin of the Storage Loop on CEM Plate S 8 ( FIG. 20 ). The circular through cavity ( 86 ) forms the terminus of the 4th Storage Loop spiral storage cavity. This one conveys the energy laden caloric energy transport media to circular cavity ( FIG. 16 a ), ( 82 ) into the Mixer. The circular cavity ( 87 ) forms the terminus of the up-welling from the 3rd Storage Loop conveyed by the circular through cavity ( FIG. 17 a ), ( 92 ).
FIG. 17 : It illustrates the CEM Plate S 5 , an energy storage plate. FIG. 17 a : The circular through cavity ( 90 ) conveys the depleted caloric energy transport media to the first Storage Loop level on CEM Plate S 8 ( FIG. 20 ). The circular cavity ( 91 ) from the terminus of the 4th Storage Loop levels in concert with the mirror circular through the cavity on CEM Plate S 4 ( FIG. 16 b ), ( 87 ). The circular through cavity ( 92 ) conveys the up-welling of caloric energy transfer media from the Storage Loop third level.
FIG. 17 b : The circular through cavity ( 95 ) is the terminus of the circular through cavity ( FIG. 17 a ), ( 90 ). The circular cavity ( 95 ) is the continuance of circular cavity ( FIG. 16 a ), ( 90 ). The circular cavity ( 96 ) is the terminus of the spiral on the 4th Storage Loop level in combination with the circular through cavity ( FIG. 16 b ), ( 86 ). The circular through cavity ( 97 ) is the up-well to level two in concert with ( FIG. 16 a ), ( 92 ).
FIG. 18 : It illustrates the CEM Plate S 6 , as an energy storage plate. FIG. 18 a : The circular through cavity ( 100 ) conveys the depleted caloric energy transport media to the first Storage Loop level. The circular through cavity ( 102 ) conveys the up-well originated on ( FIG. 18 b ), ( 108 ). The circular cavity ( 104 ) serves as the terminus of circular through cavity ( FIG. 17 b ), ( 97 ).
FIG. 18 b : The circular through cavity ( 106 ) conveys depleted caloric energy transfer media to the first Storage Loop level. The circular through cavity ( 108 ) conveys up-welling caloric energy transport media that originates on CEM Plate S 7 ( FIG. 19 a ), ( 116 ). The circular cavity ( 109 ) serves as the terminus of the spiral then the up-welling to Storage Loop level three that is conveyed through circular through cavity ( FIG. 17 a ), ( 92 ).
FIG. 19 : It illustrates the CEM Plate S 7 an energy storage plate. FIG. 19 a : The circular through cavity ( 112 ) conveys depleted caloric energy transport media to the first Storage Loop level through the circular through cavity ( FIG. 19 b ), ( 118 ). The circular cavity ( 114 ) serves as the terminus of the up-welling conveyed through circular through cavity ( FIG. 18 b ), ( 108 ). The circular through cavity ( 116 ) conveys the up-welling, which origin is at the circular through cavity ( FIG. 20 a ), ( 128 ).
FIG. 19 b : The circular through cavity ( 118 ) conveys depleted caloric energy transport media to the first Storage Loop level ( FIG. 20 a ), ( 125 ). The circular cavity ( 119 ) conveys caloric energy transport media into the Storage Loop spiral cavity, originating the media at the terminus of the rectangular geometrical cavity ( FIG. 20 a ), ( 125 ).
FIG. 20 : It illustrates the CEM Plate S 8 is an energy embedding storage plate. FIG. 20 a : The rectangular geometrical cavity ( 125 ) conveys caloric energy transport media, guiding it to the spiral storage element ( 127 ). This Storage Loop level differs from every other storage level. As shown in ( FIG. 3 ), the spiral is interspersed with many Cerfite quills, while the plate itself is also made of thermal conducting Cerfite material. These features provide the possibility to embed the media with caloric energy transformed by a heating-coil ( FIG. 27 ) that is activated by a wall transformer or other proper direct current source. The circular cavity ( 128 ) is the terminus of the Storage Loop level 1 . The caloric energy transport media is up-welled through the circular through cavity ( FIG. 19 b ), ( 121 ).
FIG. 20 b : The bottom ( 129 ) surface of CEM Plate S 8 is slightly buffed as to closely mate with CEM Plate S 9 A, the interim buffer plate ( FIG. 26 ). Heat sink compound is placed on both sides of the interim plate to aid the transfer of caloric energy.
FIG. 21 : It Illustrates the CEM Plate S 9 , the final plate in the caloric-energy manager. FIG. 21 a : The S 9 A plate has two functions: thermal isolation and electrical supply lead access, which is managed through angled oval cavity ( 130 ) that is designed to support the cable, which shall be fixed by RTV application. FIG. 21 b : The secondary function of thermal isolation is completed as the edge plate S 9 ( 131 ) is sealed to the case ( FIG. 9 ) by the application of RTV around all external edges.
FIG. 22 : It Illustrates the Cerfite CEM Caloric Induction Ring, which is constructed solely of caloric energy conducting ceramic. FIG. 22 a : The ring body ( 143 ) snugly conforms to the groove in the turret ( FIG. 9 ), ( 2 ). FIG. 22 b : All of the eight ( 145 ) Cerfite pins that protrude from the ring body to proceed through the Case Turret wall ( FIG. 9 ) ( 2 ) into a groove cut for them inside of the turret. The groove and the quill's angle follow within that alignment centered on the plate E edge, facing spiral routing ( FIG. 10 c ), ( 6 ). This construction optimizes induction of energy transfer to embed into the caloric energy transport media as the media circumscribes the spiral path between the inside turret surface and the half-circle cavity of the Caloric Induction loop.
FIG. 23 : It illustrates the Shuttle, a Cerfite construction, of non-caloric energy conducting ceramic. FIG. 23 a : The geometrical dome protrusions ( 151 ) interface with the extended serrations of the pump-rotor base ( 268 ) to influence the hub rotation in accommodation with the Shuttle, passing the serrations in a perpendicular motion, which affects the angular motion between the rotating serrations and the semi-dome extrusions. The dual circular extrusions on top and bottom provide a four point ( 2 -S 2 , 2 -S 3 ) channel ( FIG. 34 , FIG. 35 ) interface to ensure that the Shuttle maintains a proper and stable trajectory, while sliding along the channel. The rear surface of the Shuttle slides against the central raised buttresses of both tracks ( FIG. 35 b ), ( 252 ) to enhance shuttle stability, while sliding. The geometrical cavity ( FIG. 34 ), ( 244 ) is mirrored in each track ( FIG. 34 b , 35 a ), ( 246 , 250 ), and is a channel to guide the Shuttle through a complex trajectory, which allows the Shuttle to follow a power stroke, then to perform a retrace stroke without any mechanical springs or belts. FIG. 23 b : The rectangular soft-ferrite ( 157 ) embedded within the Shuttle provides magnet influence capability to the ceramic, allowing electromagnetic and magnetic control of the part in its sliding movements. The physical component of the Shuttle ( 159 ) is a precisely defined and extremely stable entity to insure uninhibited movement within the tracks ( FIG. 34 , 35 ) with extended wear characteristics.
FIG. 24 : It illustrates the pressed soft-ferrite magnetic interface component of the Shuttle. FIG. 24 a : It shows that the pressed material is loosely confined within the Shuttle to allow for different thermal expansion of their characteristics.
FIG. 25 : It illustrates the hot-spots that are constructed entirely of caloric energy, conducting ceramic. FIG. 25 a : The four hot-spots ( 165 ) are each individually matched to their Caloric Embedding Spiral position. The devices are unique in this way. Therefore, one may not be interchanged with the other. Each hot-spot has Cerfite pins within curves that are matching the embedding spiral ( FIG. 1 ), ( 168 ).
FIG. 26 : It illustrates the CEM Plate S 9 A that is entirely constructed of caloric energy conducting ceramic. FIG. 26 a : The surface of the plate ( 170 ) is slightly roughed to enhance the thermal transfer to heat-sink compound, the S 9 A plate acts as a thermal buffer, where it equalizes out the caloric energy created by the electric coil ( FIG. 27 ). The plate also retains heat after the electrical coil has de-energized, allowing a gradual reduction of caloric energy embedded with the caloric energy transport media. FIG. 26 b : The bottom side of CEM Plate S 9 A has an identical characteristics, as the top has.
FIG. 27 : It illustrates the Electrical Heating Coil. FIG. 27 a : The heating coil is designed to provide the proper wattage for the application. This coil does not get red-hot but cycles on and off under control of the temperature of the CEM Plate S 9 A ( FIG. 26 ) to maintain approximately 160 degrees Fahrenheit on the plate. FIG. 27 b : The return leg of the heating coil is a non resistive leg to avoid creating uneven heating zones.
FIG. 28 : It illustrates the Cerfite Ball valve or actuator that is constructed of non-caloric energy conducting ceramic. FIG. 28 a : The soft-ferrite core ( 190 ) of the Cerfite Ball provides a magnetic response to the ceramic.
FIG. 29 : It illustrates the Switch Magnet A, a hard-ferrite construction. FIG. 29 a : The molded hard-ferrite material ( 200 ) is magnetized permanently to the proper intensity, as necessary, for the application. FIG. 29 b : There is not any requirement to encase the ferrite ( 204 ) in ceramic, as there is not any acid or other oxidizing agent within the construction.
FIG. 30 : It illustrates the Switch Magnet B, a hard-ferrite construction. FIG. 30 a : The molded hard-ferrite material ( 102 ) is magnetized permanently to the proper intensity, as necessary, for the application. FIG. 30 b : There is not any requirement to encase the ferrite ( 212 ) within ceramic, as there is not any acid or other oxidizing agent within the construction.
FIG. 31 : It illustrates the Bias Magnet, a hard-ferrite construction. FIG. 31 a : The molded hard-ferrite material ( 202 ) is magnetized permanently to the proper intensity, as necessary, for the application. FIG. 30 b : There is not any requirement to encase the ferrite ( 224 ) within ceramic, as there is not any acid or other oxidizing agent within the construction.
FIG. 32 : It illustrates the Lock Magnet, a hard-ferrite construction. FIG. 32 a : The molded hard-ferrite material ( 230 ) is magnetized permanently to the proper intensity, as necessary, for the application. FIG. 32 b : There is not any requirement to encase the ferrite ( 322 ) within ceramic, as there is not any acid or other oxidizing agent within the construction.
FIG. 33 : It illustrates the combined CEM Plate S 2 ( FIG. 14 ) and CEM Plate S 3 ( FIG. 15 ), where the 3D construction of the Mixer ( 235 ) may be seen.
FIG. 34 : It illustrates the CEM Plate S 2 track, a component, constructed of non-caloric energy conducting ceramic. FIG. 34 a : The back side ( 240 ) of the track is precisely constructed to closely fit the rectangular cavity in the CEM Plate S 2 ( FIG. 14 a ), ( 54 ), which is prescribed for this track. The top surface ( 244 ) of the track shall rest ( 246 ) flush in the surface of plate S 2 .
FIG. 35 : It illustrates the CEM Plate S 3 track, a component, constructed of non-caloric energy conducting ceramic. FIG. 35 a : The back side ( 250 ) of the track is precisely constructed to closely fit the rectangular cavity in the CEM Plate S 3 ( FIG. 15 a ), ( 67 ), which is prescribed for this track. The top surface ( 252 ) of the track shall rest flush in the surface of plate S 3 .
FIG. 36 : It illustrates the CEM pump rotor, a component, constructed of non-caloric energy conducting ceramic. FIG. 36 a : The triangular extrusions ( 260 ) are set to accelerate the media that encounters the top of the rotor towards the edge of the pump, as it turns counter-clockwise. The area in the center of the pump rotor ( 262 ) is open to decrease the action of vortex for media that enters the center, allowing simple centrifugal force to move the centralized media to the extrusions. FIG. 36 b : The pump-rotor exhibits a beveled edge ( 264 ) to promote the circular sliding, while partially submerged in media, driving the media by this motion to the pump toward the exit chute ( FIG. 13 b ), ( 39 ), ( FIG. 14 a ), ( 41 ). FIG. 36 c : The pump rotor seats into the cavity ( FIG. 15 a ), ( 51 ), while the serrations on the side of the hub ( 268 ) match with the dome spacing of the Shuttle ( FIG. 23 a ), ( 151 ). The passing motion of the Shuttle ( FIG. 23 ) instigates rotation of the pump-hub counter-clockwise by a few degrees with each pass.
Assembly of the CEM
To assemble the CEM one must first locate the turret of the case. A clean glovebox is necessary. Then place all components into the glove box sealed in their delivery bags. Close the glovebox. Open the bag of square plate parts, then lay them out sequentially on the work-strip with the index notch ( FIG. 13 a ), ( 34 ) oriented to the index tab ( FIG. 6 b ), ( 4 ) in the corner of the case. These small parts are necessary and found in one bag: One S 3 Track; One S 2 Track; One Shuttle; One pump Rotor; two switch Balls; One Bias Magnet; One Lock Magnet; four hot-spots, F 1 -F 4 . The case must be placed turret up into a jig, so that the access to the bottom of the case is clear by two or three inches. Beginning with the S 1 ( FIG. 13 ) plate, stack the plates' C ( FIG. 12 ), D ( FIG. 11 ), then E ( FIG. 10 ), insuring the holes ( FIG. 13 a ), ( 30 - 33 ) align as shown on top of the S 1 plate, first the C plate, next the D plate, and finally, the E plate. Once you have all these parts assembled, you may push the arrangement gently into the case until the assembly top butts into the turret all the way to the end of easy travel. Next assemble the S 3 ( FIG. 15 ) plate, placing the Bias Magnet ( FIG. 15 a ), ( 68 ) and Lock Magnet ( FIG. 15 a ), ( 66 ), and the S 3 Track onto the S 3 plate surface properly positioned. Place the two switch balls into place. Place the Shuttle ( FIG. 23 ) onto the track in the park position ( FIG. 15 ), ( 66 ). Press the S 2 Track into place into the lower surface of the S 2 plate. Lower the S 2 plate onto the S 3 plate. Place the pump rotor onto the S 2 plate, next push the (S 2 , S 3 ) arrangement up into the S 1 plate inside the case until ease of insertion is resisted. Finally, place the S 9 A plate into the work area. Place the S 8 plate on top of the S 9 A plate, be sure the index notch is similarly matched on each plate. Next place the S 7 plate at the top of the S 8 plate, pay attention to the index notch. Then next place the S 6 plate on top of the S 7 plate. Place the S 5 plate on top of the S 6 plate and continue ceasing the assembly when the S 4 plate is placed on top of the S 5 plate. Check to be sure all index notches are on the same corner. Rotate the assembly to match the index notch in the case, then push the arrangement into the case. Finally, if the S 9 plate has the electrical cord attached to handle it carefully to keep the cord from getting into the way, apply silicone RTV around all vertical outside edges of the S 9 plate. Remove the case from the jig. Place the case assembly turret down into the cavity designed for it. Place the S 9 plate into the case allow it to sit five minutes then turn the assembly over. Draw a vacuum in the glovebox. Place the tube fitting over the E plate. Pump media into the unit until 1.3 oz of media has been loaded as indicated by the meter. Remove the tube fitting. Place each hot-spot into its proper alignment ( FIG. 25 a ), ( 165 ) position, make sure each unit snaps all the way down. At this point, you have a completely assembled and loaded the CEM that is sealed and ready for installation.
Method of Operation
On cold start, the engine control PLC would sense through 1-WIRE™ components the presence of fuel or electric energy. If both are available, the electric activation retains priority. The electric power is switched on to the heat element, then the pump Shuttle inside the space between S 2 and S 3 commences to cycle around its track channel rotating the pump rotor 7 degrees on each pass. The PLC controls the cycle of the shuttle by activation of an inline Electromagnet is located on the outside of the caloric manager case. Cycling this electromagnet produces slow media movement within the CEM. It could take up to two minutes for the system to reach minimal operating temperature from electrical activation. Once the storage levels heat to the minimal level the control PLC would issue engine start sequence. Alternately, when fuel is the energy source for a cold starting the cycle is somewhat reversed. The PLC would activate an electromagnet to inline with switch B directing pump output to enter the caloric energy inductor loop. The PLC would turn on the fuel valve, then a command to initiate the spark sequence to start combustion. The media circulating around the induction loop would be heated by the Caloric Induction Ring, which conducts caloric energy from the convection and infrared caloric radiation immediately, surrounding its vicinity from fuel that was combusted. This outside caloric energy is absorbed by the ring, whose fingers protrude inside to embed the transfer media with caloric energy. As media travels across the induction loop, some of the media is routed by switch And, when activated by the PLC to go to the mix chamber, where heated media is mixed with media of fewer caloric intensity, this mixed media is directed to the caloric conductor loop by switch B. The switches oscillate between the loops, allowing the heating of the caloric storage area and conducting the hot-spots to occur simultaneously, while the engine runs. Once the caloric storage levels are at a temperature level for sustained operation without caloric energy input by the fuel or electrical activation, the caloric energy source becomes inactive for a period. If there is a significant temperature drop detected at the electronic sensor, the caloric energy source restart sequence begins. On shutting down caloric energy held in the storage is maintained with high integrity for days to months. With that stored energy a quick-start sequence would activate the engine in less than a minute. | The components in this application utilize advanced ceramics, which are homogeneous rather than crystalline. This feature allows strong, fine detail parts of great definition, that remain stable and have extraordinary wear resistant characteristics. The Porcupine Pin is a solid-bodied extrusion from a surface through a surface or tangent to a surface. The homogeneous features give extreme durability and equalized flow characteristics. The porcupine pin may be created in other shapes, where within it is embedded ferrite material to form a part that is an electromagnet sensitive or magnetically stable, while exhibiting excellent sliding ability and a precision of detail. These features also allow exceptional miniaturization of magnetically active parts called a Cerfite. | 5 |
RELATED APPLICATIONS
This is a continuation of and claims priority to U.S. patent application Ser. No. 10/633,831, filed Aug. 4, 2003, entitled “Phase Synchronization For Wide Area Integrated Circuits” by inventors Huy M. Nguyen, Benedict C. Lau, Leung Yu, and Jade M. Kizer, now U.S. Pat. No. 6,861,884.
TECHNICAL FIELD
The invention relates to clock signal synchronization in integrated circuits.
BACKGROUND
Integrated circuits (IC), including application specific integrated circuits (ASIC), are increasing in processing capability and are shrinking in physical size. Smaller ICs contain added components such as digital receiving and processing devices. Decreasing the size of ICs has led to an increase in IC processing speed since communication paths are decreased between IC components.
As IC size decreases, however, resistance-capacitance (RC) time delay of metal interconnects between IC components begins to limit IC performance. Interconnect RC time delay is associated with metal resistance of interconnections and capacitance associated with dielectric media. Because metal resistance and dielectric media are inherently part of the materials used in construction of an IC, only a change in materials will affect (improve) RC time delay. A change in materials may be technically impossible or cost prohibitive.
Differences in propagation delay, when compounded across all interconnections, such as clock nets or paths, in a complex IC may lead to unacceptable degradations in overall system-timing. This problem is often referred to as “clock skew.”
FIG. 1 illustrates a clock tree that distributes clock signals in a controlled manner. An IC may contain numerous clocked components requiring clock signals. A clock tree or similar clock architecture provides the necessary clock signals to the components. Components within an IC, specifically registers of the components, may require that the clock signals be synchronized. To be considered “synchronized,” clock signals have the same phase at different receivers, despite propagation delays.
In this particular example, clock receiving components 10 , 15 , 20 , and 25 reside on a single IC. Components 10 , 15 , 20 , and 25 may be at varying distances from one another. In other words component 10 may be an unequal distance from component 15 , as component 15 is to component 20 . Oftentimes, due to IC design constraints or physical architecture restrictions on an IC, components must be placed at varying locations at varying distances from one another. In this example, components 10 , 15 , 20 , and 25 are components that must be synchronized with one another (i.e. have the same phase clock signals). Further, since components are placed at varying distances from one another, components may also be located at varying distances from a clock source such as clock driver 30 . Since clock signals travel over varying distances from the clock source to the components, assuring that each clock signal is in phase with the other clock signals becomes a complicated task.
In typical clock architectures such as the clock tree of FIG. 1 , a controller such as controller 35 initiates a clock signal. Controller 35 can be located on an IC (on-chip) or external to an IC (off-chip). Controller 35 instructs clock driver 30 to generate a clock signal. Clock driver 30 may be implemented for example as a clock oscillator or clock generator or similar component. Alternatively, clock driver 30 may be a clock buffer. A clock signal transmitted by clock driver 30 is passed on to fan-out clock drivers 40 , 45 , 50 , 55 , 60 , and 65 . All clock signals derived from clock driver 30 have the same frequency, although clock signals arriving at various components or registers may have different phase values.
To assure that the clock signals arriving at components 10 , 15 , 20 , and 25 are properly synchronized and have the same phase, paths 70 , 75 , 80 , and 85 must have approximately the same length and propagation delay characteristics. If components 10 , 15 , 20 , and 25 are not located equidistant from their respective clock drivers 50 , 55 , 60 , and 65 , certain paths may have to be wrapped around to assure equal lengths and propagation characteristics of all paths. When IC space is at a premium, this approach may not be feasible.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a clock tree diagram in accordance of the prior art.
FIG. 2 is a schematic illustrating component synchronization for multiple registers in an IC.
FIG. 3 is a schematic illustrating a phase feedback element that makes use of a phase comparator and clock skew register.
FIG. 4 is a schematic illustrating a phase feedback element that makes use of matched current sources.
DETAILED DESCRIPTION
FIG. 2 illustrates a circuit having registers that are to be synchronously clocked. Specifically, this circuit has a plurality of components 200 , 205 , and 210 . In this example, each component comprises one or more multi-bit or byte-word registers. Each byte-word register might have eight individual bit registers, as shown, or some other number of bit registers, typically from 8 to 16 bit registers. In certain other embodiments, all bit registers might be treated as separate registers.
In FIG. 2 , component 200 is made up of bit registers 200 A–H. Component 205 is made up of bit registers 205 A–H. Component 210 is made up of bit registers 210 A–H. In this example, bit registers 200 A–H, 205 A–H, and 210 A–H make up a continuous string of bit registers. In other words, bit registers 200 A–H, 205 A–H, and 210 A–H are physically laid out contiguous to one another (side by side). Bit registers 200 A–H, 205 A–H, and 210 A–H may be arranged in a particular sequence. For example, for a pair of components, the last bit register of a first component may be located adjacent the first bit register of a second component. Therefore, bit register 200 H is placed directly adjacent to bit register 205 A, and bit register 205 H is placed directly adjacent to bit register 210 A. Logically, however, bit registers 200 A–H, 205 A–H, and 210 A–H are configured to comprise separate components (i.e., they are logically part of components 200 , 205 , and 210 ). As separate components, bit registers 200 A–H, 205 A–H, and 210 A–H receive separate component clock signals.
Components 200 , 205 , and 210 and their respective bit registers are intended to be synchronized with one another. In other words, these components are intended to be synchronously clocked. To achieve this, component clock signals to each byte-word register are adjusted to have matching phases at the byte-word registers, after accounting for any differing propagation delays of the component clock signals. A factor determining propagation delay difference is the difference between the lengths of the paths. In a preferred embodiment, the difference between propagation delays is less than 15%.
The described embodiment includes a clock driver corresponding to each set of components, which in this case equates to a separate clock driver for each respective byte-word register. Thus, a clock driver 215 provides a component clock signal 218 to bit registers 200 A–H of component 200 . Component clock signal 218 travels along a path 219 from clock driver 215 . Path 219 branches out to sub-paths 219 A–H which lead to individual bit registers 200 A–H, respectively. Clock driver 220 provides a component clock signal 222 to bit registers 205 A–H of component 205 . Component clock signal 222 travels along a path 224 from clock driver 220 . Path 224 branches out to sub-paths 224 A–H which lead to individual bit registers 205 A–H, respectively. Clock driver 225 provides a component clock signal 227 to bit registers 210 A–H of component 210 . Component clock signal 227 travels along a path 229 from clock driver 225 . Path 229 branches out to sub-paths 229 A–H which lead to individual bit registers 210 A–H, respectively. Therefore, the clock drivers 215 , 220 , and 225 provide separate clock signals to each of the bit registers 200 A–H, 205 A–H, and 210 A–H by way of separate paths.
Clock driver 215 , 220 , and 225 may receive input clock signals from a common source such as a clock tree. Such a clock tree architecture may be part of the same IC in which components 200 , 205 , and 210 reside or may be part of another IC.
In this example, a master clock driver 230 produces a common clock signal 232 that branches out to clock drivers 215 , 220 , and 225 . Since clock drivers 215 , 220 , and 225 derive respective component clock signals 218 , 222 , and 227 from common clock signal 232 , each of the component clock signals is a variably-delayed version of common clock signal 232 .
Since component clock signals 218 , 222 , and 227 originate from a common clock signal source, they have the same frequency. However, as component clock signals 218 , 222 , and 227 travel across respective paths 219 , 224 , 229 , and the sub-paths leading to individual bit registers, component clock signals 218 , 222 , and 227 traverse potentially different distances. Different distances result in differing propagation delays, which result in component clock signals that are potentially out of phase with each other as they are received at the respective components 200 , 205 , and 210 . Clock drivers 215 , 220 , and 225 are capable of varying the phase of component clock signals 218 , 222 , and 227 so that the phases of the component clock signals 218 , 222 , and 227 are synchronized upon arrival at the bit registers of components 200 , 205 , and 210 .
A reference clock signal 240 is used to correct the phases of component clock signals 218 , 222 , and 227 , so that they are in phase with each other at the physical locations of the byte-word registers 210 , 215 , and 220 . Reference clock signal 240 has the same frequency as clock signals 218 , 222 , and 227 . Reference clock signal 240 may be generated by an arbitrary clock source; however, it is contemplated that reference clock signal 240 may be provided by or derived from the same clock tree or clock architecture from which component clock signals 218 , 222 , and 227 are derived. In certain cases, one of clock signals 218 , 222 , and 227 may be branched and used as reference clock signal 240 . It is not necessary for reference clock signal 240 to have any particular phase relationship with the component clock signals 218 , 222 , and 227 , although its phase preferably remains constant over time as compared to the component clock signals.
The circuit of FIG. 2 has a reference feedback element 250 that receives component clock signal 218 from path 252 . Path 252 is a continuation of one of the sub-paths 219 A–H and originates from near register 200 . In this example, path 252 is connected to path 219 D. Reference clock signal 240 travels along path 254 to reference phase feedback element 250 . Reference phase feedback element 250 compares the phases of component clock signal 218 and reference clock signal 240 , and provides an adjustment signal 251 to clock driver 215 . Adjustment signal 251 represents an advance or delay value that allows component clock signal 218 to become in phase with reference clock signal 240 . An adjusted component clock signal 218 may then be used as a reference clock signal for other component clock signals. In other words, when the components are considered in sequence, the component clock signal to any particular component is matched in phase to the component clock signal of the immediately preceding component in the sequence.
Note that in certain embodiments, reference clock signal 240 may not be used. In this case, the component clock signals of the components are simply synchronized to that of the first component in the sequence.
In addition to reference phase feedback element 250 , the circuit includes phase feedback elements 255 and 260 corresponding to adjacent pairs of components. The phase feedback element corresponding to a particular pair of components receives the component clock signal from a register of each of the components of the particular pair. The component clock signal in each case is routed from a point physically near its corresponding register (of the corresponding component). The phase feedback element is responsive to the received component clock signals to adjust the phase of one of the component clock signals to match the phase of the other component clock signal. More particularly, each phase feedback element receives a first component clock signal from a particular register and a second component clock signal from an immediately subsequent register in sequence, and adjusts the second component clock signal to match the phase of the first component clock signal.
With specific reference to FIG. 2 , phase feedback element 255 receives component clock signal 218 from path 256 , and component clock signal 222 from path 257 . Path 256 is a continuation of one of the sub-paths 219 A–H, and path 257 is a continuation of one of the sub-paths 224 A–H. In this example, path 256 continues sub-path 219 H and path 257 continues sub-path 224 A. Sub-paths 219 H and 224 A may and are expected to differ in length. To assure that component clock signals 218 and 222 have the same phase at the respective registers, paths 256 and 257 should be equal in length and have the same or similar propagation delay characteristics. A factor determining propagation delay difference is the difference between the lengths of the paths. In a preferred embodiment, the difference between propagation delay of length of paths 256 and 257 is less than 15%.
Paths 256 and 257 couple their respective components to phase feedback element 255 . Phase feedback element 255 determines the phase difference between component clock signals 218 and 222 , and generates an adjustment signal 267 , which is provided to clock driver 220 in either analog or digital form (analog skew or digital skew values). Adjustment signal 267 is a measure of an advance or delay that allows component clock signal 222 to become in phase with component clock signal 218 . An adjusted clock signal 222 may then be used as a “reference clock” signal for other component clock signals.
In a similar manner, phase feedback element 260 receives component clock signal 222 from path 261 , and component clock signal 227 from path 262 . Path 261 is a continuation of one of the sub-paths 224 A–H, and path 262 is a continuation of one of the sub-paths 229 A–H. In this example, path 261 continues sub-path 224 H and path 262 continues sub-path 229 A. Sub-paths 224 H and 229 A may and are expected to differ in length. To assure that component clock signals 222 and 227 have the same phase at the respective registers, paths 261 and 262 should be equal in length and have the same propagation delay characteristics.
Paths 261 and 262 couple their respective components to phase feedback element 260 . In this example, phase feedback element 260 corresponds to the adjacent pair of components 200 and 205 . Phase feedback element 260 determines the phase difference between component clock signals 218 and 222 , and generates an adjustment signal 277 which is provided to clock driver 225 in either analog or digital form (analog skew or digital skew values). Adjustment signal 277 is a measure of an advance or delay that allows component clock signal 227 to become in phase with component clock signal 222 . Since component clock signal 222 has been adjusted to match the phase of component clock signal 218 , it follows that component clock signal 227 is adjusted to match the phase of component clock signal 218 .
Although this example describes synchronization of component clock signals from a left to right sequence beginning with a left most component, it is contemplated that synchronization may start with any component clock signal, including a component clock signal received at a middle component (byte-word register) or middle bit register.
FIG. 3 illustrates an exemplary embodiment of phase feedback element 255 . Phase feedback element 260 is similarly implemented. This implementation of feedback element 255 is particularly appropriate in circuits where components or registers have 10 or fewer bits.
Phase feedback element 250 includes a phase comparator 305 . Phase comparator 305 receives component clock signals from a pair of components; allowing the phase feedback element to adjust the phase of one of the component clock signals to match that of the other component clock signal. In particular examples, the phase comparator 305 receives a clock signal from a first bit register of a plurality of bit registers in a component and a clock signal from a last bit register of a plurality of bit registers in a second component. The clock signals from these bit registers may be routed through paths that have matched lengths. In this example, phase comparator 305 receives component clock signals 218 and 222 , and determines the phase difference between component clock signals 218 and 222 . Phase comparator 305 may include a phase converter that converts the phase difference to a phase offset value or digital skew time value 310 . Digital phase offset value or digital skew time value 310 may be stored in a clock register 315 . Based on digital phase offset value or digital skew time value 310 , clock register 315 instructs clock driver 220 to advance or delay transmission of component clock signal 222 . Digital phase offset value or digital skew time value 310 is used as adjustment value 267 of FIG. 2 .
Referring now to FIG. 4 , illustrated is an exemplary embodiment of a phase feedback element 255 using current sources. Phase feedback element 260 is similarly implemented. This implementation is particularly appropriate in circuits having more than 10 bits in each component or register.
In this embodiment, phase feedback element 255 has an integrator or capacitance 405 and current sources 415 and 420 . Current sources 415 and 420 are controlled by switches 425 and 430 , respectively. Current source 415 corresponds to component 200 and current source 420 corresponds to component 205 , where in this example components 200 and 205 are treated as a pair. Switches 425 and 430 are preferably implemented as transistors. Current sources 415 are connected through the respective switches 425 and 430 to charge and discharge capacitance 405 . Specifically, current source 415 is connected through and enabled by switch 425 to charge capacitance 405 when switch 425 is closed. Current source 420 is connected through and enabled by switch 430 to discharge capacitance 405 when switch 430 is closed. Current sources 415 and 420 preferably source equal currents, albeit in opposite directions. In other words, current sources 415 and 420 are matched current sources.
Switches 425 and 430 are selectively enabled or controlled by the component clock signals of the two adjacent components corresponding to phase feedback element 255 , in this case by component clock signals 218 and 222 . Switch 425 is closed when component clock signal 218 is logically true or high, and is open when component clock signal 218 is logically false or low. Switch 430 is closed when component clock signal 222 is logically true or high and is open when component clock signal 222 is logically false or low. If the component clock signals 218 and 222 are in phase, switches 425 and 430 close and open at the same times, and the net effect of the opposite current sources 415 and 420 is null—the capacitance 405 is neither charged nor discharged.
If, on the other hand, component clock signals 218 and 222 are out of phase, switches 425 and 430 do not close and open at the same times, and there is a net charging or discharging effect on capacitance 405 . Assuming a relatively large capacitance 405 , the voltage at the capacitance will increase or decrease, relative to ground, in accordance with any phase difference between the two component clock signals 218 and 222 . Thus, the voltage at capacitive node 435 represents a phase difference between component clock signals 218 and 222 . In the illustrated embodiment, phase feedback element 255 has an analog to digital (A/D) converter 440 that converts the analog skew or voltage value at capacitive node 435 to a digital skew time value 445 . Clock driver 220 advances or delays component clock signal 222 based on digital skew time value 445 . Clock driver 220 therefore is responsive to the voltage value at capacitive node 435 . In other embodiments, analog skew value 435 is passed directly on to clock driver 220 .
Although details of specific implementations and embodiments are described above, such details are intended to satisfy statutory disclosure obligations rather than to limit the scope of the following claims. Thus, the invention as defined by the claims is not limited to the specific features described above. Rather, the invention is claimed in any of its forms or modifications that fall within the proper scope of the appended claims, appropriately interpreted in accordance with the doctrine of equivalents. | A circuit and method for synchronized clocking of components such as registers. Registers are clocked by individual component clock signals having the same frequency but potentially different phases due to differing propagation delays. Separate component clock signals are received by registers are brought into phase by evaluating the phases of the component clock signals at the registers, and synchronizing the component clock signal of each register to that of the previous register in a sequence. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. application Ser. No. 12/900,864, filed Oct. 8, 2010, to be issued as U.S. Pat. No. 8,245,556, which is a continuation of U.S. application Ser. No. 12/564,807, filed Sep. 22, 2009, now abandoned, which is a continuation of U.S. application Ser. No. 12/114,416, filed May 2, 2008, now abandoned, which is a continuation of U.S. application Ser. No. 11/314,630, filed Dec. 21, 2005, now U.S. Pat. No. 7,398,665, which is a continuation of U.S. application Ser. No. 10/182,643, filed Sep. 30, 2002, now U.S. Pat. No. 7,003,999, all of which are related to PCT Application No. PCT/GB01/00526, filed Feb. 9, 2001, G.B. Application No. 0003033.8, filed Feb. 10, 2000, and G.B. Application No. 0026325.1, filed Oct. 27, 2000, all of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to deformation of generally thin walled bodies, particularly thin walled containers or tube-form bodies which may be of cylindrical or other form.
The invention is particularly suited to embossing of thin walled metallic bodies (particularly aluminium containers) by embossing or the like. More specifically the invention may be used in processes such as registered embossing of thin walled bodies, particularly registered embossing of containers having pre-applied (pre-printed) surface decoration.
2. State of the Art
It is known to be desirable to deform by embossing or the like the external cylindrical walls of metallic containers such as aluminium containers. In particular attempts have been made to emboss the walls of containers at predetermined locations to complement a printed design on the external surface of such a container. In such techniques it is important to coordinate the embossing tooling with the preprinted design on the container wall. Prior art proposals disclose the use of a scanning system to identify the position of the container relative to a datum position and reorientation of the container to conform to the datum position.
Prior art embossing techniques and apparatus are disclosed in, for example, WO-A-9803280, WO-A-9803279, WO-A-9721505 and WO-A-9515227. Commonly in such techniques the container is loaded into an internal tool which acts to support the container and also co-operate with an external tool in order to effect embossing. Such systems have disadvantages, as will become apparent from the following.
SUMMARY OF THE INVENTION
An improved technique has now been devised.
According to a first aspect, the present invention provides a method of deforming a thin walled body, the method comprising:
i) holding the body gripped securely at a holding station; ii) engaging tooling to deform the wall of the body at a predetermined wall zone, the tooling being provided at a tooling station which is adjacent the holding station during deformation;
wherein the predetermined wall zone is co-aligned with the tooling by means of co-ordinated movement of the tooling prior to deforming engagement with the wall of the body.
According to a further aspect, the invention provides apparatus for deforming a thin walled body, the apparatus including:
i) a holding station for holding the body gripped securely; ii) a tooling station including tooling to deform the body at a predetermined wall zone of the body, the tooling station being positioned at a location adjacent the holding station during deformation; iii) determination means for determining the orientation of the cylindrical body relative to a reference (datum) situation; iv) means for co-ordinated movement to reconfigure the tooling to co-align with the predetermined wall zone prior to deforming engagement of the tooling with the body.
Co-alignment of the tooling and the wall zone of the body is typically required in order to ensure that embossing deformation accurately lines up with pre-printed decoration on the body. In the technique of the present invention, the body is not passed from being supported at a holding station to being supported by the tooling but, by contrast, remains supported at the holding station throughout the deforming process.
Re-configuration of the tooling avoids the requirement for the or each holding or clamping station to have the facility to re-orientate a respective body.
The technique is particularly suited to embossing containers having wall thicknesses(t) in the range 0.25 mm to 0.8 mm (particularly in the range 0.35 mm to 0.6 mm). The technique is applicable to containers of aluminium including alloys, steel, tinplate steel, internally polymer laminated or lacquered metallic containers, or containers of other materials. Typically the containers will be cylindrical and the deformed embossed zone will be co-ordinated with a pre-printed/pre-applied design on the circumferential walls. Typical diameters of containers with which the invention is concerned will be in the range 35 mm to 74 mm although containers of diameters outside this range are also susceptible to the invention.
Beneficially the tooling will be re-configurable by rotation of the tooling about a rotational tooling axis to co-align with the predetermined wall zone.
The determination means preferably dictates the operation of the tooling rotation means to move/rotate the tooling to the datum position. The determination means preferably determines a shortest rotational path (clockwise or anti-clockwise) to the datum position and triggers rotation of the tooling in the appropriate sense.
The length of time available to perform the steps of re-orientation and deformation is relatively short for typical production runs which may process bodies at speeds of up to 200 containers per minute. Re-orientation of the tooling (particularly by rotation of the tooling about an axis) enables the desired re-orientation to be achieved in the limited time available. The facility to re-orientate clockwise or anti-clockwise following sensing of the container orientation and shortest route to the datum position is particularly advantageous in achieving the process duration times required.
According to a further aspect, the invention provides apparatus for use in deforming a wall zone of a thin walled container, the apparatus comprising internal tooling to be positioned internally of the container, and external tooling to be positioned externally of the container, the external and internal tooling co-operating in a forming operation to deform the wall zone of the container, the internal tooling being moveable toward and away from the centreline or axis of the container between a retraction/insertion tooling configuration in which the internal tool can be inserted or retracted from the interior of the container, to a wall engaging configuration for effecting deforming of the wall zone.
Correspondingly a further aspect of the invention provides a method of deforming a thin walled container, the method comprising:
inserting internal tooling into the interior of the container, the internal tooling being in a first, insertion configuration for insertion; moving the tooling to a second, (preferably expanded) position or configuration closely adjacent or engaging the internal container wall so as to facilitate deformation of a wall zone of the container; returning the tooling from the second position toward the first tooling configuration thereby to permit retraction of the internal tooling from the container.
Because the internal tooling is movable toward and away from the container wall (preferably toward and away from the axis/centreline of the container), embossed relief features of greater depth/height can be produced. This is because prior art techniques generally use an internal tool which also serves to hold the container during deformation (embossing) and therefore typically only slight clearance between the internal tool diameter and the internal diameter of the container has been the standard practice.
In accordance with the broadest aspect of the invention, the relief pattern for embossing may be carried on cam portions of internal and/or external tools, the eccentric rotation causing the cam portions to matingly emboss the relevant portion of the container wall.
A particular benefit of the present invention is that it enables a greater area of the container wall (greater dimension in the circumferential direction) to be embossed than is possible with prior art techniques where the emboss design would need to be present on a smaller area of the tool. Rotating/cam-form tooling, for example, has the disadvantage of having only a small potential area for design embossing.
Re-configurable, particularly collapsible/expandable internal tooling provides that greater depth/height embossing formations can be provided, the internal tooling being collapsed from engagement with the embossed zone and subsequently retracted axially from the interior of the container.
Embossed feature depth/height dimensions in the range 0.5 mm and above (even 0.6 mm to 1.2 mm and above) are possible which have not been achievable with prior art techniques.
According to a further aspect, the invention provides apparatus for use in deforming the cylindrical wall of a thin walled cylindrical container, the apparatus comprising an internal tooling part to be positioned internally of the container, and an external tooling part to be positioned externally of the container, the external and internal tools co-operating in a forming operation to deform a portion of the cylindrical container wall therebetween; wherein tooling actuation means is provided such that:
(a) the external and internal tools are movable independently of one another to deform the container wall; and/or (b) deforming force applied to the external and internal tools is positioned at force action zones spaced at opposed sides of the zone of the container wall to be deformed.
As described above, the technique of the invention is particularly suited to embossing containers having relatively thick wall thickness dimensions (for example in the range 0.35 mm to 0.8 mm). Such thick walled cans are suitable for containing pressurised aerosol consumable products stored at relatively high pressures. Prior art techniques have not been found to be suitable to successfully emboss such thicker containers, nor to produce the aesthetically pleasing larger dimensioned emboss features as is capable with the present invention (typically in the range 0.3 mm to 1.2 mm depth/height).
The technique has also made it possible to emboss containers (such as seamless monobloc aluminium containers) provided with protective/anti-corrosive internal coatings or layers without damage to the internal coating or layer.
According to a further aspect, the invention therefore provides an embossed container or tube-form product, the product comprising a product side-wall having a thickness substantially in the range 0.25 mm to 0.8 mm and a registered embossed wall zone, the embossed deformation having an emboss form depth/height dimension substantially in the range 0.3 mm to 1.2 mm or above.
Preferred features of the invention are defined in the appended claims and readily apparent from the following description. The various features identified and defined as separate aspects herein are also mutually beneficial and may be beneficially included in combination with one another.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described in a specific embodiment, by way of example only, and with reference to the accompanying drawings, in which:
FIG. 1 is a flow diagram of a process according to the invention;
FIG. 2 is a view of a container to be operated upon in accordance with the invention;
FIG. 3 is a side view of the container of FIG. 2 in a finish formed state;
FIG. 4 is a 360 degree view of a positional code in accordance with the invention;
FIG. 5 is a schematic side view of apparatus in accordance with the invention;
FIGS. 6 and 7 are half plan views of apparatus components of FIG. 5 ;
FIGS. 8 , 9 and 10 correspond to the views of FIGS. 5 , 6 and 7 with components in a different operational orientation;
FIG. 11 is a schematic close up sectional view of the apparatus of the preceding figures in a first stage of the forming process;
FIG. 11 a is a detail view of the forming tools and the container wall in the stage of operation of FIG. 11 ;
FIGS. 12 , 12 a to 16 , 16 a correspond to the views of FIGS. 11 and 11 a ; and
FIG. 17 is a schematic sectional view of an embossed zone of a container wall in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings the apparatus and technique is directed to plastically deforming (embossing or debossing) the circumferential wall of an aluminium container 1 at a predetermined position relative to a preprinted decorative design on the external container wall. Where the embossing deformation is intended to coincide with the printed decorative design, this is referred to in the art as Registered Embossing.
In the embodiment shown in the drawings, a design 50 comprising a series of three axially spaced arc grooves is to be embossed at 180 degree opposed locations on the container wall (see FIG. 16 a ). For aesthetic reasons it is important that the location at which the design 50 is embossed is coordinated with the printed design on the container 1 wall. Coordination of the container 1 axial orientation with the tooling to effect deformation is therefore crucial.
Referring to FIGS. 5 to 7 the forming apparatus 2 comprises a vertically orientated rotary table 3 operated to rotate (about a horizontal axis) in an indexed fashion to successively rotationally advanced locations. Spaced around the periphery of table 3 are a series of container holding stations comprising clamping chucks 4 . Containers are delivered in sequence to the table in random axial orientations, each being received in a respective chuck 4 , securely clamped about the container base 5 .
A vertically orientated forming table 6 faces the rotary table 3 and carries a series of deformation tools at spaced tooling stations 7 . Following successive rotary index movements of rotary table 3 , table 6 is advanced from a retracted position ( FIG. 5 ) to an advanced position ( FIG. 8 ). In moving to the advanced position the respective tools at tooling stations 7 perform forming operations on the container circumferential walls proximate their respective open ends 8 . Successive tooling stations 7 perform successive degrees of deformation in the process. This process is well known and used in the prior art and is frequently known as necking. Necked designs of various neck/shoulder profiles such as that shown in FIG. 3 can be produced.
Necking apparatus typically operates at speeds of up to 200 containers per minute giving a typical working time duration at each forming station in the order of 0.3 seconds. In this time, it is required that the tooling table 6 moves axially to the advanced position, the tooling at a respective station contacts a respective container and deforms one stage in the necking process, and the tooling table 6 is retracted.
In accordance with the invention, in addition to the necking/shoulder-forming tooling at stations 7 , the tooling table carries embossing toling 10 at an embossing station 9 . The embossing tooling (shown most clearly in FIGS. 11 to 16 ) comprises inner forming tool parts 11 a , 11 b of respective arms 11 of an expandible internal tool mandrel 15 . Tool parts 11 a , 11 b carry respective female embossing formations 12 .
The embossing tooling 10 also includes a respective outer tool arrangement including respective arms 13 carrying tooling parts 13 a , 13 b having complementary male embossing formations 14 . In moving to the table 7 advanced position the respective internal tool parts 11 a , 11 b are positioned internally of the container spaced adjacently the container 1 wall; the respective external tool parts 13 a , 13 b are positioned externally of the container spaced adjacently the container 1 wall.
The internal mandrel 15 is expandible to move the tooling parts 11 a , 11 b to a relatively spaced apart position in which they abut the internal wall of the container 1 (see FIG. 12 ) from the collapsed position shown in FIG. 11 (tools 11 a , 11 b spaced from the internal wall of the container 1 ). An elongate actuator rod 16 is movable in a longitudinal direction to effect expansion and contraction of the mandrel 15 and consequent movement apart and toward one another of the tool parts 11 a , 11 b . A the cam head portion 17 of the actuator rod 16 effects expansion of the mandrel 15 as the actuator rod 16 moves in the direction of arrow A. The cam head portion 17 acts against sloping wedge surfaces 65 of the tool parts 11 a , 11 b to cause expansion (moving apart) of the tool parts 11 a , 11 b . The resilience of arms 11 biases the mandrel 15 to the closed position as the rod 16 moves in the direction of arrow B.
Outer tool arms 13 are movable toward and away from one another under the influence of closing cam arms 20 of actuator 21 acting on a cam shoulder 13 c of respective arms 13 . Movement of actuator 21 in the direction of arrow D causes the external tooling parts 13 a to be drawn toward one another. Movement of actuator 21 in the direction of arrow E causes the external tool parts 13 a to relatively separate. Arms 13 and 11 of the outer tool arrangement and the inner mandrel are retained by cam support ring 22 . The arms 11 , 13 resiliently flex relative to the support ring 22 as the actuators 21 , 16 operate.
As an alternative to the cam/wedge actuation arrangement, other actuators may be used such as hydraulic/pneumatic, electromagnetic (e.g. solenoid actuators) electrical (servo/stepping) motors.
The operation of the embossing tooling is such that the internal mandrel 15 is operable to expand and contract independently of the operation of the external tool parts 13 a.
The internal mandrel 15 (comprising arms 11 ) and the external tooling (comprising arms 13 ) connected at cam support ring 22 , are rotatable relative to table 6 , in unison about the axis of mandrel 15 . Bearings 25 are provided for this purpose. A servo-motor (or stepping motor) 26 is connected via appropriate gearing to effect controlled rotation of the tooling 10 relative to table 6 in a manner that will be explained in detail later.
With the tooling 10 in the position shown in FIG. 11 , the mandrel 15 is expanded by moving actuator rod 16 in the direction of arrow A causing the internal tooling parts 11 a to lie against the internal circumferential wall of cylinder 1 , adopting the configuration shown in FIGS. 12 , 12 a . Next actuator 21 moves in the direction of arrow D causing cam arms 20 to act on cam shoulder 13 c and flexing arms 13 toward one another. In so doing the external tooling parts 13 a engage the cylindrical wall of container 1 , projections 14 deforming the material of the container 1 wall into respective complementary receiving formations 12 on the internal tooling parts 11 a.
The deforming tooling parts 11 a , 13 a , can be hard, tool steel components or formed of other materials. In certain embodiments one or other of the tooling parts may comprise a conformable material such as plastics, polymeric material or the like.
An important feature is that the internal tooling parts 11 a support the non deforming parts of the container wall during deformation to form the embossed pattern 50 . At this stage in the procedure, the situation is as shown in FIGS. 13 , 13 a . The configuration and arrangement of the cam arms 20 , cam shoulders 13 c of the external embossing tooling and the sloping (or wedge) cam surface of internal tooling parts 11 a (cooperating with the cam head 17 of rod 16 ) provide that the embossing force characteristics of the arrangement can be controlled to ensure even embossing over the entire area of the embossed pattern 50 . The external cam force action on the outer tool parts 13 a is rearward of the embossing formations 14 ; the internal cam force action on the inner tool parts 11 a is forward of the embossing formations 12 . The forces balance out to provide a final embossed pattern of consistent depth formations over the entire zone of the embossed pattern 50 .
Next actuator 21 returns to its start position (arrow E) permitting the arms 13 of the external toling to flex outwardly to their normal position. In so doing tooling parts 13 a disengage from embossing engagement with the container 1 external surface. At this stage in the procedure, the situation is as shown in FIGS. 14 , 14 a.
The next stage in the procedure is for the internal mandrel to collapse moving tooling parts 11 a out of abutment with the internal wall of the cylinder 1 . At this stage in the procedure, the situation is as shown in FIGS. 15 , 15 a.
Finally the tooling table 6 is retracted away from the rotatable table 3 withdrawing the tooling 10 from the container. At this stage in the procedure, the situation is as shown in FIGS. 16 , 16 a.
In the embodiment described, the movement of the tools to effect embossing is translational only. It is however feasible to utilise rotational external/internal embossing tooling as is known generally in the prior art.
The rotary table is then indexed rotationally moving the embossed container to adjacent with the next tooling station 7 , and bringing a fresh container into alignment with the embossing tooling 10 at station 9 .
The embossing stages described correspond to stages 106 to 112 in the flow diagram of FIG. 1 .
Prior to the approachment of the embossing tooling 10 to a container 1 clamped at table 3 ( FIG. 11 and stage 106 of FIG. 1 ) it is important that the container 1 and tooling 10 are accurately rotationally oriented to ensure that the embossed pattern 50 is accurately positioned with respect to the printed design on the exterior of the container.
According to the present invention this is conveniently achieved by reviewing the position of a respective container 1 whilst already securely clamped in a chuck 4 of the rotary table 3 , and rotationally reorientating the embossing tooling 10 to the required position. This technique is particularly convenient and advantageous because a rotational drive of one arrangement (the embossing tooling 10 ) only is required. Chucks 4 can be fixed relative to the table 3 and receive containers in random axial rotational orientations. Moving parts for the apparatus are therefore minimised in number, and reliability of the apparatus is optimised.
The open ends 8 of undeformed containers 1 approaching the apparatus 2 have margins 30 printed with a coded marking band 31 comprising a series of spaced code blocks or strings 32 (shown most clearly in FIG. 4 ). Each code block/string 32 comprises a column of six data point zones coloured dark or light according to a predetermined sequence.
With the container 1 clamped in random orientation in a respective chuck 4 a charge coupled device (CCD) camera 60 views a portion of the code in its field of view. The data corresponding to the viewed code is compared with the data stored in a memory (of controller 70 ) for the coded band and the position of the can relative to a datum position is ascertained. The degree of rotational realignment required for the embossing tooling 10 to conform to the datum for the respective container is stored in the memory of main apparatus controller 70 . When the respective container 10 is indexed to face the embossing tooling 10 the controller instigates rotational repositioning of the tooling 10 to ensure that embossing occurs at the correct zone on the circumferential surface of the container 1 . The controller 70 when assessing the angular position of the tooling relative to the angular position to be embossed on the container utilises a decision making routine to decide whether clockwise or counterclockwise rotation of the tooling 10 provides the shortest route to the datum position, and initiates the required sense of rotation of servo-motor 26 accordingly. This is an important feature of the system in enabling rotation of the tooling to be effected in a short enough time-frame to be accommodated within the indexing interval of the rotating table 3 .
The coding block 32 system is in effect a binary code and provides that the CCD camera device can accurately and clearly read the code and determine the position of the container relative to the tooling 10 datum by viewing a small proportion of the code only (for example two adjacent blocks 32 can have a large number of unique coded configurations). The coding blocks 32 are made up of vertical data point strings (perpendicular to the direction of extent of the coding band 31 ) in each of which there are dark and light data point zones (squares). Each vertical block 32 contains six data point zones. This arrangement has benefits over a conventional bar code arrangement, particularly in an industrial environment where there may be variation in light intensity, mechanical vibrations and like.
As can be seen in FIG. 4 , because the tooling 10 in the exemplary embodiment is arranged to emboss the same pattern at 180 degree spacing, the coding band 31 includes a coding block pattern that repeats over 180 degree spans.
The position determination system and control of rotation of the tooling 10 are represented in blocks 102 to 105 of the flow diagram of FIG. 1 .
The coding band 31 can be conveniently printed contemporaneously with the printing of the design on the exterior of the container. Forming of the neck to produce, for example a valve seat 39 ( FIG. 3 ) obscures the coding band from view in the finished product.
As an alternative to the optical, panoramic visual sensing of the coding band 31 , a less preferred technique could be to use an alternative visual mark, or a physical mark (e.g. a deformation in the container wall) to be physically sensed.
Referring to FIG. 17 , the technique is particularly switched to forming aesthetically pleasing embossed formations 50 of a greater height/depth dimension(d) (typically in the range 0.3 mm to 1.2 mm) than has been possible with prior art techniques. Additionally, this is possible with containers of greater wall thickness(t) than have been successfully embossed in the past. Prior art techniques have been successful in embossing aluminium material containers of wall thickness 0.075 mm to 0.15 mm. The present technique is capable of embossing aluminium containers of wall thickness above 0.15 mm, for example even in the range 0.25 mm to 0.8 mm. The technique is therefore capable of producing embossed containers for pressurised aerosol dispensed consumer products which has not been possible with prior art techniques. Embossed monobloc seamless aluminium material containers are particularly preferred for such pressurised aerosol dispensed products (typically having a delicate internal anti-corrosive coating or layer protecting the container material from the consumer product). The present invention enables such containers to be embossed (particularly registered embossed).
As an alternative to the technique described above in which the embossing tooling is rotated to conform to the datum situation, immediately prior to the container being placed in the chuck 4 and secured, the position of the container may be optically viewed to determine its orientation relative to the datum situation. If the orientation of the container 1 differs from the desired datum pre-set situation programmed into the system, then the container is rotated automatically about its longitudinal axis to bring the container 1 into the pre-set datum position. With the container in the required datum position, the container is inserted automatically into the clamp 4 of the holding station, and clamped securely. In this way the relative circumferential position of the printed design on the container wall, and the position of the tooling is co-ordinated. There is, thereafter, no requirement to adjust the relative position of the container and tooling. This technique is however less preferred than the technique primarily described herein in which the embossing tooling 10 is re-orientated.
The invention has primarily been described with respect to embossing aluminium containers of relatively thin wall thicknesses (typically substantially in the range 0.25 mm to 0.8 mm. It will however be readily apparent to those skilled in the art that the essence of the invention will be applicable to embossing thin walled containers/bodies of other material such as steel, steel tinplate, lacquered plasticised metallic container materials an other non-ferrous or non-metallic materials. | A thin walled body is deformed in a process in which the body is gripped securely in a holding station and, while gripped in the holding station, tooling engages to deform the peripheral wall of the body at a predetermined wall zone. The tooling is provided at a tooling station which is adjacent the holding station during deformation. The predetermined wall zone is co-aligned with the tooling by rotation of the body about an axis prior to securing at the holding station. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present continuation application claims the benefit of priority under 35 U.S.C. 120 to application Ser. No. 11/854,204, filed on Sep. 12, 2007, which is a continuation of U.S. application Ser. No. 11/250,187 filed on Oct. 13, 2005, and claims the benefit of priority under 35 U.S.C. 119 from Norwegian Patent Application No. 20051721 filed on Apr. 7, 2005 and Norwegian Patent Application No. 20044349 filed on Oct. 13, 2004. The contents of each of these documents are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is related to decoding of block wise coded video pictures.
[0004] 2. Description of the Related Art
[0005] Transmission of moving pictures in real-time is employed in several applications like e.g. video conferencing, net meetings, TV broadcasting and video telephony.
[0006] However, representing moving pictures requires bulk information as digital video typically is described by representing each pixel in a picture with 8 bits (1 Byte) Such uncompressed video data results in large bit volumes, and can not be transferred over conventional communication networks and transmission lines in real time due to limited bandwidth.
[0007] Thus, enabling real time video transmission requires a large extent of data compression. Data compression may, however, compromise with picture quality. Therefore, great efforts have been made to develop compression techniques allowing real time transmission of high quality video over bandwidth limited data connections.
[0008] In video compression systems, the main goal is to represent the video information with as little capacity as possible. Capacity is defined with bits, either as a constant value or as bits/time unit. In both cases, the main goal is to reduce the number of bits.
[0009] The most common video coding method is described in the MPEG* and H.26* standards. The video data undergo four main processes before transmission, namely prediction, transformation, quantization and entropy coding.
[0010] The prediction process significantly reduces the amount of bits required for each picture in a video sequence to be transferred. It takes advantage of the similarity of parts of the sequence with other parts of the sequence. Since the predictor part is known to both encoder and decoder, only the difference has to be transferred. This difference typically requires much less capacity for its representation. The prediction is mainly based on vectors representing movements. The prediction process is typically performed on square block sizes (e.g. 16×16 pixels). Note that in some cases, predictions of pixels based on the adjacent pixels in the same picture rather than pixels of preceding pictures are used. This is referred to as intra prediction, as opposed to inter prediction. Consequently, when the pixels in a block are coded by means of intra prediction, the block is said to be an intra coded.
[0011] The residual represented as a block of data (e.g. 4×4 pixels) still contains internal correlation. A well-known method of taking advantage of this is to perform a two dimensional block transform. In H.263 an 8×8 Discrete Cosine Transform (DCT) is used, whereas H.264 uses a 4×4 integer type transform. This transforms 4×4 pixels into 4×4 transform coefficients and they can usually be represented by fewer bits than the pixel representation. Transform of a 4×4 array of pixels with internal correlation will probability result in a 4×4 block of transform coefficients with much fewer non-zero values than the original 4×4 pixel block.
[0012] Direct representation of the transform coefficients is still too costly for many applications. A quantization process is carried out for a further reduction of the data representation. Hence the transform coefficients undergo quantization. A simple version of quantisation is to divide parameter values by a number—resulting in a smaller number that may be represented by fewer bits. It should be mentioned that this quantization process has as a result that the reconstructed video sequence is somewhat different from the uncompressed sequence. This phenomenon is referred to as “lossy coding”. The outcome from the quantisation part is referred to as quantized transform coefficients.
[0013] Entropy coding implies lossless representation of different types of parameters such as overhead data or system description, prediction data (typically motion vectors), and quantized transform coefficients from the quantisation process. The latter typically represent the largest bit consumption.
[0014] The coding is performed on block wise parts of the video picture. A macro block consists of several sub blocks for luminance (luma) as well as for chrominance (chroma).
[0015] The present video standards H.261, H.262, H.263, H.264/AVC, MPEG1, MPEG2, MPEG4 all use blockbased coding. This means blockbased prediction from previously encoded and decoded pictures as well as blockbased coding of residual signal.
[0016] Blockbased coding/decoding has proven to be very efficient. However, one of the drawbacks is that the reconstructed image may visible artifacts corresponding to the blocks used for prediction and residual signal coding. This phenomenon is usually referred to as blocking or blocking artifacts.
[0017] One way of reducing the artifacts known in prior art is to add a post processing filter between the decoder an the display unit at the receiver. An example of which is shown in FIG. 1 . The filtering operation takes place right before the presentation of the picture. It is therefore a pure decoder/display issue that is unrelated to what the encoder does. In alternative solution, as shown in FIG. 2 , the filter is integrated in the coding loop. This is a more powerful approach, and is the preferred solution in the specification ITU-T Rec. H.264|ISO/IEC 14496-10 AVC, even if it implies that both encoder and decoder need to do the same operations to avoid drift in the reconstructed pictures. However, the integrated solution is a quite processor consuming i.a. as it requires a test procedure for each pixel line crossing the block edges to be smoothed.
SUMMARY OF THE INVENTION
[0018] The present invention discloses a method in video decoding for reducing blocking artifacts between a first and a second block in a block wise coded video picture by performing a test on pixel lines crossing a boundary and/or an extension of the boundary between the first and the second block and executing a de-blocking filter operation on boundary neighboring pixels if the test indicates artifacts, wherein the method further includes performing the test on a subset of the pixel lines only, and if the test indicates artifacts, executing a de-blocking filter operation on the boundary neighboring pixels in each of the pixel lines crossing the boundary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In order to make the invention more readily understandable; the discussion that follows will refer to the accompanying drawings and tables.
[0020] FIG. 1 is a block scheme illustrating a decoder with a post-processing de-blocking filter,
[0021] FIG. 2 is a block scheme illustrating a decoder with an integrated de-blocking filter,
[0022] FIG. 3 illustrates a boundary between two blocks and lines of adjacent pixel positions crossing the boundary,
[0023] FIG. 4 shows a look-up table from the H.264/AVC specification for threshold values
[0024] FIG. 5 shows a look-up table from the H.264/AVC specification for clipping values.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The present invention is an improvement of prior art method for removal of blocking and quantization noise. As already mentioned, this method is described in the specification ITU-T Rec. H.264|ISO/IEC 14496-10 AVC, the basics of which are described in the following.
[0026] In H.264/AVC an adaptive deblocking filter is applied in the coding loop. This means that further prediction is performed on filtered images. The filter is designed to remove as much as possible of the blocking and quantization noise and still maintain as much of the image content as possible. It is often a challenge to separate quantization noise and picture content. This is why the filter is highly content adaptive and therefore complex concerning computational operations.
[0027] In FIG. 3 , an edge between two picture blocks is shown. The letters c and d denotes two adjacent pixel positions on each side of the edge, and the other letters denotes the 6 horizontal pixel positions closest to the two first-mentioned pixels. According to H.264/AVC, pixels b c d e may be modified based on the value of each of the pixels and on the characterization of the edge itself. This modification is for equalizing the above-mentioned artifacts. The modification is therefore carried out only when artifacts are likely to occur.
[0028] Similar filter operations are performed on all the lines a, b, c, d, e, f. In the following description, the letters will be used without the numbering 0-7.
[0029] According to H.264, a strength value (Str) is defined for the edge. This strength value reflects whether artifacts are likely to occur between two blocks and depends on one or more of the following situations are detected:
a) If any of the two blocks on each side of the boundary is intra coded, i.e. coded based on already coded blocks in present picture. b) If any of the two blocks on each side of the boundary includes nonzero transform coefficients c) If the size of motion vectors used to predict the blocks on each side of the boundary exceeds a certain threshold.
[0033] Furthermore, to each 4×4 block a Quantization Parameter (QP) is assigned. The QP representing the edge is the maximum value of the QPs representing the 2 blocks.
[0034] Several QP dependant threshold parameters are used:
[0035] α(QP)
[0036] β(QP)
[0037] γ(QP, Str)
[0038] α, β and γ are found in the look-up tables shown in FIG. 4 . Table 1 is the look-up table for determining α, β and table 2 is the look-up table for determining γ, which is a clipping value. Here, indexA and indexB denotes QP, and bS=1, 2, 3 corresponds to criteria c, b, a, respectively, which are listed above. Consequently, the deciding criteria a, b, c, also state the boundary characteristics.
[0039] Based on these values, a main test is performed determining whether de-blocking filtering is to be carried out or not.
[0040] Filtering is performed only if:
[0000] | c−d |<α( QP ) and |b−c |<β( QP ) and |d−e |<β( QP )
[0041] If the above statement is true, then a delta is calculated:
[0000] Δ=( b− 4 c+ 4 d−e )/8
[0042] This delta value is then clipped within the range (=γ,γ) As an example of clipping, if the quantization value is 32 and the characteristic of the boundary comply with criterion b, which corresponds to bS=2, the table indicates that γ is 2. This implies that delta should be clipped within the interval {−2,2}. I.e. when delta is greater than 2, delta is assigned the value 2, when delta is less than −2, delta is assigned the value −2, and when delta lies is within {−2,2}, delta remains unchanged.
[0043] Delta is then used to calculate modified values:
[0000]
c′=c+Δ
[0000]
d′=d−Δ
[0044] An additional test is performed to decide if b also is to be corrected:
[0000] | a−c |<β( QP )
[0045] If this is true, then a value δ is calculated:
[0000] δ=(2 a− 4 b+c+d )/2
[0046] The value is then further clipped the value to the range (−γ′,γ′), wherein γ′ is a slight modification of γ. A modification of b is then calculated by means of δ:
[0000]
b′=b+δ
[0047] The test and calculation is similar for e:
[0000] | c−f |<β( QP ):
[0048] If this is true another value δ is calculated:
[0000] δ=(2 f− 4 e+c+d )/2
[0049] The value is then further clipped to the range (−γ′,γ′). A modification of e is then calculated by means of δ:
[0000]
e′=e+δ
[0050] The present invention is based on the standardized method described above, but discloses a simplification resulting in a reduction in complexity without compromising too much with the qualitative result of the de-blocking operation.
[0051] Two embodiments of the invention will now described by an illustrative example.
[0052] The main difference compared to prior art, is that the decision test for filtering/no-filtering preformed on one or a subset of lines crossing the a boundary between two macro blocks applies to all the lines crossing the same boundary. If more than one “decision line” is involved in the decision test, as will follow from the description bellow, when considering the criterions a) b) c) above, not only two, but four blocks must be taken into account. The “decision lines” will cross two different boundaries, and hence involving four blocks.
[0053] As a first embodiment of the present invention, the second line in the FIG. 4 is selected as the “decision line” for the four lines 0 - 3 crossing the boundary.
[0054] Then, filtering of all 4 edge lines are performed if:
[0000] d =(| a 1−2 b 1 +c 1 |+|d 1−2 e 1 +f 1|)<β( QP )
[0055] Otherwise no filtering is performed.
[0056] As opposed to prior art, the test for one line applies for all the lines crossing the block boundary. Thus, the value β is not necessarily determined in the same way as the β earlier described herein. E.g. other look-up tables than those depicted in FIGS. 4 and 5 may be used to determine β.
[0057] In a second embodiment of the present invention, the third and the sixth line of in FIG. 4 in combination are used as the “decision lines” for all the eight lines 0 - 7 crossing the boundary.
[0058] Then, filtering of all 8 edge lines are performed if:
[0000] d ′=(1 a 2−2 b 2 +c 2 |+|d 2−2 e 2 +f2 |+|a 5−2 b 5 +c 5 |+|d 5−2 e 5 +f 5|)<β′( QP )
[0059] Otherwise no filtering is performed. β′ may also be determined in still a another way than in prior art. A typical relation to β of the first embodiment would be β′=2 β.
[0060] Further, if the above tests on the “decision line” is true, a separate calculation is performed for each of the line for deriving delta and a corresponding corrected pixel values.
[0061] This can generally be expressed as in the following, using the same notation as for the description of prior art:
[0000] Δ=( a−b− 2 c+ 2 d+e−f )/4
[0062] Alternatively, for accommodating the calculation to the state of the art processor commonly used in codecs for videoconferencing, expression above could be transformed to:
[0000]
Δ
=
d
+
a
+
e
2
2
-
c
+
b
+
f
2
2
[0063] The delta value is clipped the value to the value range (−γ,γ)
[0000] b′=b+Δ/ 2
[0000]
c′=c+Δ
[0000]
d′=d−Δ
[0000] e′=e−Δ/ 2
[0064] Simulations comparing the prior art H.264 filter and a filter according to the present invention has shown a decreased requirement for computational resources of about 50%, with practically the same subjective image quality.
[0065] The description herein has been related to filtering of block artifacts in the horizontal direction, i.e. filtering pixels on both sides of vertical block boundaries. However, the present invention is directly applicable to filtering of block artifacts in vertical direction. This implies a 90° rotation of the pixels notation in FIG. 3 . | The invention is related to decoding of block wise coded video pictures. The determination of using de-blocking filtering between coded blocks is based on alternative characteristics compared to the characteristics used in H.264/AVC. | 7 |
CLAIM OF PRIORITY AND RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation of and claims the benefit of priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 12/441,336, filed on Mar. 13, 2009, entitled “METHOD AND APPARATUS FOR WRAPPING TRAIN WITH ADVERTISEMENT INCLUDING ELECTROLUMINESCENT LIGHTING,” which is a U.S. National Stage Filing under 35 U.S.C. 371 from International Patent Application Serial No. PCT/US2007/019936, filed Sep. 13, 2007, and published on Mar. 20, 2008, as WO 2008/033470, which claims priority benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application Ser. No. 60/825,552, filed Sep. 13, 2006, entitled “METHOD AND APPARATUS FOR WRAPPING TRAIN WITH ADVERTISEMENT INCLUDING ELECTROLUMINESCENT LIGHTING”; which applications and publication are incorporated herein by reference in their entirety and made a part hereof.
TECHNICAL FIELD
[0002] The present invention relates to method and apparatus for wrapping a vehicle with a sheet of material carrying an advertisement, such as one or more images and/or text for the advertisement, wherein there are provided electroluminescent portions of the advertisement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a view of an apparatus according to example embodiments of the invention.
[0004] FIG. 2A is a schematic view of an apparatus according to example embodiments of the invention.
[0005] FIG. 2B is a cross sectional taken generally along line 2 B- 2 B of FIG. 2A .
[0006] FIG. 3 is a partial view of an apparatus according to example embodiments of the invention
[0007] FIG. 4 is a schematic according to example embodiments of the invention
DETAILED DESCRIPTION
[0008] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, electrical changes, etc. may be made without departing from the scope of the present invention.
[0009] Referring now to FIGS. 1 , 2 A and 2 B there is illustrated a train 100 “wrapped” with advertising indicia 110 carried on a film 120 . In the instant example, the advertising indicia 110 is for a camera, and depicts a climbing wall together with the slogan “LIVE THE ACTIVE LIFE” 130 a , the manufacturer's name PENTAX 130 b , the name of the camera line or product “K100D” 130 c and a depiction of the camera 130 d . In the example, indicia 130 a to 130 d are illuminated with planar electroluminescent (EL) lamps that are disposed on the surface of the train under the film 120 . According to one embodiment, indicia 130 a and 130 c and the white portions of the depiction of camera 130 d may be illuminated by white or light colored EL lamps, while indicia 130 b may be illuminated with an EL lamp producing an orange color. According to another example embodiment, the entire depiction of the camera 130 d may be illuminated by an EL lamp. According to one example embodiment, the orange color or the white colors may be produced by the EL light produced directly by the lamps or by the light produced by the lamp and filtered through a colored transparent overlay, for example but not limited to as shown in U.S. Pat. No. 6,769,138 to Golle, incorporated herein by reference.
[0010] Referring to FIGS. 2A and 2B , train 100 is shown with the film 120 cut away exposing EL lamp units 140 a to 140 g with in this example embodiment are rectangular, and carry the respective EL illuminated indicia 130 a to 130 d . Lamp units 140 are each rectangular, planar lamp assemblies that include planar EL lamps. In one embodiment, the EL lamps are formed in the shape of the alphanumeric characters of indicia 130 a to 130 d . In another embodiment, the lamp units 140 are covered with a mask that exposes only the alphanumeric characters of indicia 130 a to 130 d , such that the entire surface area of the lamp units 140 produces EL light but only the area exposed the mask is visible.
[0011] As illustrated in FIG. 2B , each of the planar lamp units 140 a to 140 g are attached to the side 138 of the train 100 using an adhesive or any other suitable attachment. The film 120 (indicated by hashing) is then applied over the side of the train and the lamp units 140 a to 140 g , adhering to the side of the train and to the top of the lamp units 140 a to 140 g . The film may then be removed from over the indicia 130 a to 130 d . so that only the alphanumeric characters or the camera depiction are exposed and the remaining portions of the lamp units 140 a to 140 g are covered by the film 120 . Alternatively, the alphanumeric characters may be left covered by the film 120 but the film 120 is thin enough or translucent enough to allow the EL illuminated indicia to shine through it or be visible when the illumination is not active.
[0012] Referring now to FIGS. 2A and 3 , the EL lamp units 140 a to 140 g are each connected to a source of energy produced by a power and control unit 150 . The connection to unit 150 is provided by individual conductors 152 (four for each lamp unit 140 a to 140 g , carrying power and ground to, in one embodiment, opposite sides or ends of the lamp units). Conductors 152 may leave unit 150 wrapped as a single bundle 151 , and leave the bundle 151 to run to the respective units 140 a to 140 g . Accordingly, units 140 a to 140 g may each have its own separate power lines. Alternatively, a single bus may be used to run power to each unit 140 a to 140 g , although such an arrangement does not allow for controlling the illumination of each unit 140 a to 140 g individually.
[0013] Power and control unit 150 is housed in a wiring or electrical compartment 160 on the train 100 , and is connected to a master power source, such as a 110 volt power supply or any suitable master power supply. Cable bundle 151 runs from the unit 150 through an aperture in the floor of the compartment and to the underside of the train and runs along the side edge on the bottom of the train undercarriage, for example held in place with fasteners 154 that may be attached to any suitable portion of the undercarriage.
[0014] According to still another example embodiment, the power and control unit 150 is shown in more detail in FIG. 4 . Unit 150 includes a power inverter 170 that supplies power to conductors 152 through switches 172 a through 172 n . Switches 172 are in turn controlled by a computer control device or other controller device 174 that may sequentially activate switches 172 a through 172 n and then, for example, activate them all in combination. In another embodiment, each switch may be activated in sequence and left on until all other switches are activated, and leaving all activated for a period of time until all are deactivated. According to another example embodiment, the switches may be deployed remotely from the unit 150 , such as on the undercarriage of the train or adjacent the lamp unit 140 , and a control line for the switch run from the control unit to the switch.
[0015] According to one example embodiment, suitable materials for use as the film 120 include various sheets, preferably comprised of thermoplastic or thermosetting polymeric materials, such as films, providing a substrate to carry the advertising indicia 110 , in this example an advertisement for a camera. Further, such films may, in one example embodiment, be low surface energy substrates. “Low surface energy” refers to materials having a surface tension of less than about 50 dynes/cm (also equivalent to 50 milliNewtons/meter). The polymeric substrates are typically nonporous. However, microporous, apertured, as well as materials further comprising water-absorbing particles such as silica and/or super-absorbent polymers, may also be employed provided the substrate does not deteriorate or delaminate upon expose to water and temperature extremes, as previously described. Other suitable substrates include woven and nonwoven fabrics, particularly those comprised of synthetic fibers such as polyester, nylon, and polyolefins. The substrates as well as the imaged article (e.g., sheets, films, polymeric materials) may be clear, translucent, or opaque. Further, the substrate and imaged article may be colorless, comprise a solid color or comprise a pattern of colors. Additionally, the substrate and imaged articles (e.g. films) may be transmissive, reflective, or retroreflective.
[0016] Representative examples of polymeric materials (e.g. sheet, films) for use as the substrate 120 include single and multi-layer constructions of acrylic-containing films (e.g. poly(methyl) methacrylate [PMMA]), poly(vinyl chloride)-containing films, (e.g., vinyl, polymeric materialized vinyl, reinforced vinyl, vinyl/acrylic blends), poly(vinyl fluoride) containing films, urethane-containing films, melamine-containing films, polyvinyl butyral-containing films, polyolefin-containing films, polyester-containing films (e.g. polyethylene terephthalate) and polycarbonate-containing films. Further, the substrate may comprise copolymers of such polymeric species. Other particular films for use as the substrate according to the inventive subject matter include multi-layered films having an image reception layer comprising an acid- or acid/acrylate modified ethylene vinyl acetate resin, as disclosed in U.S. Pat. No. 5,721,086 (Emslander et al.). The image reception layer comprises a polymer comprising at least two monoethylenically unsaturated monomeric units, wherein one monomeric unit comprises a substituted alkene where each branch comprises from 0 to about 8 carbon atoms and wherein one other monomeric unit comprises a (meth)acrylic acid ester of a nontertiary alkyl alcohol in which the alkyl group contains from 1 to about 12 carbon atoms and can include heteroatoms in the alkyl chain and in which the alcohol can be linear, branched, or cyclic in nature. A preferred film for increased tear resistance includes multi-layer polyester/copolyester films, such as those described in U.S. Pat. Nos. 5,591,530 and 5,422,189. Depending of the choice of polymeric material and thickness of the substrate, the substrate (e.g., sheets, films) may be rigid or flexible. Preferred primer and ink compositions are preferably at least as flexible as the substrate. “Flexible” refers to the physical property wherein imaged primer layer having a thickness of 50 microns can be creased at 25 C. without any visible cracks in the imaged primer layer.
[0017] Commercially available films include a multitude of films typically used for signage and commercial graphic uses, such as available from 3M under the trade designations “Panaflex”, “Nomad”, “Scotchcal”, “Scotchlite”, “Controltac”, and “Controltac Plus”. According to one example embodiment, the train 100 may be wrapped with 3M™ Controltac™ Plus Graphic Film with Comply™ Performance IJ180C-10, printed on roll having, for example, a width of 54 in and a length of 50 yd. This 2 mil, opaque film to produces high quality, long-term graphics with selected piezo ink jet printers. The film 120 may pressure-activated adhesive and 3M Comply™ Performance for easier installation of large fleet graphics, signs, emblems and more. In another embodiment, the film 120 may be 3M Scotchcal™ Luster Overlaminate 8519, 2 mil with PSA, 54 in×300 ft.
[0018] Primer compositions and optional barrier compositions applied to substrate 120 are made by mixing together the desired ingredients using any suitable technique. For example, in a one step approach, all of the ingredients are combined and blended, stiffed, milled, or otherwise mixed to form a homogeneous composition. As another alternative, some of the components may be blended together in a first step. Then, in one or more additional steps, the remaining constituents of the component if any, and one or more additives may be incorporated into the composition via blending, milling, or other mixing technique. During the manufacture of the substrate 120 , the primer composition may be applied to a surface of the substrate or to the optional barrier layer. The primer may be applied with any suitable coating technique including screen printing, spraying, ink jetting, extrusion-die coating, flexographic printing, offset printing, gravure coating, knife coating, brushing, curtain coating, wire-wound rod coating, bar coating and the like. The primer is typically applied directly to the substrate. Alternatively, the primer may be coated onto a release liner and transfer coated onto the substrate. However, for embodiments wherein the primer surface is exposed and thus is non-tacky, additional bonding layers may be required. After being coated, the solvent-based primer compositions and optional barrier compositions are dried. The coated substrates are preferably dried at room temperature for at least 24 hours. Alternatively the coated substrates may be dried in a heated oven ranging in temperature from about 40° C. to about 70° C. for about 5 to about 20 minutes followed by room temperature drying for about 1 to 3 hours. For embodiments wherein a barrier layer is employed, it is preferred to employ a minimal thickness of primer to minimize the drying time.
[0019] The imaged, polymeric sheets may be a finished product or an intermediate and are useful for a variety of articles including signage and commercial graphics films. The commercial graphic films as for example shown in FIG. 1 as substrate 120 may include a variety of advertising, promotional, and corporate identity imaged films. The films typically comprise a pressure sensitive adhesive on the non-viewing surface in order that the films can be adhered to a target surface such as an automobile, truck, airplane, billboard, building, awning, window, floor, etc. Alternatively, imaged films lacking an adhesive are suitable for use as a banner, etc., that may be mechanically attached to building, for example, in order to display. The films in combination with any associated adhesive and/or line range in thickness from about 5 mils (0.127 mm) to as thick as can be accommodate by the printer (e.g. ink jet printer). According to one example embodiment, printing on the films 120 may be done using the Xaar Jet XJ128-200 piezo printhead on an x-y stage at 317 by 295 dpi at room temperature.
[0020] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. It is to be understood that the above description is intended to be illustrative, and not restrictive. Combinations of the above embodiments and other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention includes any other applications in which the above structures and fabrication methods are used. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | An example includes printing a graphic on a vinyl billboard sign and defining a translucent portion of the vinyl billboard sign, disposing adhesive on one of the vinyl billboard sign and a target surface, overlaying the translucent portion of the vinyl billboard sign with at least one planar electroluminescent lamp unit, overlaying the electroluminescent lamp unit with the target surface; attaching a power bus to the at least one planar electroluminescent lamp, connecting the lamp unit to a source of power, wherein the source of power comprises a power source, and the power bus includes a plurality of individual power lines to carry power to the at least one lamp unit and switching the power source to control illumination of the at least one planar electroluminescent lamp unit to shine through the vinyl billboard sign. | 8 |
RELATED APPLICATIONS
[0001] This patent application is a continuation of U.S. patent application Ser. No. 09/950,059, filed Sep. 10, 2001, which patent application claims priority upon U.S. provisional patent application Ser. No. 60/231,313, filed Sep. 8, 2000, entitled Authorization/Credential Service and Authorization/Credential Service Proposal, U.S. provisional patent application Ser. No. 60/231,315, filed Sep. 8, 2000, entitled Authorization/Credential Service Proposal, and U.S. provisional patent application Ser. No. 60/231,318, filed Sep. 8, 2000, entitled Authorization/Credential Service, all four of which patent applications are hereby incorporated by reference in their entireties into the present patent application.
BACKGROUND OF THE INVENTION
[0002] The world of electronic commerce has created new challenges to establishing relationships between contracting parties. One of those challenges springs from the fact that the parties to the transaction cannot see or hear each other, and cannot otherwise easily confirm each other's identity and authority to act.
[0003] One remedy for this problem is to provide each contracting party with a private key for signing transmitted messages. The signing party makes available an associated public key that decrypts messages signed with the party's private key, and thus enables a receiving party to confirm the identity of the sender.
[0004] But the sender's public key may not be known a priori to the recipient. In that event, the sender may transmit with its signed message a digital certificate issued by a certification authority. The certificate is itself a signed electronic document (signed with the private key of the certification authority) certifying that a particular public key is the public key of the sender.
[0005] In some cases, the recipient may be unfamiliar with the public key of the certification authority or may not know whether the certificate is still valid. In that event, the recipient may wish to check the validity of the certificate. In addition, the recipient may wish to check whether or not the sender is authorized to sign the transmitted message.
DISCLOSURE OF INVENTION
[0006] Methods, apparati, and computer-readable media for providing authorization and other services. In a preferred embodiment, these services are provided within the context of a four-corner trust model. The four-corner model preferably comprises a subscribing customer (sometimes referred to as the “buyer”) and a relying customer (sometimes referred to as the “seller”), who engage in an on-line transaction.
[0007] In a preferred embodiment, the subscribing customer is a customer of a first financial institution, referred to as an issuing participant. The issuing participant acts as a certification authority for the subscribing customer and issues the subscribing customer a hardware token including a private key and a digital certificate signed by the issuing participant.
[0008] In a preferred embodiment, the relying customer is a customer of a second financial institution, referred to as the relying participant. The relying participant acts as a certification authority for the relying customer and issues the relying customer a hardware token including a private key and a digital certificate signed by the relying participant. The system also includes a root entity that maintains a root certification authority that issues digital certificates to the issuing and relying participants.
[0009] The present system provides a generalized framework for designing and implementing one or more authorization services that may be used to confirm the authority of an individual to act on behalf of a customer. Such authorization services may be used, for example, to determine whether a particular employee is authorized to purchase certain goods, negotiate a particular contract, or undertake to perform in a particular manner on behalf of its employer.
[0010] In a preferred embodiment, authorization services in the present system may be designed and implemented in accordance with the following process. First, a customer and its participant work together to define a desired authorization service. The authorization-service definition preferably includes both a messaging specification for the service and a set of rules that govern its use, as described in more detail below.
[0011] Second, the proposed authorization service is presented to a policy management authority maintained by the root entity for approval. The policy management authority reviews the proposed authorization service for compliance with system operating rules and specifications promulgated by the root entity.
[0012] Third, if the proposed authorization service is approved by the root-entity policy management authority, the service is implemented within the four-corner model.
[0013] When a relying customer wishes to utilize an approved authorization service, it prepares an authorization request that complies with the service's messaging specification and transmits the request to its relying participant.
[0014] The relying participant transmits the request to the issuing participant which processes the request in accordance with authorization information provided by the subscribing customer as well as any implementation rules that have been specified for the service. The issuing participant then prepares an authorization response that complies with the service's messaging specification and transmits the response to the relying participant. The relying participant transmits the authorization response to its relying customer.
[0015] The features and advantages described in the specification are not all inclusive, and many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims hereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above summary of the invention will be better understood when taken in conjunction with the following detailed description and accompanying drawings, in which:
[0017] FIG. 1 is a block diagram of a preferred embodiment of a four-corner model suitable for use in the present system;
[0018] FIG. 2 is a block diagram of a preferred embodiment showing components provided at entities in the present system;
[0019] FIG. 3 illustrates a preferred embodiment for establishing an authorization service;
[0020] FIG. 4 illustrates a preferred embodiment of a process flow for using an authorization service;
[0021] FIG. 5 illustrates a preferred embodiment of certain messages transmitted in the preferred embodiment of FIG. 4 .
[0022] FIG. 6 illustrates a preferred embodiment of a process flow in which an authorization service and a certificate validation service are bundled together; and
[0023] FIG. 7 illustrates a preferred embodiment of certain messages transmitted in the preferred embodiment of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present disclosure relates to a system and method for providing authorization and other services. In a preferred embodiment, these services are provided within the context of a four-corner trust model. A preferred embodiment of a four-corner model suitable for use in the present system is shown in FIG. 1 .
[0025] As shown in FIG. 1 , the four-corner model preferably comprises a first institution 102 and a second institution 104 . First institution 102 is referred to as the “issuing participant” because it is a participant in the present system and issues to its customers tokens that include a private key and a digital certificate signed by the issuing participant, as described below. Second institution 104 is referred to as the “relying participant” because it is a participant in the present system and its customers rely on representations made by issuing participant 102 and issuing participant 102 's customers, as described below. Participants 102 , 104 may preferably be banks or other financial institutions.
[0026] Also shown in FIG. 1 are a first customer 106 and a second customer 108 . First customer 106 and second customer 108 are preferably customers of issuing participant 102 and relying participant 104 , respectively. First customer 106 is referred to as the “subscribing customer” because this customer subscribes to services provided by issuing participant 102 . First customer 106 is also sometimes referred to as the “buyer” because it typically fills that role in transactions with second customer 108 , as described below.
[0027] Second customer 108 is referred to as the “relying customer” because it relies on representations made by both issuing participant 102 and subscribing customer 106 . Second customer 108 is also sometimes referred to as the “seller” because it typically fills that role in transactions with first customer 106 , as described below. It should be recognized, however, that although the description below speaks primarily in terms of a buyer 106 and a seller 108 , first customer 106 and second customer 108 may instead have different roles in a given transaction. For example, first customer 106 may be a borrower repaying a loan to second customer 108 .
[0028] As will be recognized, although the preferred embodiments described below speak primarily in terms of customer 106 acting as a subscribing customer and customer 108 acting as a relying customer, the roles of these two customers may at times be reversed, even within a single transaction and with respect to a single document. For example, in connection with a particular transaction, customers 106 , 108 may prepare a contract to be signed by both parties. With respect to customer 106 's signature on the contract, customer 106 is the subscribing customer and customer 108 is the relying customer. By contrast, with respect to customer 108 's signature on the contract, customer 108 is the subscribing customer and customer 106 is the relying customer.
[0029] It should also be noted that each customer 106 , 108 , may be a business entity, such as a corporation, that employs many individuals. In such cases, customers 106 , 108 preferably authorize some or all of these individual employees to transact and utilize system services on their behalf. Issuing participant 102 preferably issues a separate smartcard token having a distinct private key and associated digital certificate to each authorized employee of subscribing customer 106 . Similarly, relying participant 104 (in its capacity as “issuing participant” to relying customer 108 ) preferably issues a separate smartcard token having a distinct private key and associated digital certificate to each authorized employee of relying customer 108 . The digital certificates preferably include the individual employee's name and identify the customer for whom he or she works. In an alternative embodiment, the private key may instead be included in a software token provided to the individual.
[0030] It should be recognized that although the description that follows may speak in terms of messages or other data being signed by a “subscribing customer” or “relying customer,” the signature may in fact typically be created by an individual employee using his or her digital certificate and associated private key acting on behalf of his or her employer.
[0031] Also shown in FIG. 1 is a root entity 110 . Root entity 110 is preferably an organization that establishes and enforces a common set of operating rules for facilitating electronic commerce and electronic communications. Root entity 110 may be owned jointly by a plurality of banks and/or other financial institutions that have agreed to adhere to these operating rules. One exemplary embodiment of such a root entity is described in copending U.S. application Ser. No. 09/502,450, filed Feb. 11, 2000, entitled System and Method for Providing Certification Related and Other Services and in copending U.S. application Ser. No. 09/657,623, filed Sep. 8, 2000, entitled System and Method for Providing Certificate-Related and Other Services, which are hereby incorporated by reference.
[0032] FIG. 2 is a block diagram of a preferred embodiment showing components provided at each entity in the present system. As shown in FIG. 2 , participants 102 , 104 , and root entity 110 are each preferably provided with a transaction coordinator 202 that serves as a gateway for transmitting and receiving all inter-entity messages related to services provided by the present system. Transaction coordinators 202 provide a single interface to issuing participant 102 's and relying participant 104 's on-line services and implement safeguards necessary to ensure secure electronic communications between transaction coordinators 202 and other entities in the four-corner model, as described in copending U.S. application Ser. No. 09/657,605, filed on Sep. 8, 2000, entitled System and Method for Providing Certificate Validation and Other Services, which is hereby incorporated by reference. Each transaction coordinator 202 is preferably provided with an associated hardware security module (HSM) 218 for signing and verifying messages. Participants 102 , 104 , and root entity 110 are each further preferably provided with an OCSP responder 204 and associated hardware security module (HSM) 206 for signing and verifying signatures on messages.
[0033] Root entity 110 is also preferably provided with a central repository 260 . Central repository 260 is preferably adapted to store data, such as, for example, messaging specification and other data as described in more detail below.
[0034] Participants 102 and 104 are each preferably provided with a directory 270 . Directory 270 is preferably adapted to store data, such as, for example, credential records and messaging specification data, as described in more detail below.
[0035] Subscribing customer 106 is preferably provided with a Web browser 224 adapted to receive and transmit information via the Internet. Subscribing customer 106 is also preferably provided with a smartcard subsystem 226 adapted to sign electronic messages. In a preferred embodiment, smartcard subsystem 226 may include a smartcard reader, a smartcard driver, a smartcard token, and other software, as described in U.S. provisional application Ser. No. 60/224,994, filed Aug. 14, 2000, entitled Signing Interface Requirements, Smart Card Compliance Requirements, Warranty Service Functional Requirements, and Additional Disclosure and copending U.S. application Ser. No. 09/928,999, filed Aug. 14, 2001, entitled System and Method for Secure Smartcard Issuance, which are hereby incorporated by reference. In a preferred embodiment, the smartcard token is issued to subscribing customer 106 by its issuing participant 102 .
[0036] Subscribing customer 106 is also preferably provided with a signing interface 225 . Signing interface 225 is adapted to invoke smartcard 226 to execute a digital signature, as described in U.S. provisional application Ser. No. 60/224,994, filed Aug. 14, 2000, entitled Signing Interface Requirements, Smart Card Compliance Requirements, Warranty Service Functional Requirements, and Additional Disclosure and U.S. application Ser. No. 09/929,035, filed Aug. 14, 2001, entitled System and Method for Facilitating Signing by Buyers in Electronic Commerce, which are hereby incorporated by reference.
[0037] Relying customer 108 is preferably provided with a Web server 220 adapted to receive and transmit information via the Internet and a bank interface 222 for accessing system services. An exemplary bank interface is described in copending U.S. application Ser. No. 09/657,604, filed on Sep. 8, 2000, entitled System and Method for Facilitating Access by Sellers to Certificate-Related and Other Services, which is hereby incorporated by reference. Relying customer 108 is preferably further provided with an HSM 250 for signing and verifying signatures on messages.
[0038] Customers 106 , 108 are also each preferably provided with a directory 280 that is adapted to store data, such as, for example, credential records and messaging specification data, as described in more detail below.
[0039] In a preferred embodiment, each system entity is further preferably provided with two digital certificates (and corresponding private keys) to facilitate authentication: an identity certificate and a utility certificate.
[0040] The identity private key is used to produce digital signatures that are required by root entity 110 as evidence of an entity's contractual commitment to the contents of an electronic transaction, such as a purchase order.
[0041] The utility private key is used to provide additional transactional security. Typically, utility certificates are used to support secure socket layers (SSL), to sign secure multipurpose internet mail extension (S/MIME) messages, and for other utility applications. Any reference in this document to the term “certificate” refers to an identity certificate unless otherwise stated.
[0042] In a preferred embodiment, root entity 110 , in its capacity as a certification authority, uses a root private key to create the digital certificates of each system participant (e.g., issuing participant 102 and relying participant 104 ). In addition, it uses the root private key to create digital certificates for each system component maintained by root entity 110 that has digital signing capability, including OCSP responder 204 R and transaction coordinator 202 R .
[0043] In addition, each system participant (e.g., issuing participant 102 and relying participant 104 ), in its capacity as a certification authority, uses the private key associated with its certificate from root entity 110 to create the digital certificates of its customers (e.g., subscribing customer 106 and relying customer 108 ). In addition, it uses this private key to create digital certificates for each system component that it maintains that has digital signing capability, including its OCSP responder 204 and transaction coordinator 202 . In an alternative embodiment, the digital certificates for system components with digital signing capability that are maintained by a participant may be issued by root entity 110 .
[0044] It should be noted that the system entities may each be provided with additional components not shown in FIG. 2 , such as the components described in copending U.S. application Ser. No. 09/657,605, filed on Sep. 8, 2000, entitled System and Method for Providing Certificate Validation and Other Services, U.S. provisional application Ser. No. 60/224,994, filed Aug. 14, 2000, entitled Signing Interface Requirements, Smart Card Compliance Requirements, Warranty Service Functional Requirements, and Additional Disclosure, U.S. provisional application Ser. No. 60/259,796, filed Jan. 4, 2001, entitled Warranty Manager Application Programming Interface, Warranty Messaging Specification, and Warranty Manager Functional Requirements, and copending U.S. application Ser. No. 09/928,998, filed Aug. 14, 2001, entitled System and Method for Providing Warranties in Electronic Commerce.
[0000] Overview of Authorization Services
[0045] The authorization services described herein provide a mechanism by which a first customer (e.g., customer 108 ) may confirm the authority of an individual to act on behalf of a second customer (e.g., customer 106 ). For example, authorization services may be used to confirm the authority of an individual to sign a particular document or to undertake a particular financial or performance obligation on behalf of the second customer. More specifically, authorization services maybe used, to cite just a few specific examples, to determine whether a particular employee is authorized to purchase a particular class of goods, negotiate a particular type of contract, or undertake to perform in a particular manner on behalf of the second customer.
[0046] It should be recognized that the present system is intended to support a wide variety of authorization services that are preferably tailored to the business needs of a particular customer or industry. It is therefore impossible to describe completely every possible authorization service that may be supported by the present system. Rather, the description below provides a generalized framework for defining and implementing authorization services in a variety of business settings.
[0047] To facilitate understanding of this generalized framework, an exemplary embodiment for defining and implementing a particular authorization service is described below. The exemplary embodiment comprises a hypothetical subscribing customer, ABC Co., that is a customer of an issuing participant, Bank A, and a hypothetical relying customer XYZ Co., that is a customer of a relying participant, Bank B. ABC Co. employs an office manager, known as John Smith, who is authorized to transact on behalf of ABC Co. in particular ways, as described in more detail below.
[0048] As noted above, in a preferred embodiment, authorization services are designed and implemented in the present system using the following steps. First, a customer and its participant work together to define a desired authorization service. The authorization-service definition preferably includes both a messaging specification for the service and a set of rules that govern its use, as described in more detail below.
[0049] Second, the proposed authorization service is presented to a policy management authority maintained by root entity 110 for approval. The policy management authority reviews the proposed authorization service for compliance with system operating rules and specifications promulgated by root entity 110 .
[0050] Third, if the proposed authorization type is approved by the root-entity policy management authority, the service is implemented within the four-corner model.
[0051] The first and second steps are described in more detail in connection with FIG. 3 below. The third step is described in more detail in connection with FIGS. 4-7 below.
[0000] Establishing an Authorization Service
[0052] FIG. 3 illustrates a preferred embodiment for establishing a new authorization service. As shown in FIG. 3 , in step 301 , subscribing customer 106 and issuing participant 102 work together to broadly identify the parameters of an authorization service to be defined. For example, it may be determined that it would be useful to define an authorization service for ABC Co. to be used in authorizing purchase of goods or services by ABC Co. employees.
[0053] In step 302 , subscribing customer 106 and issuing participant 102 work together to identify the particular customer and employee information needed to respond appropriately to such an authorization request. For example, it may be determined that each employee of ABC Co. has a title and that the types and amount of goods and services that the employee is authorized to obtain on behalf of ABC Co. are a function of that title. As will be recognized, this information will typically vary significantly from authorization service to authorization service as a function of the customer, industry, or type of authorization desired.
[0054] In step 303 , subscribing customer 106 and issuing participant 102 work together to define a credential-record format for storing the categories of information (e.g., title, purchasing limit) identified in step 302 . This credential-record format is preferably customized as appropriate for the particular customer and industry to which the authorization service pertains.
[0055] In a preferred embodiment, each credential record comprises one or more pairs of roles and attributes. A role is a characteristic relevant to the authority of an individual to take a particular action. An attribute represents the particular value assigned to a role for a given individual.
[0056] For example, in the exemplary embodiment, it may be determined that each credential record should comprise the following roles:
[0057] (1) Name
[0058] (2) Title
[0059] (3) Purchasing Authority
[0060] (4) Purchasing Limit
[0061] An exemplary set of attributes for these roles may be:
[0062] (1) John Smith
[0063] (2) Office Manager
[0064] (3) Office Supplies
[0065] (4) $1,000
[0066] In step 304 , subscribing customer 106 and issuing participant 102 work together to identify any additional information that may be necessary to properly respond to authorization requests for the authorization type being defined. In a preferred embodiment, this information may include definition information and mapping information.
[0067] Definition information is information used to construe particular attributes assigned to one or more employees of subscribing customer 106 . For example, as noted above, the purchasing-authority role for ABC Co.'s office manager may be assigned the attribute “Office Supplies.” Definition information is preferably used to define the scope of this attribute. For example, definition information may be provided that defines “Office Supplies” as including pens, pencils, paper, adhesive tape, etc., but as excluding (either explicitly or by implication) desks, telephones, photocopy machines, etc. As described below, Bank A may refer to this definition information in responding to authorization requests concerning the purchasing authority of John Smith.
[0068] Mapping information is information used to interpret an authorization request received from an entity that uses different terminology than subscribing customer 106 to describe the same things. For example, seller XYZ Co. may be located in the United Kingdom where the term “sellotape” is used to described what ABC Co. (located, for example, in the United States) would refer to as “adhesive tape.” Mapping information may be used to translate terms in an authorization request into appropriate terminology that matches that used by ABC Co.
[0069] Additional mapping data may also preferably be maintained by issuing participant 102 to allow, for example, for currency conversion. Thus, for example, if seller XYZ Co. is located in the United Kingdom, it may specify a purchase amount in an authorization request in pounds sterling. Bank A may use dynamically-maintained mapping information to translate the purchase amount to dollars if, for example, ABC Co. specified its employee purchasing limits in that currency.
[0070] In step 305 , issuing participant 102 and subscribing customer 106 preferably work together to create a messaging specification that defines a format for authorization requests and responses to be used in connection with the defined authorization service. As noted, the present system is intended to support a wide variety of authorization services each of which may be defined as desired by issuing participant 102 and subscribing customer 106 . Accordingly, in a preferred embodiment, the messaging specification may define messages in any suitable format such as extensible markup language (XML), hypertext markup language (HTML), etc.
[0071] For purposes of the exemplary embodiment described herein, it will be assumed that all messages are to be defined in XML format. As such, the messaging specification created by issuing participant 102 and subscribing customer 106 preferably comprises a document type definition (DTD) that provides the formal description of all valid XML authorization request and response messages used in connection with the authorization service being defined. Exemplary embodiments for such authorization request and response messages are described below.
[0072] In a preferred embodiment, an authorization service may be designed to support static authorization requests, dynamic authorization requests, or both.
[0073] A dynamic authorization request is a request for approval that an individual is authorized to perform a certain act or undertake a particular transaction. For example, a dynamic authorization request may specify that a proposed transaction has a value of $500 and seek to determine whether a particular individual is authorized to transact in that amount. A dynamic authorization response preferably returns a Boolean value (e.g., “Authorized” or “Not Authorized”).
[0074] A static authorization request is a request for the attribute(s) of one or more roles associated with a particular individual. For example, a static request may seek the signing limit of a particular corporate officer. A static authorization response returns the particular attribute(s) requested.
[0075] In step 306 , issuing participant 102 and subscribing customer 106 preferably work together in order to define a set of implementation rules that govern use of the authorization service being defined. As noted above, the present system is designed to be flexibly adaptable to the needs of various businesses in various industries. Accordingly, it is impossible to create a complete list of all such rules that might be proposed by a particular subscribing customer 106 and/or issuing participant 102 . Illustrative examples of such rules, however, may include the following:
[0076] 1. Issuing participant 102 may respond to a request for authorization concerning purchase of office supplies only if the request is received from a company that sells office supplies.
[0077] 2. Issuing participant 102 may respond to a request for authorization concerning purchase of office supplies only if the request is received from a company on a list of approved suppliers established by subscribing customer 106 .
[0078] 3. Issuing participant 102 may respond to a request for authorization concerning purchase of office supplies only if the request is received from a particular company, e.g., XYZ Co.
[0079] 4. Issuing participant 102 may respond to a request for authorization concerning purchase of office supplies only if the request is received from an individual with a title of “sales manager.”
[0080] 5. Issuing participant 102 may respond to a request for authorization concerning purchase of office supplies only if the request is received from a particular individual employed by XYZ Co., e.g., Jane Doe.
[0081] It should be noted that the implementation rules may differ as a function of authorization-request type (i.e., a static vs. dynamic authorization request). In particular, a subscribing customer 106 may wish to establish more restrictive rules for responding to static authorization requests than dynamic information requests.
[0082] It should also be noted that it may often be possible to enforce one or more implementation rules by properly defining the messaging specification for the proposed service. For example, a subscribing customer 106 may wish to permit issuing participant 102 to respond to authorization requests only from relying customers 108 that are in possession of a signed purchase order from subscribing customer 106 . This implementation rule may be enforced by defining an authorization-request message format that includes a signed-purchase-order field in which relying customer 108 must include a signed purchase order from subscribing customer 106 .
[0083] In a preferred embodiment, the implementation rules may also define access controls that limit the ability of relying customers to obtain the messaging formats for the proposed service. As will be recognized, the very structure of an authorization-request or authorization-response message, and the fields it comprises, may reveal valuable business information regarding the structure of a business entity. Such message-format data may also provide an attacker with information that might be useful in generating forged authorization requests or responses. Accordingly, in a preferred embodiment, the implementation rules also define access controls that limit access to messaging specification data for the proposed service. For example, access controls may be used to determine whether or not a particular relying customer 108 is entitled to receive the message format for a particular type of authorization request. In a preferred embodiment, these implementation rules are typically enforced by root entity 110 which is responsible for responding to requests for message-format data, as described in more detail below.
[0084] In step 307 , issuing participant 102 presents the proposed authorization service including its messaging specification and implementation rules to a policy management authority maintained by root entity 110 . In step 308 , the root-entity policy management authority reviews the proposed service for compliance with system operating rules and specifications promulgated by root entity 110 and determines whether or not to approve the proposed service.
[0085] If the root-entity policy management authority does not approve the proposed service, it notifies issuing participant 102 of this fact (step 309 ). The policy management authority may include with the denial suggested amendments to the messaging specification or implementation rules that would conform the authorization service to the operating rules and specifications promulgated by root entity 110 and permit approval of the proposed service.
[0086] If the root-entity policy management authority approves the proposed service, then, in step 310 , root entity 110 stores the messaging specification and implementation rules for the service in central repository 260 and notifies issuing participant of the approval.
[0087] Once approval notification is received, issuing participant 102 stores the approved messaging specification and implementation rules in directory 270 and notifies subscribing customer 106 of the approval (step 311 ). In step 312 , subscribing customer 106 supplies attribute information to issuing participant 102 to populate credential records for subscribing customer 106 's employees. For example, as noted above, ABC Co. may have an employee whose name is John Smith, whose title is “Office Manager” and who is therefore authorized to purchase up to $1000 of office supplies. In the exemplary embodiment, ABC Co. would transmit this attribute information (and analogous information for its other employees) to Bank A.
[0088] In step 313 , issuing participant 102 establishes a credential record for each employee of subscribing customer 106 identified to it in step 312 . In the exemplary embodiment, for example, a credential record for John Smith may appear as follows:
[0089] Name=John Smith
[0090] Title=Office Manager
[0091] Purchasing Authority=Office Supplies
[0092] Purchasing Limit=$1,000
[0093] In step 314 , issuing participant 102 stores the credentials records in directory 270 . In a preferred embodiment, this information may also be stored at subscribing customer 106 in directory 280 .
[0094] The authorization service is now ready for use by system customers, as described in the following section.
[0000] Authorization Service Process Flow
[0095] A preferred embodiment of a process flow for using an approved authorization service is now described in connection with FIGS. 4-5 . It should be recognized that the present system is intended to provide authorization services in a wide variety of situations in which one entity might seek authorization of another to transact or undertake some obligation. It is therefore impossible to describe completely every possible situation in which the authorization services of the present system might be used. The exemplary preferred embodiment described below describes a typical example (purchase of goods by one customer from another) in which authorization of an individual might be sought. It will be recognized, however, that the authorization services of the present system may be used in many other circumstances such as to confirm the authorization of one individual to negotiate a particular contract before commencing negotiations (which may be time-consuming and costly) with that individual.
[0096] For purposes of the present exemplary embodiment, it will be assumed that the components shown in FIG. 2 as being associated with the subscribing customer are owned and maintained by ABC Co. and assigned for use to John Smith, its office manager. It will further be assumed that the components shown in FIG. 2 as being associated with the relying customer are owned and maintained by XYZ Co. It will further be assumed that the components shown in FIG. 2 as being associated with the issuing participant and relying participant are owned and maintained by Bank A and Bank B, respectively.
[0097] Beginning with FIG. 4 , in step 401 , John Smith, the office manager for ABC Co., visits the Web site of XYZ Co. using his browser 224 . The parties preferably authenticate themselves to each other over an SSL session with their utility keys.
[0098] Once John Smith agrees to a transaction (e.g., to purchase $200 of adhesive tape), Web server 220 communicates data to be digitally signed to browser 224 (e.g., a purchase order for the agreed to transaction) (step 402 ). In step 403 , the data to be signed is forwarded to smartcard subsystem 226 which signs the data to create a digitally-signed document.
[0099] In step 404 , browser 224 receives the digitally-signed document and transmits it to Web server 220 or another appropriate location specified by XYZ Co. In a preferred embodiment, this signing process may be facilitated by using a signing interface 225 to invoke smartcard subsystem 226 , as described in U.S. provisional application Ser. No. 60/224,994, filed Sep. 8, 2000, entitled Signing Interface Requirements, Smart Card Compliance Requirements, Warranty Service Functional Requirements, and Additional Disclosure and copending U.S. application Ser. No. 09/929,035, filed Aug. 14, 2001, entitled System and Method for Facilitating Signing by Buyer's in Electronic Commerce, which are hereby incorporated by reference.
[0100] In step 405 , XYZ Co. receives the digitally-signed document. In step 406 , XYZ Co. decides to confirm that John Smith is authorized to sign the purchase order.
[0101] In step 407 , XYZ Co. determines whether it has previously obtained the appropriate message format for the desired authorization request to be created. As noted, the desired authorization request may be a static authorization request or a dynamic authorization request depending on the type of information that XYZ Co. would like to obtain. If XYZ Co. has previously obtained the appropriate message format, processing proceeds to step 416 , described below.
[0102] Otherwise, in step 408 , XYZ Co. generates a request for the appropriate authorization-request message format, signs the request, and sends the request to Bank B (message 1 in FIG. 5 ). In step 409 , Bank B transmits the request to root entity 110 (message 2 in FIG. 5 ).
[0103] In step 410 , root entity 110 receives the request and retrieves from central repository 260 the access-control implementation rules developed by Bank A and ABC Co. for the authorization service identified in the request. In step 411 , root entity 110 applies these access-control implementation rules to determine whether or not XYZ Co. is authorized to receive the requested authorization-request message format.
[0104] If XYZ Co. is not authorized to receive the requested message format, then, in step 412 , root entity 110 generates a rejection message indicating this fact, signs it, and transmits it to Bank B (message 3 in FIG. 5 ). In step 413 , Bank B transmits the rejection message to XYZ Co. (message 4 in FIG. 5 ), and processing concludes.
[0105] Otherwise, in step 414 , root entity 110 retrieves from central repository 260 the requested authorization-request message format, creates a signed message that includes the requested message format, and transmits the message to Bank B (message 5 in FIG. 5 ). In step 415 , Bank B transmits the message to XYZ Co. (message 6 in FIG. 5 ).
[0106] In step 416 , XYZ Co. uses the authorization-request message format to generate an authorization request for some aspect of the transaction documented by the digitally-signed document.
[0107] Assuming for purposes of the present exemplary embodiment that the authorization service permits a relying customer to make a dynamic request to determine whether an employee of ABC Co. is authorized to purchase a particular type and value of goods, an exemplary dynamic authorization request message might include the following fields:
[0108] Authorization Request Message Code (indicating that the message is a request for authorization and specifying a particular authorization service by number)
[0109] Request Type (indicating whether the request is a static request or a dynamic request)
[0110] Request ID (unique identifier generated by relying customer 108 )
[0111] Relying Customer Name (e.g., XYZ Co.)
[0112] Subscribing Customer Name (e.g., ABC Co.)
[0113] Subscribing Customer Employee (e.g., John Smith)
[0114] Transaction Type (e.g., purchase, rental, etc.)
[0115] Transaction Item
[0116] Transaction Amount
[0117] An exemplary XML implementation of a dynamic authorization request generated for John Smith's authorization to purchase $200 worth of adhesive tape may be as follows:
[0000] <AuthorizationRequestServiceNo 12345>
[0118] <RequestType Type=“dynamic”/>
[0119] <RequestId Id=“0034021”/>
[0120] <RCNameAndId Id=“123456” Name=“XYZ Co.”/>
[0121] <SCNameAndId Id=“654321” Name=ABC Co.”/>
[0122] <SCEmployeeNameAndId Id=“13579” Name=“John Smith”/>
[0123] <TransactionType Type=“purchase”/>
[0124] <TransactionItem Item=“adhesive tape”/>
[0125] <TransactionAmount Currency=“USD” Amount=“200”/>
[0000] </AuthorizationRequestServiceNo 12345>
[0126] Alternatively, assuming for purposes of the present exemplary embodiment that the authorization service permits a relying customer to make a static request to determine the purchasing authority of an employee of ABC Co., an exemplary static authorization request message might include the following fields:
[0127] Authorization Request Message Code (indicating that the message is a request for authorization and specifying a particular authorization service by number)
[0128] Request Type (indicating whether the request is a static request or a dynamic request)
[0129] Request ID (unique identifier generated by relying customer 108 )
[0130] Relying Customer Name (e.g., XYZ Co.)
[0131] Subscribing Customer Name (e.g., ABC Co.)
[0132] Subscribing Customer Employee (e.g., John Smith)
[0133] Requested Attributes (indicating the attributes that are the subject of the authorization request)
[0134] An exemplary XML implementation of a static authorization request to determine the type and value of items that John Smith is authorized to purchase (i.e., his purchasing authority and purchasing limit) may be as follows:
[0000] <AuthorizationRequestServiceNo 12345>
[0135] <RequestType Type=“static”/>
[0136] <RequestId Id=“00255501”/>
[0137] <RCNameAndId Id=“123456” Name=“XYZ Co.”/>
[0138] <SCNameAndId Id=“654321” Name=“ABC Co.”/>
[0139] <SCEmployeeNameAndId Id=“13579” Name=“John Smith”>
[0140] <RequestedAttributes Attributes=“Purchasing Authority, Purchasing Limit”/>
[0000] </AuthorizationRequestServiceNo 12345>
[0141] Continuing with FIG. 4 , in step 417 , XYZ Co. signs the authorization request message and sends it to Bank B (message 7 in FIG. 5 ). In step 418 , Bank B transmits the authorization request message to Bank A (message 8 in FIG. 5 ).
[0142] In step 419 , Bank A receives the request and checks its repository 270 IP to determine whether or not it has the appropriate messaging specification data in order to generate a response to the authorization request. If Bank A has the appropriate messaging specification data, processing proceeds to step 427 , described below.
[0143] Otherwise (which may occur, for example, if the authorization service that is the subject of the request was developed by a different system participant), then, in step 420 , Bank A generates a request for the appropriate response message format, signs the request, and sends the request to root entity 110 (message 9 in FIG. 5 ).
[0144] In step 421 , root entity 110 receives the request and retrieves from central repository 260 any applicable access-control implementation rules necessary to process the request. In step 422 , root entity 110 applies these rules to determine whether or not it will release the requested authorization-response message format to Bank A.
[0145] If Bank A is not authorized to receive the requested message format, then, in step 423 , root entity 110 generates a rejection message indicating this fact, signs it, and transmits it to Bank A (message 10 in FIG. 5 ). In step 424 , Bank A generates a message indicating that it cannot process the authorization request, signs it, and transmits it to Bank B (message 11 in FIG. 5 ). In step 425 , Bank B transmits the message to XYZ Co., and processing ends (message 12 in FIG. 5 ).
[0146] Otherwise, in step 426 , root entity 110 retrieves from central repository 260 the requested authorization-response message format, creates a signed message that includes the requested message format, and transmits the message to Bank A (message 13 in FIG. 5 ).
[0147] In step 427 , Bank A retrieves from directory 270 IP the appropriate credential record for the individual that is the subject of the authorization request (e.g., John Smith). In addition, Bank A retrieves from directory 270 IP any necessary definition and mapping information for processing the request. Bank A uses this information to process the authorization request from XYZ Co.
[0148] For example, if the authorization request seeks to determine whether John Smith is authorized to purchase $200 of adhesive tape, Bank A reviews John Smith's purchasing authority attributes (and any necessary related definition or mapping information) and his purchasing limit, and determines (on these facts) that John Smith is authorized to conduct the transaction.
[0149] It should be noted that, in the present exemplary embodiment, it is assumed that the purchasing limit attribute assigned to John Smith is a per-transaction limit. It will be recognized that subscribing customer 106 may alternatively or in addition assign to its employees time-based (e.g., monthly) or other purchasing limits. If, for example, John Smith was also assigned a monthly limit, Bank A would preferably track all purchases made by John Smith and maintain a running total of those purchases during the last month. Upon receipt of an authorization request for a specified transaction amount, Bank A would add this transaction amount to John Smith's running total for the month, compare the sum to John Smith's monthly purchasing limit, and issue a positive authorization only if the sum did not exceed the monthly purchasing limit.
[0150] In step 428 , Bank A uses the authorization-response message format to generate an appropriate response to XYZ Co.'s authorization request. Continuing with the exemplary embodiment, a response to the dynamic authorization request described above may include the following fields:
[0151] Authorization Response Message Code (indicating that the message is an authorization response message and specifying a particular authorization service by number)
[0152] Request ID
[0153] Response (Boolean value such as Authorized or Not Authorized)
[0154] An exemplary XML implementation of the above response may be as follows:
[0000] <AuthorizationResponseServiceNo 12345>
[0155] <RequestId Id=“0034201”/>
[0156] <Response>Authorized</Response>
[0000] </AuthorizationResponseServiceNo 12345>
[0157] A response to the static authorization request described above may include the following fields:
[0158] Authorization Response Message Code (indicating that the message is an authorization response message and specifying a particular authorization service by number)
[0159] Request ID
[0160] Credential Record
[0161] An exemplary XML implementation for such a response message may be:
[0000] <AuthorizationResponseServiceNo 12345>
[0162] <RequestId Id=“0034201”/>
[0163] <EmployeeName>John Smith</EmployeeName>
[0164] <EmployeeTitle>Office Manager</EmployeeTitle>
[0165] <PurchasingAuthority>Office Supplies</PurchasingAuthority>
[0166] <PurchasingLimit Currency=“USD”>75,000</PurchasingLimit>
[0000] </AuthorizationResponseServiceNo 12345>
[0167] In step 429 , Bank A signs the authorization response message and sends it to Bank B (message 14 in FIG. 5 ). In step 430 , Bank B transmits the authorization response message to XYZ Co. (message 15 in FIG. 5 ). If the authorization response is satisfactory to XYZ Co., then, in step 431 , XYZ Co. sends a confirmation message for the transaction to John Smith at ABC Co. Otherwise, if the authorization response is not satisfactory to XYZ Co., then, in step 432 , XYZ Co. may send a message to John Smith at ABC Co. disaffirming the transaction.
[0000] Process Flow for Bundled Authorization Service and Certificate Validation or Other System Services
[0168] In a preferred embodiment, an authorization request by a relying customer 108 may preferably be bundled and processed concurrently with a request for another system service such as certificate validation. Preferred embodiments for validating a subscribing customer 106 's certificate are described, for example, in copending U.S. application Ser. No. 09/657,605, filed Sep. 8, 2000, entitled System and Method for Certificate Validation and Other Services, which is hereby incorporated by reference. A summarized version of that certificate validation process is described below in connection with the bundled authorization/certificate validation services. This preferred embodiment is now described in connection with FIGS. 6-7 .
[0169] Beginning with FIG. 6 , in step 601 , subscribing customer 106 visits relying customer 108 's Web site. The parties preferably authenticate themselves to each other over an SSL session with their utility keys.
[0170] In step 602 , Web server 220 communicates data to be digitally signed to browser 224 (e.g., a purchase order for an agreed-to transaction). In step 603 , the data to be signed is forwarded to smartcard subsystem 226 which signs the data to create a digitally-signed document. In step 604 , browser 224 receives the digitally-signed document and transmits it to Web server 220 or another appropriate location specified by relying customer 108 . In a preferred embodiment, this signing process may be facilitated by using a signing interface 225 to invoke smartcard subsystem 226 , as described in U.S. provisional application Ser. No. 60/224,994, filed Sep. 8, 2000, entitled Signing Interface Requirements, Smart Card Compliance Requirements, Warranty Service Functional Requirements, and Additional Disclosure, which is hereby incorporated by reference.
[0171] In step 605 , relying customer 108 receives the digitally-signed document. In step 606 , relying customer 108 generates an authorization request message in accordance with steps 407 - 416 , as described above. In step 607 , relying customer 108 creates an OCSP request for subscribing customer 106 's digital certificate. In step 608 , relying customer 108 concatenates the two requests and signs the resulting message. In a preferred embodiment, the messaging specification for the authorization service may include a single request that seeks both authorization and certificate validation. In step 609 , relying customer 108 transmits the request(s) to relying participant 104 (message 1 in FIG. 7 ).
[0172] In step 610 , relying participant 104 identifies the issuing participant that issued the digital certificate that is the subject of the OCSP request and, in step 611 , transmits the request to that participant (i.e., issuing participant 102 in the present example) (message 2 in FIG. 7 ).
[0173] In step 612 , issuing participant 102 processes the authorization request in accordance with steps 419 - 428 as described above. In step 613 , issuing participant creates an OCSP response for the validation request using its OCSP responder 204 IP . In step 614 , issuing participant 102 concatenates the authorization response message and OCSP response and signs the resulting message. In a preferred embodiment, the messaging specification for the authorization service may include a single response message for responding to a bundled authorization/certificate validation request.
[0174] In step 615 , issuing participant 102 transmits the response(s) to relying participant 104 (message 3 in FIG. 7 ). In step 616 , relying participant 104 transmits the response(s) to relying customer 108 (message 4 in FIG. 7 ). In step 617 , relying customer 108 reviews the response(s). If the authorization and validation responses are satisfactory to relying customer 104 , then, in step 618 , XYZ Co. sends a confirmation message for the transaction to subscribing customer 106 . Otherwise, if one or more of the service responses are not satisfactory to relying customer 108 , then, in step 619 , relying customer 108 may send a message to subscribing customer 106 disaffirming the transaction.
[0175] It will be recognized that, in other preferred embodiments, system services other than certificate validation may be processed concurrently with the authorization service. These system services may, for example, include a warranty service.
[0176] It should be noted that, in a preferred embodiment, all inter-entity messages transmitted and received by participants 102 , 104 , and root entity 110 may be routed through an appropriate system component adapted for such processing, such as, for example, transaction coordinator 202 .
[0177] It should be noted that although the preferred embodiments described above speak primarily in terms of a transaction conducted by an individual employee of subscribing customer 106 , the transaction may alternatively be automatically conducted by an appropriate server maintained by subscriber customer 106 . In that case, relying customer 108 may, for example, seek an authorization that the subscribing customer will stand behind a transaction conducted with the server.
[0178] It should also be recognized that although in the preferred embodiments described above subscribing customer 106 and issuing participant 102 work together to design a desired authorization service, in an alternative preferred embodiment, issuing participant 102 (or other entities such as root entity 110 ) may design in advance one or more authorization services and seek approval from the policy management authority for them. Once approved, these may serve as “off-the-shelf” authorization services that may be offered to a subscribing customer 106 . In particular, it may be desirable to design and seek approval for industry-specific authorization services that an issuing participant expects will be popular with its customers.
[0179] While the invention has been described in conjunction with specific embodiments, it is evident that numerous alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. | Methods, apparati, and computer-readable media for providing authorization and other services. In a preferred embodiment, an authorization service includes both a messaging specification and a set of rules that govern its use. A first customer wishing to use the authorization service prepares a request that complies with the service's messaging specification and transmits it to a first participant. The first participant transmits the request to a second participant, which processes the request according to authorization information provided by a second customer and rules that have been specified for the service. The second participant then prepares a response that complies with the service's messaging specification. | 6 |
TECHNICAL FIELD
This invention relates to a product feeding apparatus. In particular, the invention relates to an apparatus for replacing packets found to be defective in a cigarette packeting line. In the ensuing description reference will be made to the handling of packets of cigarettes, however the apparatus of the invention can be used for handling any type of product.
BACKGROUND OF THE INVENTION
As is well known, the packets of cigarettes produced on a packeting line are checked during their transit along the line to ensure that their shape is correct and that all their required component parts are present. Following these checks, any packets found to be defective are expelled from the packeting line at appropriate discarding stations, and are then replaced at a replacement station with sound packets, to maintain the continuity of succession of the conveyed packets. Maintaining this continuity is necessary to prevent problems arising at the subsequent working stations to which the packets are conveyed, in that for example the arrival of an incomplete group of packets at a subsequent working station would result in the inevitable discarding of the entire group.
Apparatus for replacing discarded defective packets with sound packets are known, for example from GB patent 2,021,082, in which the sound packets to be fed into a conveying line to replace the missing packets are contained in one or more stores, from which transfer means extract the packets in succession as required. Such apparatus are however considerably bulky, complicated and costly, because of the presence of said stores and the transfer means for extracting the packets from the stores.
In addition, the packets have to be periodically loaded into the said stores by an operator, which means that a person must be assigned to periodically check the degree of filling of the stores and to fill them manually.
SUMMARY OF THE PRESENT INVENTION
The object of the present invention is to provide a completely automatic apparatus for replacing defective packets in a packeting line, which is free of the aforesaid drawbacks of the known art, and which is therefore simple, economical and of small overall size.
This object is attained according to the present invention by an apparatus for feeding products, comprising feeder means for transporting a succession of products, a first conveyor driven with intermittent motion and provided with a plurality of seats for receiving respective products from said feeder means at an entry station, and receiver means for receiving said products in succession from said first conveyor at an exit station.
The invention a second conveyor driven with intermittent motion and having a plurality of seats for containing respective products, and reversible motor means for driving said second conveyor, the path of travel of the seats of said second conveyor intersecting the path of travel of the seats of said first conveyor at a station for the discarding and replacement of defective products. The movement of said first conveyor taking place during halt stages of said second conveyor.
The movement of said second conveyor taking place during halt stages of said first conveyor, the second conveyor being able, during each of its stages of movement in a first direction of advancement through said discarding and replacement station, to remove a defective product from a seat of said first conveyor and retain it in a first seat of said second conveyor, and to introduce into the same seat of said first conveyor a sound product contained in a second seat of said second conveyor adjacent to said first seat.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described hereinafter with reference to the accompanying drawings, which illustrate a non-limiting example thereof and in which:
FIG. 1 is a schematic plan view of an apparatus constructed in accordance with the present invention in a first operating position;
FIG. 2 is a schematic elevation of the apparatus of FIG. 1; and
FIG. 3 is a schematic plan view of the apparatus of FIGS. 1 and 2 in a further operating position.
DETAILED DESCRIPTION
In FIG. 1 the reference numeral 1 indicates overall an apparatus for transferring products, such as packets 2 of cigarettes, between a delivery unit, not shown, consisting for example of a wrapping machine for wrapping the finished packets 2 of cigarettes in a sheet of transparent material, and receiver means comprising a receiving unit 3 consisting for example of a packaging machine for cartoning groups 4 of packets 2 in a sheet of cartoning material (not shown).
The apparatus 1 comprises a feeder means consisting of a conveyor unit 5 starting at the exit of said delivery unit and comprising two parallel and mutually facing belt conveyors 6 spaced apart by a distance equal to the longitudinal dimension of a packet 2 of cigarettes and each consisting of an endless belt 7 extending about a pair having a rollers 8 (only one of which is shown) of vertical axis.
At the exit end of the conveyor unit 5 there is a facing conveyor comprising a transfer wheel 9 having a vertical axis, provided peripherally with a plurality of radially equidistant seats or compartments 10 and driven with intermittent rotary motion in an counterclockwise direction, with reference to FIG. 1, by motor means not shown.
During respective halt stages of the wheel 9 the conveyor unit 5 conducts the packets 2 in succession into respective compartments 10 at an entry station 11, corresponding to the region of substantial tangency between the exit end of the conveyor unit 5 and the wheel 9, by the cooperation of a pusher element 12 of known type driven with reciprocating motion. Said packets 2 are extracted in succession from the compartments 10 by a pusher element 13 of known type at an exit station 14 diametrically opposite the station 11. The pusher element 13 pushes the packets onto an inlet table 15 of the cartoning machine 3, to form groups 4 of packets 2 which rest against each other along their smaller lateral faces. The groups 4 are urged in succession by a pusher element 16 towards the cartoning line (not shown) of the machine 3.
At a discarding and replacement station 17, in which one compartment 10 is positioned at each halt stage of the wheel 9, the path of travel of the compartments 10 is intersected by the path of travel of the seats or compartments 18 of a conveyor comprising a wheel 19 having a horizontal axis parallel to the direction of extension of the conveyor unit 5, provided peripherally and equidistantly with a plurality of such compartments 18 and driven with intermittent rotary motion by reversible motor means 20.
More precisely, when the wheels 9 and 19 are in their halt stage, the wheel 9 has a compartment 10 coinciding with a compartment 18 of the wheel 19, the halt and movement stages of the two wheels 9 and 19 being such as to prevent any mutual interference between these wheels, as the wheel 9 can undergo rotational steps only when the wheel 19 is at rest and vice versa.
The reference numeral 21 indicates an optical sensor device of known type (see FIG. 2) able to sense whether the compartments 18 of the wheel 19 are full or empty.
When the apparatus 1 is in use under normal operating conditions, the wheel 19 is at rest and a certain number of its compartments 18 internally contain respective packets 2. An empty compartment 18 remains at rest in the discarding and replacement station 17 during the rotational steps of the wheel 9, as stated.
The packets 2 are transferred in succession by the conveyor unit 5 into the compartments 10 of the wheel 9 at the station 11, and are conducted by said wheel 9, by means of rotational steps in a counterclockwise direction (FIG. 1), through said empty compartment 18 and towards the station 14, in which the pusher element 16 pushes them onto the table 15, as stated.
When a packet 2 is found to be defective, control means of known type, not shown, positioned upstream of the apparatus 1 operate the motor means 20 in such a manner as to cause the wheel 19, on arrival of the defective packet 2 at the station 17 during a halt stage of the wheel 9, to undergo a clockwise rotation step (FIG. 2) such that the defective packet 2 is seized from the compartment 10, at rest in the station 17, by a compartment 18 of the wheel 19, and a sound packet 2 contained in the adjacent compartment 18 is led into the compartment 10 which has been freed of the defective packet 2. Extractor means of known type, not shown, then remove the defective packet 2 from the compartment 18 and feed it towards a collection container, not shown. During the course of successive rotation steps of the wheel 9 the sound packet 2 fed into a compartment 10 of the wheel 9 is conducted towards the station 14 and deposited on the table 15, so that the continuity of the succession of packets 2 fed to the cartoning machine 3 is not interrupted.
The described operation involving the replacement of defective packets conveyed by the wheel 9 can be repeated a determined number of times before the compartments 18 of the wheel 19 are all empty. When this situation occurs, the optical sensor 21 senses the fact that all the compartments 18 of the wheel 19 are empty, and operates the motor means 20 in the opposite direction to that already considered, to cause the wheel 19, in synchronism with the rotation steps of the wheel 9, to undergo a number of steps sufficient to fill all the compartments 18 with packets from the compartments 10 of the wheel 9 which successively halt at the station 17. In other words, after activation of the motor means 20, a compartment 18 at rest in the station 17 receives a packet 2 from a compartment 10 which has arrived at the station 17, and removes said packet 2 from said compartment 10 when the wheel 19 undergoes a counterclockwise rotation step (see FIG. 2). The wheel 19 undergoes a further rotation step to bring to the station 17 a further packet 2, which is seized by a compartment 18 of the wheel 19, and so on. After a certain number of rotation steps of the wheel 19, all its compartments 18 have been filled with that number of packets 2, the fact that all the compartments 18 of the wheel 19 are now full being sensed in known manner by the sensor device 21 or other checking means of known type, not shown, the motor means 20 then being halted, the wheel 19 then being again ready to deliver sound packets into the compartments 10 of the wheel 9 in the aforesaid manner.
During the described stage in which the compartments 18 of the wheel 19 are filled, no packet 2 is fed onto the table 15, and the cartoning machine 3 undergoes one or more idle cycles, in that the pusher element 16 undergoes a feed stroke without encountering a group 4 of packets 2 on the table 15. Inhibition means of known type, not illustrated or described as they do not form part of the apparatus according to the present invention, halt the feed of cartoning material to the cartoning machine 3 during said idle cycle.
Within the principle of the invention, numerous modifications can be made to the described apparatus without leaving the scope of the inventive idea.
For example, according to a modification shown in FIG. 3, the table 15 of the cartoning machine 3 adjoins the wheel 9 at an exit station 14 diametrically opposite the station 17, with reference to the axis of the wheel 9. The exit station 14 is angularly offset from the entry station 11 by an angle equal to 90° or 270° in the illustrated example. The packets 2 which on leaving the compartments 10 are to be arranged in succession on the table 15 are urged by a pusher element 22 onto said table 15 along a direction parallel to the direction of extension of the conveyor unit 5, to form groups 4 of packets 2 abutting against each other. Finally, it should be noted that the wheel 9 can have any number of compartments 10, and said stations 14 and 17 could be arranged angularly offset from the entry station 11 by different amounts than so far considered, but with the obvious condition that the station 17 must precede the station 14, with reference to the direction of rotation of the wheel 9.
From the aforegoing it is apparent that the described apparatus 1 enables packets 2 found defective in a cartoning line to be replaced in a completely automatic manner, in accordance with the stated object, and that it does not suffer from the described drawbacks of the known art, being simple, economical, and of small overall size. | An apparatus (1) for feeding products, in particular packets of cigarettes (3) comprising a feeder (5) for feeding a succession of packets (2), a first conveyor (9) driven with intermittent motion and provided with seats (1) for receiving respective packets (2) from the feeder (5), and a receiver (3) for receiving the packets (2) from the first conveyor (9) in succession. The apparatus (2) also comprises a second conveyor (19) driven with intermittent motion and provided with seats (18) for containing respective packets (2), the path of travel of the seats (18) of the second conveyor (19) intersecting the path of travel of the seats (10) of the first conveyor (9) at a station (17) for the discarding and replacement of defective packets (2). During each of its stages of movement the second conveyor (19) is able to remove a defective packet (2) from a seat (10) of the first conveyor (9), and to introduce a sound packet (2) into the same seat (10). | 8 |
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